Editing MOST Delta end effector for nylon

{{MOST}}

 '''Print only in hood or well ventilated area.'''
==BOM==
* Lulzbot hexagon hotend $70 https://www.lulzbot.com/products/lulzbot-hexagon-hot-end
* 24V/4-5A power supply
* 3mm id x 6mm od PTFE tubing 630mm long
* 2x M6 x 0.8mm hex nut
* 3mm print effector
* 3mm extruder drive body
* ~1m 18ga speaker wire
* 2x ~1m 28ga twisted pair
* Heat shrink tubing

==OpenSCAD design==
* End effector - download latest version of [[https://github.com/phidiasllc/athena Athena SCAD files]] and [[https://github.com/phidiasllc/scad_libraries SCAD libraries]]. Change the Bowden dimensions in athena.scad. Render the end effector and print.
* Extruder drive - download latest version of [[https://github.com/phidiasllc/extruder_drive extruder drive SCAD files]] (requires the SCAD library, as above). Change the filament dimensions in extruder_drive_renderer.scad. Render the extruder drive body and print.

==Build Instructions==

==Testing with Athena RepRap 3D printer==
===10/22/15 - Test 0===
[[File:Athena_max333605_test0.JPG|thumb|left|Maxpower 333605 test 0 print result.]]
====Conditions====
*Filament: Maxpower 333605 Residential Grade Round .105-Inch Trimmer Line 690-Foot Length from [http://www.amazon.com/dp/B001BKZT1S/ref=pe_175190_21431760_M2T1_SC_dp_1 Amazon] for $24.35/3 pounds (1.3kg $18.73/kg)
*End effector: 3mm Athena print effector
*Hot end: Lulzbot Hexagon, 3mm x 0.35mm
*Extruder drive: 3mm Phidias extruder drive
*Firmware: Franklin (latest)
*Temperature: 260 C
*Print speed: Variable (testing capabilities)
*Slicing: Cura 15.04 set to 3mm filament, 1 multiplier, 0.2mm layer height, print speed 70mm/s, 25% infill, 30mm/s initial layer speed
*Bed: Mirror with glue stick
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====Notes====
#Using a 12V fan on the end effector with pwm. Fan speed too high, end effector would not reach target temperature. Occluded lower half of fan with masking tape.
#First layer too close to glass requiring decrease in speed.
#Adjusted speed from 30% (21mm/s) to 140% (98mm/s) in 10% increments (70mm/s speed set in slicing) while printing first ~100 layers.
#Lower layers exhibited poor interlayer bonding.
#Print is flexible, but makes cracking noise when strained due to poor interlayer bonding.
#Bridging performance improved when speed lowered to ~30mm/s
#Experienced minor respiratory irritation during test. Future tests will be conducted under a hood.

===10/23/15 - Test 1===
[[File:Athena_max333605_test1.JPG|thumb|left|Maxpower 333605 test 1 print result.]]
====Conditions====
*Filament: Maxpower 333605 Residential Grade Round .105-Inch Trimmer Line 690-Foot Length from [http://www.amazon.com/dp/B001BKZT1S/ref=pe_175190_21431760_M2T1_SC_dp_1 Amazon] for $24.35/3 pounds (1.3kg $18.73/kg)
*End effector: 3mm Athena print effector
*Hot end: Lulzbot Hexagon, 3mm x 0.35mm
*Extruder drive: 3mm Phidias extruder drive
*Firmware: Franklin (latest)
*Temperature: 260 C
*Print speed: 70mm/s
*Slicing: Cura 15.04 set to 3mm filament, 1 multiplier, 0.2mm layer height, print speed 70mm/s, 25% infill, 30mm/s initial layer speed
*Bed: Mirror with glue stick
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====Notes====
#Using a 12V fan on the end effector with pwm. Fan speed too high, end effector would not reach target temperature. Occluded lower half of fan with masking tape.
#Adjusted switch position (smaller) still some skipping on first layer
#Bridging performance is abysmal. Cura doesn't help it.
#Interlayer bonding improved.

===10/23/15 - Test 2 ABORTED plugged nozzle===

====Conditions====
*Filament: Maxpower 333605 Residential Grade Round .105-Inch Trimmer Line 690-Foot Length from [http://www.amazon.com/dp/B001BKZT1S/ref=pe_175190_21431760_M2T1_SC_dp_1 Amazon] for $24.35/3 pounds (1.3kg $18.73/kg)
*End effector: 3mm Athena print effector
*Hot end: Lulzbot Hexagon, 3mm x 0.35mm
*Extruder drive: 3mm Phidias extruder drive
*Firmware: Franklin (latest)
*Temperature: 265 C
*Print speed: 70mm/s
*Slicing: Slic3r 1.2.9, 2.667mm filament, 1 multiplier, 0.2mm layer height, print/infill.perimeter speed 70mm/s, bridge speed 30mm/s, 25% infill, 30mm/s initial layer speed
*Bed: Mirror with glue stick
{{clear}}
====Notes====
#Using a 12V fan on the end effector with pwm. Fan speed too high, end effector would not reach target temperature. Occluded lower half of fan with masking tape.

===10/27/15 - Test 3===

[[File:Athena_max333605_test3.JPG|thumb|left|Maxpower 333605 test 3 print result. Note print warped off bed.]]
====Conditions====
*Filament: Maxpower 333605 Residential Grade Round .105-Inch Trimmer Line 690-Foot Length from [http://www.amazon.com/dp/B001BKZT1S/ref=pe_175190_21431760_M2T1_SC_dp_1 Amazon] for $24.35/3 pounds (1.3kg $18.73/kg)
*End effector: 3mm Athena print effector
*Hot end: Lulzbot Hexagon, 3mm x 0.35mm
*Extruder drive: 3mm Phidias extruder drive
*Firmware: Franklin (latest)
*Model: raptor_reloaded_gauntlet_supported.stl
*Temperature: 265 C
*Print speed: 70mm/s
*Slicing: Cura 15.04, 2.667mm filament, 1 multiplier, 0.2mm layer height, print/infill.perimeter speed 70mm/s, bridge speed 30mm/s, 10% infill, 30mm/s initial layer speed
*Bed: Mirror with glue stick
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====Notes====
#First print with 24V fan. Too much cooling, occluded fan with tape.
#Part of print warped off of the bed.
#Reduced print speed to 50% (35 mm/s max)
#Reduced acceleration to 1000 mm.s^2
#Reduced max speed to 100 mm/s
*Above done to counter end effector being dislodged during printing, which occurred on two previous attempts.
#Print was brittle and broke easily at sides.

===10/27/15 - Test 4===

[[File:Athena_max333605_test4.JPG|thumb|left|Maxpower 333605 test 4 print result. Note raft used for adhesion. Mirror was cracked when print started, it broke and displaced more due to stress from the print shrinking.]]
====Conditions====
*Filament: Maxpower 333605 Residential Grade Round .105-Inch Trimmer Line 690-Foot Length from [http://www.amazon.com/dp/B001BKZT1S/ref=pe_175190_21431760_M2T1_SC_dp_1 Amazon] for $24.35/3 pounds (1.3kg $18.73/kg)
*End effector: 3mm Athena print effector
*Hot end: Lulzbot Hexagon, 3mm x 0.35mm
*Extruder drive: 3mm Phidias extruder drive
*Firmware: Franklin (latest)
*Model: raptor_reloaded_gauntlet_supported.stl
*Temperature: 265 C
*Print speed: 45mm/s
*Slicing: Cura 15.04, 2.667mm filament, 1 multiplier, 0.2mm layer height, print/infill.perimeter speed 70mm/s, bridge speed 30mm/s, 10% infill, 30mm/s initial layer speed, raft with 0 air gap, support: touching build plate
*Bed: Mirror with glue stick
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====Notes====
[[File:Athena_max333605_test4_cleaned.JPG|thumb|left|Removed from bed with raft and support (top) and raft and support removed (bottom). Note warping - should be flat on table top.]]
#Printed with a raft having no air gap so print is fused to raft attempting to counter warping.
#The mirror was cracked at startup and developed two more cracks during this print. The long crack through the center was also displaced in shear (see photo, above).
#The raft tore off despite no air gap.
#Overhang support was more difficult to remove. It was fused well to the underside of the print. Needle nose pliers were required to pull it off. 
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==See also==
* [[Weed wacker line as 3D printing filament]]
* [[MOST Delta end effector for polypropylene]]

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[[Category:MOST methods]]