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Cellular Lamp / Week of Aug 28 to Sept 10 2012

Posted by NewPerfection 
Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 28, 2012 10:40AM
For this weeks contest, Gulf and I decided on the Cellular Lamp as the challenge. Since I proposed the object, I will be posting the competition.

The Thingiverse page is here: [www.thingiverse.com]
The cellularThing_optimizedForMakerbot.stl file will be used, as it has been slightly optimized for RepRap style 3D printers.


Since this object is so large, I propose that we print it at 75% scale, which would put it at a reasonable amount of plastic and print time. I have yet to print this, but when I do I will edit this post to include a picture of my print.

Please use this file instead:
[www.thingiverse.com]
It is pre-scaled to 75% and run through netfabb, so it should not have any errors.

Good luck!

Edit: I have changed the deadline to two weeks, especially considering this is a difficult print. Please share any thoughts on this.

Edit 2: Here is a crappy photo of my print, I will try to get a better one up later.


This was printed using Slic3r and the following settings:
; layer_height = 0.2
; perimeters = 2
; solid_layers = 4
; fill_density = 0
; perimeter_speed = 50
; infill_speed = 50
; travel_speed = 130
; scale = 1
; nozzle_diameter = 0.35
; filament_diameter = 2.9
; extrusion_multiplier = 1
; single wall width = 0.49mm
; first layer single wall width = 0.60mm

Total actual print time was 3 hours, 57 minutes, 52 seconds. Using Diamond Age kiwi green PLA and a 0.4 mm J-Head hotend.

Edited 5 time(s). Last edit at 08/29/2012 06:52PM by NewPerfection.

Cameron

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Attachments:
open | download - cellular lamp.jpg (254 KB)
open | download - cellular lamp.jpg (53.1 KB)
Re: Cellular Lamp / Week of Aug 28 to Sept 3 2012
August 28, 2012 12:25PM
OMG ! Bridging ! cool smiley


Most of my technical comments should be correct, but is THIS one ?
Anyway, as a rule of thumb, always double check what people write.
Re: Cellular Lamp / Week of Aug 28 to Sept 3 2012
August 28, 2012 03:29PM
maybe its a good idea to stretch the time limit a bit for competitions. eg 2 weeks

i just finished printing the competion thing from 2 weeks ago due to time limits. a week can be a very small time when you have to do some tinkering for right settings smiling smiley
Re: Cellular Lamp / Week of Aug 28 to Sept 3 2012
August 28, 2012 05:48PM
Weedz Wrote:
-------------------------------------------------------
> maybe its a good idea to stretch the time limit a
> bit for competitions. eg 2 weeks
>
> i just finished printing the competion thing from
> 2 weeks ago due to time limits. a week can be a
> very small time when you have to do some tinkering
> for right settings smiling smiley

This is probably a good idea. It might encourage more competition. Does anyone else agree?


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 3 2012
August 28, 2012 07:43PM
I agree, I also have finished previous competition pieces after the one week deadline.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 28, 2012 10:13PM
Hi all,

I really enjoy this segment. Just to see how well some of you can print with your machines. Anyway, everytime I look at a file I run it through netfabb to check it for errors and this file (the lamp) comes up with errors as well. Do you ignore these and just print the object or do you have other ways you fix the errors with, as I can not clean it up using netfabb?

Regards
Jan
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 29, 2012 12:26AM
I was able to clean up the file using the free version of netfabb. I will create a new thing on Thingiverse with the cleaned, 75% scaled version, and update my original post.

Generally files will print ok even if the STL is not perfect, you just need to check the resulting gcode to make sure nothing funky is happening.


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 3 2012
August 29, 2012 04:03AM
Agreed with the 2 weeks change - might let me finally participate sometimes smiling smiley


Most of my technical comments should be correct, but is THIS one ?
Anyway, as a rule of thumb, always double check what people write.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 29, 2012 06:57PM
I updated my initial post with a picture and printing information. I think the two week deadline will stand.


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 30, 2012 05:24AM
Looks like a great challenge!

2 weeks is a good time-scale especially this time of the year.


[richrap.blogspot.com]
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 31, 2012 12:37AM
NewPerf, is the instruction on thingiverse "Print with 3 shells and zero infill" a requirement for the competition or just general advice ?


Most of my technical comments should be correct, but is THIS one ?
Anyway, as a rule of thumb, always double check what people write.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
August 31, 2012 04:56PM
Just general advice. I actually printed it with two shells and zero infill. I will make a note of that.


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 03, 2012 11:51AM
Here's my take of it. It's not the best of quality as I was hoping to be but at least it didn't fail. There was one section where the bridging was failing, causing it to blob all over the place and I was debating to bail on the print. Although, after a few layers, it seemed to correct itself and I figured I just touch it up later with some sanding and acetone welding/smoothing. Going back to fine tune my bridging calibration.



Slic3r Settings:

; layer_height = .2
; perimeters = 3
; solid_layers = 3
; fill_density = 0
; perimeter_speed = 35
; infill_speed = 40
; travel_speed = 130
; scale = 1
; nozzle_diameter = 0.25
; filament_diameter = 2.73
; extrusion_multiplier = 1
; single wall width = 0.26mm

Machine: Printrbot LC+
Print time:6 hours, 39 minutes
Material: Makerbot's Natural ABS
Hotend: Ubis Hot End

Edited 1 time(s). Last edit at 09/03/2012 11:52AM by gyronictonic.
Attachments:
open | download - Cellular Cell.jpg (607.6 KB)
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 04, 2012 01:32PM
That's not too bad considering how difficult of a print this is. I hope we get some more competition in here!


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 05, 2012 09:24AM
I've tried three times so far and had three failures.
The first two got knocked loose, the third one stayed stuck on the bed but suffered a massive shift in the X axis, presumably when the nozzle was obstructed by one of the bridges as it curled up.
I might give it another go but any suggestions for tweaks to the gcode would be gratefully received.
; generated by Slic3r 0.9.2 on 2012-09-01 at 12:43:29
; layer_height = 0.1
; perimeters = 2
; solid_layers = 3
; fill_density = 0
; perimeter_speed = 40
; infill_speed = 50
; travel_speed = 130
; scale = 1
; nozzle_diameter = 0.5
; filament_diameter = 2.7
; extrusion_multiplier = 0.8
; single wall width = 0.49mm
; first layer single wall width = 0.40mm

Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 05, 2012 01:30PM
If you are printing PLA you will most likely need a fan blowing over the print to stop the curling. I use a PVA solution on my heated bed, which makes everything stick really well.


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 05, 2012 02:48PM
@richgain - I'm having almost exactly the same results, first two times, looks identical to your pictures. (Nice Brown PLA BTW)

I pumped up the BRIM to 2.6mm and added PVA solution and the third is sticking, but I can see I'm printing way too fast (80mm/sec and 260mm travel speed) and trying to do it without an external fan with PLA is not going very well.

And the X axis has just skipped on the last 5mm of the print! damn. it was just about acceptable until that. I'll let it finish.

It's finished now 3Hours 6mins, I think it needs to be 5+ hours for a decent print.

I'm using some concentric infill, maybe that's not a good idea after all.

Anyone know how to make Slic3r 0.9.1 do each island completely then move on, on older versions you just set Perimeters to 10+ and that did it. With V0.9.1 it jumps around all over the place for each section in the layer, my fast travel moves are crashing into each island...

At 0.3mm layer height my Gcode is over 17MB, that's not a good sign.

This is a tricky one...

I'll try to post a picture and have another go, slower, with lift on the Z axis and maybe an external fan, or two... or three...


[richrap.blogspot.com]
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 05, 2012 06:32PM
I tried to print it several times also richrap 4th time was the charm for me. I used three loops with zero infill.
The best advice is to use Kisslicer, I have used several versions of Slic3r and since switching never looked back, it handles everything much better. I am still using the free version after several months and a couple pounds of PLA, and some ABS and PC and hands down the best slicer out there.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 05, 2012 08:35PM
It printed just fine for me the first time using Slic3r, no brim. Total print time was close to 4 hours. I do have two 40 mm fans blowing over the hotend and print though, which helps with the curling problem.


Cameron

Help improve the RepRap wiki! Edit the following page to add suggestions, comments, pages that need updated or fixed, etc.: http://reprap.org/wiki/To_Do
Just click "Edit" in the top-right corner of the page and start typing.
If you are feeling adventurous, take on some of the requested to-do items yourself. Anyone can edit the wiki!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 06, 2012 02:07AM
@newperfection - I'm using my new ducted fan on full power but even that didn't seem to stop the bridges from curling up.

@gulf - I tried Kisslicer a while back and liked the look of it but the output seemed incompatible with Repetier Host, which I use for all my printing now. I might go back and give it another try to see if that's been sorted out.

@richrap - glad it's not just me. Perhaps printing more slowly would help me too.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 06, 2012 05:06AM
i have been using it with repetier all along i did have to tweak something to get the display to work properly, i can take a look and l will let you know.
The other advice seems spot on with what my experiences are with complicated prints. Slow down, then go slower qnd use a lot of air across the part to speed phase transformation. I have had good luck running the heated bed @ about 60 C measured at the edge, its about 70 in the middle acording to my infared tempgun. Seems to keep the prints anchored rather well without any loops to keep it anchored.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 06, 2012 08:29AM
richgain Wrote:
-------------------------------------------------------
> @newperfection - I'm using my new ducted fan on
> full power but even that didn't seem to stop the
> bridges from curling up.
>
> @gulf - I tried Kisslicer a while back and liked
> the look of it but the output seemed incompatible
> with Repetier Host, which I use for all my
> printing now. I might go back and give it another
> try to see if that's been sorted out.
>
> @richrap - glad it's not just me. Perhaps printing
> more slowly would help me too.

I use KISSlicer with repetier host all the time, what wat the issue?
I did add code in the KISSlicer extra code window to wait for the Hotend to reach temperature, but that was it.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 06, 2012 10:01AM
Polygonhell Wrote:
> I use KISSlicer with repetier host all the time, what was the issue?

I don't want to hijack this competition thread so I've posted here to continue the discussion.

Cheers
richgain
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 07, 2012 03:57AM
Not going to lie, I really struggled with the overhangs on this one. I printed it on a prototype of an as yet unnamed new machine a friend and I are working on. But here is my stab at it, print is straight off the machine:



My slic3r settings for ABS, printed with a fan @230degrees. I had a lift turned on between travel moves to prevent the problems of nozzle collisions Richgain is having (I didn't try it without)
; layer_height = 0.2
; perimeters = 2
; solid_layers = 4
; fill_density = 0
; nozzle_diameter = 0.3
; filament_diameter = 1.75
; extrusion_multiplier = 1
; perimeter_speed = 30
; infill_speed = 50
; travel_speed = 150
; scale = 1
; single wall width = 0.40mm

Edited 4 time(s). Last edit at 09/07/2012 04:30AM by rhysjones.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 07, 2012 05:08AM
rhysjones, that looks fantastic! I'm blown away.
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 07, 2012 05:56AM
My attempts from a few days ago (the problems I was talking about above) -



Not sticking


With Brim and PVA - ok, but printed too fast and no cooling. X skipped at top last 5mm or so.

It's still welded to my Printbed, 2 days later!

I'll try again. sad smiley


[richrap.blogspot.com]
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 07, 2012 09:45AM
@rhysjones - Wow! love the colour and the quality looks superb.
What version of slic3r? Apparently, lift is broken on the latest version (0.9.2).
How much did you lift the nozzle by?

@richrap - frustrating innit?

richgain
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 07, 2012 10:45AM
@richgain Its black Makerbot abs, but it appears dark blue under bright lights, I think I lucked out on the photosmiling smiley. I'm using Slic3r 0.72b and I guessed at a lift of 0.2mm. I only did that one print, so I'm not sure if I actually need it.

I tried upgrading to a newer version of slic3r but for some reason the print quality got worse for me, I'm 99% sure it was in part due to them reversing the order the perimeters are printed. I hacked a newer version of Slic3r manually to fix it and it still looks worse to me. The newer versions of Slic3r don't really have any features I want, so I thought I'd leave well alone!
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 08, 2012 01:37AM
Here is my attempt. Filament decided to jam at the last 10% or so, but it's mostly finished.



Struggling a little with big overhangs, might be a symptom of using a large nozzle with a small layer height.



; layer_height = 0.15
; perimeters = 2
; solid_layers = 4
; fill_density = 0
; perimeter_speed = 65
; infill_speed = 100
; travel_speed = 200
; scale = 1
; nozzle_diameter = 0.489
; filament_diameter = 2.9
; extrusion_multiplier = 1
Re: Cellular Lamp / Week of Aug 28 to Sept 10 2012
September 09, 2012 04:29PM
Perseverance pays off.
Reduced speed to 20, used Z lift with moves and printed in plain ABS.
Just finished in time!




richgain
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