AO-101 User Manual
Contents
1. 7 2 Changing nozzles rss 7 3 ABS Acetone Glue be dos eh Sal Nat aE dy Pattee TE ped Veh Mar Taig Mer eee teil fe TA Using 1 75mm Filament eee ee ee 8 Hardware and Software Source Code 9 3D Printer Support 9 1 LulzBot 9 2 Community e ES A Se e we EN See ia 10 Contact Information 10 1 Support 10 2 Sales 10 3 Websites Index 47 48 48 49 49 53 55 56 56 57 58 58 58 59 List of Figures 1 1 1 2 1 3 2 1 22 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 2 13 3 1 3 2 3 3 3 4 4 1 5 1 5 2 5 3 5 4 5 9 Orange Zip Ties aaa ee ee bis 12 Red Shipping Clamps lt ze a ae ac 13 Using a wrench to pry off the shipping clamps 14 Axes movement directions e 16 X and Z end stop locations 17 Y end stop location a na Acta a tre te ds 17 Power supply and USB receptacles rennen 18 Power supply plug ae are are ae 19 The power supply and USB plugs correctly plugged in gt 19 prole a guak goi a Bn ie ua ee de oe hs o 20 Spool mounte Be ante She e se ren E 21 Spool mounted Je taa pita sa 22 Blasien Guide shee EEE mais amp 4 22 Filament Guide Nuts 46 408 4 is a a5 23 Filament Guide Seins NA 23 SDERMPIS zu ZE ar ur A a br Be Gland 24 Slic3r application STL to Gcode generator 27 Printrun application for 3D printer control 29 Printrun controls ss sta et s e e o calc2. Budaschnozzle Y plates e Software binaries and source code for GNU Linux and others Also includes known good configuration files Slic3r Printrun Marlin 54 3D Printer Support 3D Printer Support 9 1 LulzBot For technical support for your AO 101 3D printer please e mail our support team at support lulzbot com Please completely read this manual before contacting for support questions or help The latest version of this information guide is also available at http download lulzbot com You can also find more information including images videos and updated versions of this manual in the Support section of LulzBot com 9 2 Community Community Support and Resources e IRC chat rooms on the irc freenode net server reprap Highly active community chat room where help can easily be found slic3r Slic3r chat room where Slic3r developers and users can give help e RepRap org forums forums reprap org 56 Contact Information Contact Information 10 1 Support Email support LulzBot com Phone 1 970 377 1111 10 2 Sales Email sales LulzBot com Phone 1 970 377 1111 10 3 Websites Aleph Objects Inc the makers of LulzBot 3D Printers www AlephObjects com LulzBot 3D Printers and parts www LulzBot com 58 INDEX Symbols 1 75mm filament 49 A ABS 49 acetone 44 45 49 advanced technigues 48 aluminum extrusions 54 anti seize 49
3. Figure 5 5 First layer adhesion very low low perfect high very high If the first layer is too high or low you can pause the print by pressing the Pause button Adjust the Z end stop trigger After making adjustments you can home the axes and press Restart to restart the print 41 Your First 3D Print 5 5 Remove Part After the part is finished printing the heated bed will automatically cool down to 60 C If you are printing PLA you will need to turn the heated bed off Once the bed cools you can you pop the finished part off of the printed surface To remove the printed part use the clam knife included in your printer kit Leather gloves are suggested to protect your hands from the clam knife blade It is also safe practice to not place your hand behind the direction you are pushing the clam knife Using the side of the clam knife blade pry up one side of the printed part If your part is large you may need to pry at multiple points to pop the part off of the print surface When removing parts take caution to not damage the PET film If the film is cut or ripped it will peel from the glass and need to be replaced Make sure to reset the heated bed to the correct temperature and allow it to heat up to the needed temperature before starting the next print 42 Maintaining Your 3D Printer Maintaining Your 3D Printer 6 1 Overview There is little maintenance needed in keeping your AO 101 3D printer running Dependin
4. Layer 22 Going Down Z 8 8 mm Figure 3 4 Printrun viewer For more information on using Printrun see the Printrun page in the Support Downloads section at www LulzBot com Instructions for running a print can be found in the Starting the First Print section in this manual 3 4 CAD and 3D Modeling Software Currently LulzBot is not distributing a CAD or 3D modeling software package However there are multiple free libre software packages available Other common non free CAD and 3D modeling software are also capable of exporting the required STL files On some CAD and 3D modeling software you will need to select millimeters as the output unit If possible it is best to build your 3D design in metric units rather than emperial units Slic3r requires STL files sized in millimeters If an STL with inches as units is loaded into the Slic3r the model will be scaled much smaller than expected The software listed below outputs millimeters as the unit by default 32 3 4 CAD AND 3D MODELING SOFTWARE FreeCAD Website free cad sourceforge net Although still in development FreeCAD is a great free libre CAD application Containing a full GUI for building CAD models FreeCAD is capable of creating simple to complex designs STL files can also easily be exported for use with 3D printing FreeCAD is available for GNU Linux Windows and Mac The latest development version is recommended OpenSCAD Website openscad org OpenSCAD i
5. With the top wooden plate removed the white PTFE tube should now be visible The PTFE tube is set through an aluminum heat sink Remove the heat sink from the hot end 9 The PTFE can generally be pushed out of the aluminum heat sink by hand Although you may need to use the 4mm hex driver to push the PTFE tube through and out of the aluminum heat sink Place aside the PTFE tube for 3mm filament 50 10 11 12 13 14 15 16 17 18 7 4 USING 1 75MM FILAMENT Push the PTFE tube for 1 75mm filament through the aluminum heat sink The PTFE tube should be approximately centered in the heat sink with egual links of the PTFE tube sticking out of the heat sink Replace the aluminum heat sink and PTFE tube back into the hot end Lightly push down on the PTFE tube to make sure it is completely set into the hot end Replace the top wooden plate Make sure to line up the strain relief slots on the side of the wires Place the printed mounting bracket on top Screw in and lightly tighten the three 3mm screws through the mounting bracket and top wooden plate Do not overtighten these screws as you can crack the wooden plates Wrap the wires through the strain relief slots in the correct path of all four wires snaking through each slot together Place the hot end back down into the X axis carriage Make sure the wires are facing the rear of the printer Place the extruder body back on top ofthe hot end and X axis c
6. axes 30 B baud rate 28 belts 45 bill of materials 54 Blender 33 blue tape 13 bottle 49 Budaschnozzle 54 burns viii bushings 44 C CAD 26 32 calibration 54 community support 56 configuration 27 connecting 28 D download 26 45 54 99 E electronics viii 54 electronics receptacles 16 end stops 16 31 extrude 30 extruder viii 28 extruder jam 44 extrusion 28 F feed tube 36 filament 38 filament guide 12 filament spool 12 36 foam padding 12 forums 56 FreeCAD 33 Freenode 56 G gcode 26 28 31 54 glass 44 GNU Linux 26 28 33 H hardware 54 hazards viii heater block viii 48 high resolution 48 hobbed bolt 44 home 31 hot end 29 30 38 45 48 I idler 13 instructions 12 IRC 56 L latex 54 load files 31 lubricant 44 M Macintosh 26 33 maintainence 44 manual controls 30 Marlin 54 motors 31 N novelties 54 nozzle 48 O OpenSCAD 33 operating system 26 P PCB Heatbed 54 PET sheet 13 44 49 plater 27 pliers 18 port 28 power supply viii 12 16 power switch 18 printed parts 54 Printrun 28 29 31 54 pronterface 28 PTFE tube 20 49 INDEX R RAMBo 18 54 RepRap 56 resolution 26 S SD card 28 SDRAMPS 54 shipping clamps 13 Slic3r 26 54 smooth rods 44 software 26 32 45 54 source code 54 spool 18 36 static ix STL 26 27 32 54 T technical support 56 temperature viii 28 30
7. to not remove the green PET tape on the glass print surface The PET tape helps keep the print attached to the print surface during printing 14 Setup Your Printer Setup Your Printer 1 Your printer has been pre calibrated and tested however after unpacking you will need to double check that everything is in order before you print 2 You should set your printer on a stable flat and level surface large enough for extra space around the printer Make sure your printer work space is clear of anything that could obstruct the movement of the printer Make sure there are no flammable fabrics or liquids near the printer space It is also best to not put your printer near a drafty window or air conditioner vent 3 Check that the three mechanical end stops are aligned to contact with the respective ends The mechanical end stops are small switches located at the home point of each axis Fig 2 1 page 16 Fig 2 2 page 17 Fig 2 3 page 17 Figure 2 1 Axes movement directions 4 Unwrap the power supply and USB cable MAKE SURE THE POWER SUPPLY IS COMPLETELY UN PLUGGED BEFORE MOVING ON TO THE NEXT STEP 16 LULZBOT AO 101 USER MANUAL Y AXIS ENDSTO Figure 2 3 Y end stop location 17 Setup Your Printer 5 Locate the power supply and USB receptacles along the bottom of the RAMBo electronics enclosure Fig 2 4 page 18 I TEA E e POWER USB SUPPLY Figure 2 4 Power supply
8. 38 threaded extension 48 tool bag 12 U USB cable 16 28 W warnings viii warping 49 Windows 26 33 wing nuts 36 wires Vill wrench 18 48 X X axis 30 x end motor mount 13 Y Y axis 30 60 INDEX y plates 54 Z Z axis 30 61 Colophon Created with 100 Free Libre Software GNU Linux KTEX Memoir
9. holes in hub of the filament spool This will keep the filament from unwinding from the spool 36 Your First 3D Print Your First 3D Print 5 1 Set Temperature Make sure to first read the instructions for using the Printrun software Connect to the printer as described in the Printrun software section page 28 Set the hot end and print surface for ABS plastic and turn both on The temperature settings should be set at 230 C for the hot end and 100 C for print surface If you have not already make sure the axes end stops are aligned to be triggered when each axis homes Click the Motors Off button 5 2 Load Filament Once the hotend is heated to the correct temperature you will now need to load the plastic filament into the extruder Loosen the two idler bolts turn the black plastic knobs by hand to take pressure off of the idler springs Fig 5 1 page 38 Pull both idler screws upwards to release the idler Figure 5 1 Extruder idler bolts The idler can be turned downwards allowing access to the hobbed bolt and filament feed hole Feed the end of the plastic filament into the filament 38 5 3 HOME PRINTER feed hole Fig 5 2 page 39 Now you can push the filament through the Figure 5 2 Extruder feed hole extruder by slowly pushing the filament down into the hot end Once the filament extrudes a small amount out of the nozzle raise the idler and slide the two idler bolts and springs back into plac
10. printer and possibly voiding your warranty The AO 101 3D printer is set up to use 3mm plastic filament by default Although we recommend using 3mm filament the AO 101 is also capable of printing 1 75mm filament To print with 1 75mm filament you will need to change the PTFE tube inside the Budaschnozzle hot end Included in the printer kit is a 25mm PTFE tube with a 1 8mm inside diameter To change out the PTFE tube 1 Remove the plastic filament from the extruder if there is any currently loaded 2 Unwrap the black wiring wrapping leading from the extruder to the electronics 3 Using the Printrun manual controls raise the Z axis to 80mm 4 Using a 3mm hex driver loosen and remove the two 4mm screws from the bottom of the extruder X axis carriage This will allow you to lift the extruder body off of the hot end and carriage Set the extruder body aside Lift the hot end up and out of the X axis carriage 5 The hot end now has to be partially disassembled to replace the PTFE tube for 1 75mm filament Along with the following instructions you can see an instructional video on how to replace the PTFE at http youtu be 7ExD51Y4 pI 6 Using the 2 5mm hex driver remove the three 3mm screws from the top of the hot end Remove the printed mounting plate 7 Note the path of the wires through the three strain relief slots in the wooden top plate Gently remove the wires from the strain relief slots Remove the top wooden plate 8
11. the top most horizontal aluminum extrusion closest to the filament spool Fig 2 11 page 23 In the extrusion you will find two loose t slot nuts The filament guide attaches to the printer by screwing in the two bolts through the filament guide into the t slot nuts First thread the two bolts through the filament guide into the t slot nuts Leave the bolts loose enough so the filament guide can slide back and forth across the extrusion Set the filament guide 1 5 2cm away from the end of the lower arms of the filament spool Fig 2 12 page 23 Once the filament guide is set in place tighten down the two bolts 20 TM LuLzBot AO 101 USER MANUAL Figure 2 8 Spool mount 11 Insert the micro SD card into the micro SD card slot found on the top of the RAMBo electronics enclosure shown in Figure 2 13 page 24 21 Setup Your Printer Figure 2 9 Spool mounted da Figure 2 10 Filament Guide 22 LULZBOT AO 101 USER MANUAL Figure 2 11 Filament Guide Nuts Figure 2 12 Filament Guide Setting 23 Setup Your Printer Figure 2 13 SDRAMPS 24 3D Printer Software 3D Printer Software 3 1 Software Overview Aleph Objects Inc the maker of the LulzBot AO 101 completely supports free libre hardware and software Along with the AO 101 being a free libre hardware design it has been tested to work with 100 free libre software To operate your desktop 3D printer you will need to instal
12. vapours are extremely flammable Pinch Hazard When the printer is in operation take care to never put your fingers in the moving parts including the belts pulleys or gears Also tie back long hair or clothing that can get caught in the moving parts of the printer viii HAZARDS AND WARNINGS Static Charge Make sure to ground yourself before touching the printer especially the electronics Electrostatic charge can burn up electronic components To ground yourself touch a grounded source Age Warning For users under the age of 18 adult supervision is recommended Beware of choking hazards around small children ix Unpacking Your Printer Unpacking Your Printer Figure 1 1 Orange Zip Ties Remove the plastic bag containing instructions cords and small parts Remove the top foam padding Slowly remove the two smaller foam pads One of these pads will contain the plastic filament spool and plastic filament guide The other pad will contain the 5lb coil of ABS plastic filament With the two small foam pads remove and set aside these items Remove the white power supply box and the black tool bag These items are along opposite sides of the printer Grab the top of the wrapped printer on the top center where you will feel two lengths of square aluminum tubing Holding the top two tubes SLOWLY pull the printer upwards out of the box The two large side foam pads should fall off when the pri
13. ventilated space Leave the mixture bottle closed except when applying a small amount to the wiping towel Acetone liquid and vapours are highly flammable Keep acetone away from open flames and high temperature sources including the 3D printer Read the warnings label on your purchased acetone packaging for additional warnings You may find that during printing printed parts lift off of the print surface on the corners If you are seeing this problem you can make an ABS acetone glue to apply to the print surface Using the HDPE acetone safe bottle included in the printer kit fill the bottle 3 4 full with acetone Now cut eight 75mm lengths of ABS filament and put them in the bottle with the acetone Allow the ABS filament to dissolve for 2 hours To apply the acetone ABS mixture put a small amount onto a paper towel Now rub the towel onto the PET print surface to apply a thin layer of ABS Generally only one thin layer of the acetone ABS solution is needed However if needed you can apply multiple coats 7 4 Using 1 75mm Filament This procedure is highly advanced and involves disassembling parts of the printer including the hot end We recommend using 3mm plastic filament as we have yet to see major advantages to using 1 75mm filament If you would still like to use 1 75mm filament make sure to follow the instructions 49 Advanced Usage carefully If the instructions are not followed correctly you will run the risk of damaging the
14. AO 101 USER MANUAL LULZBOT Aleph Objects Inc LulzBot AO 101 User Manual by Aleph Objects Inc Copyright 2012 Aleph Objects Inc Permission is granted to copy distribute and or modify this document under the terms of the Creative Commons Attribution ShareAlike 3 0 Unported license CC BY SA 3 0 Published by Aleph Objects Inc 123 SW 12th Street Loveland Colorado 80537 USA For more information call 1 970 377 1111 or go to www LulzBot com and www AlephObjects com ISBN 978 1 300 41435 3 20121120 Contents WARNINGS Safety Information o f Pead Me First 2 22 3er hip IR or 2 ase Be Hazards and Warnings AA vajad pee dete a taat tha s az ae ee Unpacking Your Printer Setup Your Printer 3 1 3 2 3 3 3 4 3D Printer Software Sta O Dl ie ety SN a SI A A A mate a a M Bi 6 Sot elk le Sb eat CAD and 3D Modeling Software rennen Loading Filament Your First 3D Print 5 1 5 2 9 3 5 4 5 9 6 1 6 2 6 3 6 4 6 5 6 6 6 7 Set Temperature ee ee Load eileen tsarka ao uke va DER DER er a E Home Printer one aa oa Yl we eae an Bas aa Z Print Height A Remove Parton A AE AAA od Maintaining Your 3D Printer O te we de AT EE ee moot R der Pi Ea a aod te ae BN AO PR Shee fib ba boo one Fe peta eee ee ee Be H bbed A aoe aan OSS aed Sel maid e Aa Ed le ee bek ae ee t A A ee ae eee oe ee aes A A er ee rae es Gee 111 CONTENTS 7 Advanced Usage 7 1 Intro
15. and USB receptacles 6 Plug in the USB cable B plug sguare plug side into the USB receptacle on the printer electronics Plug the other end of the USB cable A plug side into your computer 7 Make sure the printer power switch is turned off the circle side should be depressed The LED on the power supply should not be lit Plug in the black power supply plug from the power supply into the power supply receptacle on the printer The power supply plug must be aligned correctly with the flat side of the plug facing outwards from the printer Fig 2 5 page 19 Fig 2 6 page 19 Now you can plug in the AC power plug from the power supply into an AC power outlet 8 Locate the plastic filament spool Fig 2 7 page 20 9 Remove the large wing nut from the back of the spool Take off one washer leaving the other two on the spool mounting bolt Now locate the spool mount arm on the top right facing the rear of the printer 18 LULZBOT AO 101 USER MANUAL Figure 2 5 Power supply plug Figure 2 6 The power supply and USB plugs correctly plugged in 19 10 Setup Your Printer Figure 2 7 Spool Fig 2 8 page 21 Slide the spool mounting bolt through the hole in the spool mount arm From the back of the spool mount arm slide the one washer on to the spool mounting bolt and turn on and snug tighten the wing nut Fig 2 9 page 22 Locate the filament guide with attached PTFE tube Fig 2 10 page 22 Locate
16. arriage Line up the two mounting holes Push the two 4mm screws through the bottom of the X carriage through the hot end and into the extruder body Thread the screws using the 3mm hex driver but leave loose for now Rewrap the wire wrap around the extruder and hot end wires Finally push 1 75mm filament through the extruder and into the hot end This will align the filament travel space Tighten the two 4mm screws from the bottom of the X axis carriage Before printing with 1 75mm filament make sure to make the needed changes in Slic3r for 1 75mm filament You will need to reslice any previously sliced files with the new settings for 1 75mm filament 51 Hardware and Software Source Code Hardware and Software Source Code TM The LulzBot AO 101 3D printer is a free libre hardware design All of the source files are available at http download lulzbot com A0 101 including e The latest version of this document with ETEX source code e 3D models and print files for all of the printed parts in stl gcode and other original source files e 3D calibration objects and random novelties e Production file for calculating large print runs e Design files for all electronics and machined parts PCB Heatbed RAMBo SDRAMPS Various spec sheets e Bill of materials including every part needed to build the printer AO 101 Budaschnozzle e Drawings of components Aluminum extrusions
17. b and click the Add button In the file browser navigate to the STL you wish to load and click Open The silhouette of the model will appear in the Plater diagram To print more than one copy of the model at a time select the 27 3D Printer Software model name from the list and click the More button With each press of the More button an additional copy of the model will be added to Plater To remove a copy of the model select the model name again and click Less To completely remove the model from Plater select the model name and click Delete Export Gcode files Once you have finished setting your part s in Plater you can generate the Gcode by clicking Export G Code In the file browser navigate to where you would like to save the gcode file and list a name to save the file as Click Save and Slic3r will begin generating the gcode file When Slicer is finished you will receive a prompt If you have created a plate with multiple model designs you can also use the Export STL function to save an STL file for quickly reproducing the same plate of models 33 Printrun Website github com kliment Printrun The host software Printrun is used to start up and control your 3D printer Fig 3 2 page 29 The host controls include setting the extruder and print surface temperatures manual control of each axis and manual extrusion The host is also where you will push print files gcode to the 3D printer or load print files from
18. d clean out the hobbed bolt 44 6 5 SOFTWARE 6 5 Software Every quarter LulzBot will release new stable version of the software It is best to update the software every time a new version is released The software is as important in printing quality parts as the hardware Each quarterly software update can bring advances in print quality The files are available at http download lulzbot com A0 101 You can also updated software versions in the Support Downloads section of LulzBot com 6 6 Belts Periodically you will need to retighten the belts on the AO 101 3D printer For the X axis using the 2 5mm hex driver loosen one of the belt clamps The belts clamps are located on the X axis carriage To loosen the belt clamp loosen the M3 screws on each side of the clamp Using the needle nose pliers pull the belt tight While holding the belt tight tighten down both M3 screws Y axis belt can be tightened using the Y idler tensioner Located on the lower front of the printer the Y idler tensioner has an adjustable bolt at the top of the tensioner Turn the bolt clockwise to push the top of the Y idler tensioner away from the aluminum frame and tighten the belt 6 7 Hot End The hot end should be kept clean of extruded plastic by removing melted plastic strands with the tweezers If melted plastic builds up on the hot end nozzle it can be cleaned with a paper towel soaked with acetone Make sure the hot end is completely cool befo
19. e Tighten the two idler bolts so that the knobs are distanced 20mm away from the extruder body Now use the Extrude button in Printrun to test that the extruder is working properly 5 3 Home Printer Use the home buttons to home the X axis and then the Y axis Next home the Z axis When the Z axis is at home the nozzle tip should be sitting right against the glass Fig 5 3 page 40 The image to the right in figure 5 3 is the correct nozzle height The nozzle should not be pushing down on the print surface To lower or raise the Z home height adjust the Z end stop trigger The end stop trigger is on the far left of the printer near the print surface Fig 5 4 page 40 The end stop trigger can be lowered by turning clockwise and raised by turning counter clockwise Once you have homed 39 Your First 3D Print Figure 5 3 Nozzle height Figure 5 4 Z endstop trigger 40 5 4 Z PRINT HEIGHT the axes and the hotend and bed have reached the correct temperature it is time to print 5 4 Z Print Height Load the bedcalib gco file This file can be found at http download lulzbot com A0 101 objects calibration bedcalib gco The gcode pattern should appear in the Printrun G Code viewer Press the Print button to begin the print When the print starts make sure the first layer is not printing too close or too far from the print bed Note Figure 5 5 page 41 as an example of a good first layer adhesion From left to right
20. e a 30 Printrun viewer gt lt o e e e e e e 32 Filament spool direction 36 Extruder idler bolts 2 be AA td A ea 38 Extruder feed hole er 2 ran eo 39 Nozzle height Ada Gres tg Ads ls Boas 40 Z endstop trigger ee AAA A AAA 40 First layer adhesi n St 2 gt a 2 esta di os 41 WARNINGS SAFETY INFORMATION WARNING Read Me First READ THIS MANUAL COMPLETELY BEFORE UNPACKING AND POWERING UP YOUR PRINTER Hazards and Warnings Before you unpackage or use your printer this 3D printer has motorized and heated parts When the printer is in operation always be aware of possible hazards Electric Shock Hazard Never touch the electronics board when the printer is powered on Before touching or removing any wires from the electronics board always power down the printer and completely turn off and unplug the power supply and allow the power supply to discharge for at least 1 minute Burn Hazard Never touch the extruder nozzle or heater block without first turning off the extruder heat and allowing it to completely cool down The hot end can take up to twenty minutes to completely cool Also never touch recently extruded plastic The plastic can stick to your skin and cause burns Also beware of the heated bed which can reach high temperatures capable of causing burns Fire Hazard Never place flammable materials or liguids on or near the printer when powered or in operation Liquid acetone and
21. ection until the end stop is activated There is a home button for the X Y and Z axes There is also a white home all button that homes all of the axes at once The Motors off button will deactivate all motors allowing all of the axes to be moved by hand Caution when homing the axis will continue to move in the negative direction until the end stop switch is activated If the printer is ever transported make sure the end stop switches are in the correct position before printing The end stops should be aligned so they will be activated by the axes If an axis has missed an end stop and is continuing to try to move in the negative direction immediately turn the power switch to the off position If a print file was running pause the print by clicking the Pause button Realign the end stop and try homing again Loading Print Files To load a gcode file into Printrun click the Load file button Navigate to the gcode file in the file browser and click Open You will now see a 2D images of the first layer of your model design in the Gcode viewer Fig 3 4 page 32 Click the Gcode viewer window to see a more detailed version of the sliced model In the pop up Gcode viewer you can zoom in using the mouse scroll wheel and flip through layers with the up and down arrow keys The lines shown in the Gcode viewer represent the path the extrusion nozzle will follow to print the model 31 3D Printer Software
22. ed the amount of plastic set to the right in mm through the hot end The rate at which the plastic is fed is set below the extrusion length mm min The Reverse button will perform the opposite of Extrude pulling the plastic filament back out of the hot end The large pattern of buttons above the temperature controls are the axes manual controls These functions allows you to manually move each of the three axes of the printer The circular pattern of four quadrants 30 3 3 PRINTRUN controls the X and Y axes The top and bottom guadrants move the Y axis the top in the positive direction forward and the bottom in the negative direction back The left and right guadrants move the X axis the left in the negative direction left and the right in the positive direction right Each guadrant is split into four sections that control the length of movement of 0 1mm Imm 10mm or 100mm The innermost section moves the axis 0 1mm with each section outwards a larger movement with the outside section moving the axis 100mm The linear control bar to the right controls the Z axis The Z axis is also seperated into multiple movement lengths 0 1mm 1mm and 10mm The upper three buttons move the Z axis up and away from the printer surface the three lower buttons move the Z axis closer to the print surface The four triangular buttons around the circular pattern are the axes home buttons Each home button will move that axis in the negative dir
23. exe Slic3r includes very simple settings that allow you to easily refine prints You can create multiple configurations for changing printer setups including nozzle sizes and desired print resolution For ease of use we have pre 26 3 2 SLIC3R Slic3r File Plater Window Help Plater Print Settings Filament Settings Printer Settings Name Copies Scale octo stl 1 100 Autoarrange Export G code Delete All Export STL Print settings default gt Filament default Printer default gt Loaded home aleph shared j devel iulzbot A0 101 objects novelties octo sti El Figure 3 1 Slic3r application STL to Gcode generator defined Slic3r configurations available in the Support Downloads section at www LulzBot com Download the configurations to your Slic3r directory Loading Configurations To load configurations press the Load Config button In the file browser that opens locate the downloaded configuration files Select the configuration file that matches the nozzle size currently installed on the printer 0 5mm nozzle is installed by default Press Open and the pre defined configuration will load into Slic3r You can also save custom configurations for yourself by pressing the Export Config button A file browser will open that allows you to define a name and save your custom configuration Loading STL files To load an STL 3D model file into Slic3r activate the Plater ta
24. g on your rate of use you will want to perform a quick check of your printer every 2 4 weeks The following maintenance guide lines will keep your printer printing quality parts 6 2 Smooth Rods Wipe the smooth steel rods with a clean rag or paper towel The linear bushings leave a solid lubricant that builds up over time If you begin hearing squeaking noises while the printer is printing this is likely a sign that the smooth rods need to be cleaned NOTE never apply any lubricant to the smooth rods the bushings are self lubricating 6 3 PET Sheets After repeated use the PET sheet print surface will begin to wear To replace the PET print surface remove the glass sheet from the printer Peel off the worn PET sheet from the glass sheet If there is any glue or plastic residue left on the glass surface clean it with acetone or an alcohol based glass cleaner Using the green PET sheet from the printer kit lay down the PET sheet onto the glass sheet Use a credit card or driver s license to smooth down and push out any trapped bubbles under the sheet For additional replacement PET sheets visit the LulzBot com store 6 4 Hobbed Bolt The plastic filament is pulled through the extruder by a hobbed bolt After repeated use the teeth of the hobbed bolt can become filled with plastic Using the brush or pick from the printer kit clean out the hobbed bolt teeth If an extruder jam ever occurs remove the plastic filament from the extruder an
25. ghten the nozzle until it touches against the heater block again To loosen a stuck nozzle off of the threaded extension heat the hot end to 90 100 C This will soften the plastic inside the hot end and allow the nozzle to be turned off of the threaded extension Take care when removing the nozzle while the hot end is hot Wear leather gloves or use a towel to turn the nozzle off of the hot end Once you have removed the nozzle you can then thread on the other nozzle size you would like to use Make sure the nozzle has threaded correctly onto the threaded extension before trying to turn it with the wrench Turn the nozzle clock wise until it tightens against the heater block 48 7 3 ABS ACETONE GLUE After installing the new nozzle you may need to adjust your Z home trigger setting before printing again Refer to the Printing Your First Print section page 37 for calibrating the Z home trigger setting If you will be changing nozzles frequently we suggest reapplying a small amount of high temperate anti seize to the inside threads of the nozzles You will need an anti seize capable of temperature of at least 250 C 7 3 ABS Acetone Glue Acetone is not included or required with the AO 101 3D printer An acetone safety label is included for the HDPE bottle Acetone can cause skin irration when prolonged skin contact occurs It is recommended to use acetone safe gloves when applying the ABS acetone glue Use the ABS acetone glue in a well
26. l a few software packages onto your PC You will need a 3D printer host an STL to gcode generator and optional CAD or 3D modeling software All of the following free libre software is available for GNU Linux Windows and Macintosh However we highly recommend using these softwares on GNU Linux The required software can be found in the Support Downloads section at www LulzBot com You will also find instructions there for installing each program onto your PC Make sure to select the software version that corresponds with the AO 101 3D printer and the operating system you are using 3 2 Slic3r Website www slic3r org The Slic3r software is the first tool in the chain of 3D printing software Fig 3 1 page 27 Slic3r uses commonly used STL stereolithography files to create gcode files Gcode files contain instructions for the 3D printer on where when and how fast to make movements However Gcode programming is not very suitable for CAD and 3D design This is where Slic3r and the STL file comes into use The STL file is a 3D model file that can be exported by all common CAD and 3D modeling software The Slic3r software then slices the STL 3D model into layers and print paths to create a 3D printable gcode file To launch Slic3r navigate to the Slic3r directory and launch the slic3r pl file On GNU Linux operating systems you may need to set the slic3r pl file as executable On other operating systems it may be called slic3r
27. m s B minimum FAI segment time ms X maximum xY jerk mm 5 Z maximum Z jerk mm s 230 X echo M205 S0 00 T0 00 B20000 X20 00 20 40 Besen Si Check temp Setting hotend temperature to 230 000000 Bed Off 110 v 26 87 B 27 00 degrees Celsius echo SD init fail Extrude 5 nm bas workDir open failed ok T 26 84 B 27 00 100 mm miniso Setting bed temperature to 110 000000 degrees Celsius Reverse Send Printer is online Loaded AO x end idler ACME_FAST_2 gcode Hotend 26 84 Bed 27 00 Figure 3 2 Printrun application for 3D printer control systems the port may be named such as COM1 or tty usbserial USB ID If you only have one printer connected there will only be one port available to select Make sure the port baud rate is set to 115200 in the pull down menu to the right of the port selection You can refresh the USB ports by clicking the Port button Now to connect to the printer click the Connect button In the text output window you will see multiple return lines If you see Printer is now online you have succesfully connected to the printer The printer control buttons on the left will also darken and become clickable after connecting When you need to disconnect the printer simply press the Disconnect button Printer Controls All of the printer controls can be fou
28. nd on the left side of the Printrun interface Fig 3 3 page 30 To set the hot end and print surface temperature first click the Monitor Printer check box on This will enable the printer temparature bars and graph The hot end and print surface controls are labeled Heater and Bed Select the temperature setting by 29 3D Printer Software mm min Motors off XY 4000 z 200 UA Heater Off 230 ab v Set Check temp Bed Off orr 110 ab y set 1 28 69 B 29 00 zou 5 200 100 Extrude am mm miniso Reverse Graph offline 100 50 Figure 3 3 Printrun controls using the pull down menu for pre defined temperature settings You can also set custom temperature settings by typing into the temperature box To turn on the hot end and or printer surface click the respective Set button The Set button will highlight orange when the temperature is set to on for that component When the hot end or print surface is set to on you will see the temperature bar and graph display the set temperature and the current temperature When both components have reached the correct temperature the printer is ready for printing Clicking the Off button will turn off that component and highlight the Off button blue Below the temperature controls are the manual extrusion controls There you can manually extrude plastic through the hot end and retract the plastic filament from the hot end The Extrude button will fe
29. nter is out of the box Set you printer on a stable level surface Gently unwrap the pink ESD plastic covering the printer Remove the rolled sheet of PET tape from below the print bed Gently lift the printer to slide the plastic wrapping from under the printer 12 8 10 11 LULZBOT AO 101 USER MANUAL Find the item list attached to the plastic bag of parts Before you move on to setting up your printer make sure all of the items on the list are in your package Using scissors or wire cutters cut and remove the two ORANGE plastic zip ties Fig 1 1 page 12 One zip tie is located on the bottom front of the printer on the print bed The other zip tie is wrapped around the extruder carriage and X axis Make sure to not cut any of the surrounding wires or belts Figure 1 2 Red Shipping Clamps Remove the four red shipping clamps above and below the x end motor mount and idler Fig 1 2 page 13 Loosen and remove the wing nut and screw on each of the four clamps Remove each of the four clamps by popping them off of the smooth rod Use a screwdriver or wrench to pry open and remove the clamps if you have trouble removing them by hand Fig 1 3 page 14 Keep the clamps and hardware for future use if you need to ship or transport your printer 13 Unpacking Your Printer Figure 1 3 Using a wrench to pry off the shipping clamps 12 Remove the blue tape from the sides of the print surface Make sure
30. re attemping to clean the nozzle with acetone 45 Advanced Usage Advanced Usage 7 1 Intro After becoming fimiliar with printing with the AO 101 3D printer with the default settings there are a few advanced techniques that may help in getting better and more consistent prints Some of this instructions include items and materials not included with the AO 101 With any of these additional items or materials follow safety and usage guidelines as instructed by the manufacturer 7 2 Changing nozzles To achieve higher resolution parts you can change to a smaller sized nozzle included in the printer kit Using the 0 25mm or 0 35mm nozzles you can print at smaller layer heights to create smoother parts In most cases the nozzle is best changed when the hot end is completely cool NEVER try to remove the nozzle when the hot end is at extrusion temperature At higher temperatures the threaded extension expands in the nozzle causing the nozzle to bind if turned To change the nozzle you will need the 18mm and 13mm wrench from the printer tool kit Slide the 18mm wrench onto the rectangular aluminum heater block Using the 13mm wrench turn the nozzle counter clock wise Make sure the nozzle is turning off of the threaded aluminum extension that runs up through the heater block Do not allow the heater block to turn This can put strain on and possibly damage the wiring If the threaded aluminum extension is turning with the nozzle reti
31. s another free libre CAD software however different than FreeCAD it is script based Rather than using a GUI to generate CAD designs OpenSCAD CAD designs are created using script based renderings Users with programming experience would find this very useful Also OpenSCAD uses a simple script language that is easy to learn for users with little or no programming experience Blender Website blender org The most widely used Free Libre 3D modeling software Blender is well documented with tutorials available on the Blender org website Numerous video tutorials can be also found online 33 Loading Filament Loading Filament Figure 4 1 Filament spool direction Loosen the three wing nuts on the upper arms of the filament spool Turn the upper arms 90 degrees upwards away from the printer Remove the lb coil of filament from the plastic packaging leaving the twist ties on Slide the coil over the spool upper arms Make sure the filament coil direction is counter clock wise from the rear of the printer when placing the coil on to the spool Fig 4 1 page 36 Lower the three upper arms and re tighten the wing nuts The twist ties can now be removed Keep the twist ties for future use if you ever need to remove the filament to change to a different filament Feed the end of the filament through the filament feed tube If it is loose slide the opposite end of the filament through one of the
32. the SD card for printing out model designs To launch Printrun navigate to the Printrun directory and launch the pronterface py file On GNU Linux operating systems you may need to set the pronterface py file as executable On other operating systems the file may be called pronterface exe Connecting the Printer To start up the printer first you will need to connect to the printer with Printrun Make sure you have connected the USB cable from your PC to the printer before launching Printrun If not close Printrun connect the USB cable and relaunch Printrun In the top left Port pull down menu select the correct port for the printer generally dev ACMO On other operating 28 3 3 PRINTRUN File Settings Port Idev tty ACMO 115200 Disconnect Reset Mini mode Load file Compose SD Print Pause mm min Sanar d A 5 RR Connecting Motors off xy 4000 z 200 echo 1 0 0 Beta 1 HA BE A start Printer is now online echo Free Memory 4949 PlannerBufferBytes 1168 echo Using Default settings T echo Steps per unit lecho M92 X44 50 Y44 50 Z2560 00 E844 00 echo Maximum feedrates mm s echo M203 X500 00 Y500 00 Z5 00 E500 00 echo Maximum Acceleration mm s2 I echo M201 X5000 Y5000 Z100 E10000 jecho Acceleration S acceleration T retract N I E acceleration echo M204 3000 00 T3000 00 echo Advanced variables S Min feedrate mm m s T Min travel feedrate m
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