3D Systems BFB-3000, Manual

Page 1: ...Document No D100253 BFB 3000 Set Up and Operations Manual Version 3 0 ...

Page 2: ... bed is referenced to the extruder nozzles Load the extruders Start a print Print a successful raft Print the first model Failure to carry out all of the set up procedures contained in this document will damage the machine This document has been designed to illustrate the essential procedures and get you up and running as quickly as possible Please take time to understand how the process works and...

Page 3: ...3 6 3 Check the bed is fitted correctly 14 6 3 1 Remove the bed 15 6 3 2 Fit the bed 16 6 4 Power up 17 6 5 Manual move 18 6 6 Check the hot end nozzles are clean from plastic debris 20 6 7 Check the bed is level 21 6 8 Check the bed is referenced to the extruder nozzles 28 6 9 Load the extruders 31 6 9 1 Load the filament 31 6 9 2 Extruder control 37 6 9 3 Purge the extruder 38 6 10 Start a print...

Page 4: ... 9 3 2 Soluble support structure 52 9 3 3 Storage 52 9 4 Control panel functions 53 9 4 1 Run file 53 9 4 2 Extruder mapping 53 9 4 3 Manual move 55 9 4 4 Extruder control 55 9 4 5 Home tool head 55 9 4 6 Settings 55 9 4 7 Set Z height 56 9 5 Maintenance operations 60 9 5 1 Updating your printer 60 9 5 2 Adjusting the nozzle wipe 60 9 5 3 Fine adjustment to level the nozzles 62 9 5 4 Handling a gr...

Page 5: ...BFB 3000 Set Up and Operations Manual Document No D100253 5 3 Manual symbols CAUTION notes to prevent damage to the machine DANGER notes to prevent injury to the operator ...

Page 6: ...0 Set Up and Operations Manual Document No D100253 6 4 How this manual works How the BFB 3000 3D printing process works Initial setup of the BFB 3000 machine and testing First print Links for further printing ...

Page 7: ...al Document No D100253 7 5 Process overview how the BFB 3000 works Before reading this section please ensure that the unpacking instructions have been completed 5 1 BFB 3000 Bed Filament reel holders Control box Nozzle wipe box Extruders ...

Page 8: ...BFB 3000 Set Up and Operations Manual Document No D100253 8 5 2 Tool kit 8mm spanner Hex drivers Side cutters Model removal tool Pliers SD card Ø3mm drill bit Ø0 5mm drill bit 1 5mm Allen Wrench ...

Page 9: ...ect in your 3D modelling package1 Load your model into Axon to automatically process the file 1 Most CAD packages export to STL format However STL quality depends on the CAD package Poor quality STLs may need repairing before loading into Axon STL fixing programs are readily available e g NetFabb Save as STL Save as BFB ...

Page 10: ...BFB 3000 Set Up and Operations Manual Document No D100253 10 Extruders Filament reels Delivery tubes ...

Page 11: ...gh a hot end to produce a thin molten filament of plastic The extruder draws each layer with this filament After each layer is produced the bed increments down so that a new layer can be drawn on top of the last building up the 3D model A second optional extruder automatically prints support filament for printing overhanging features Hot end ...

Page 12: ... part of our quality control We leave these on the print bed to show that the printer has been checked and to demonstrate some basic prints Remove any previous prints with the model removal tool Slide the edge between the bed and the first layer to remove the entire print If the model is difficult to remove from the bed in situ you can take the whole bed out of the machine to make the removal proc...

Page 13: ...om the bed Use the model removal tool to remove any stuck fast tracks It is normal for prints to leave marks on the bed and for the model removal tool to lightly scratch the surface of the bed This will not affect the printer s operation However take care to avoid gouging the surface with the material removal tool the bed must be flat Clean no build material debris ...

Page 14: ...e bed is fitted correctly Ensure that bed is correctly fitted to the printer The three bed bolt heads should sit flush in the countersinks If not remove the bed then refit it as shown in the next two sections Bed bolt 3 Bed bolt 1 Bed bolt 2 Bed Bed bolt head in countersink ...

Page 15: ...p and Operations Manual Document No D100253 15 6 3 1 Remove the bed Tip removal is easier if the bed is near the bottom of the machine If it is too high you can manually lower the z axis see Manual move page 18 1 1 2 ...

Page 16: ... 16 6 3 2 Fit the bed Tip fitting is easier if the bed is near the bottom of the machine If it is too high you can manually lower the z axis see Manual move page 18 Check all bolt heads are fitted correctly see Check the bed is fitted correctly page 14 2 2 3 ...

Page 17: ...ol box on using the power switch shown in Figure 1 Figure 1 Control panel Table 1 Buttons used for navigation Button Screen Navigation Y Up Y Down X Enter Esc Escape Z Extruder selection up see Extruder control page 36 Z Extruder selection down in Extruder control page 36 Power socket Z Z Escape buttons Screen Y Y X X Enter buttons buttons Power switch Power indicator SD card indicator SD card ...

Page 18: ...ge 19 Caution Always move the Z axis first to ensure that bed is away from the extruder nozzles and does not collide during an X Y move Collisions between the extruder nozzles and the bed may damage both Caution Observe each X Y axis movement In these axes it is possible to drive the extruders too far away from the Home position Figure 2 into the printer frame Avoid this Excessive collisions will ...

Page 19: ...BFB 3000 Set Up and Operations Manual Document No D100253 19 Figure 2 Axis designation for the BFB 3000 Y Z X Home Position ...

Page 20: ...ddle of the machine see Manual move page 18 to make access to the nozzles easy Pull away any light plastic debris away from the nozzle tip using the pliers If plastic debris is stubborn you may need to heat the extruder to make the plastic soft enough to remove To heat the extruder up please refer to Extruder control page 36 Caution When heating up nozzles to remove plastic debris do not touch the...

Page 21: ...e level We make every effort to level the bed before the machine leaves our factory However the bed may move in transit therefore it is essential to check that the bed is still level The print bed is mounted on three sprung bolts which allow adjustment of the bed height in three places Bed bolt 3 Bed bolt 1 Bed bolt 2 Bed ...

Page 22: ...itted correctly page 14 On the control panel select Settings Level Bed function and press enter RUN FILE EXTRUDER MAPPING MANUAL MOVE EXTRUDER CONTROL HOME TOOL HEAD SETTINGS EXTRUDER OFFSETS LEVEL BED SET Z HEIGHT SET BED TYPE GENERAL SETTINGS Press Z to raise the bed to adjust the gap between the hot end and bed Start with approximately 10 mm distance between the nozzle and the bed This will ena...

Page 23: ...tions for more movement options During each movement along the side of the bed observe from the side of the machine any change in distance between the bed and extruder s hot end as it moves along Figure 3 Levelling bed along the Y axis viewed from the side Figure 4 Levelling the bed along the X axis viewed from the front Adjust bed bolts to make extruders move parallel to the bed ...

Page 24: ...vel using the 3mm hex driver from the toolkit Underneath each of the 3 bed bolts is a locking nut which must be loosened with the 8mm spanner before the bolt can be adjusted It may take several movements of the extruder and consequent bolt adjustments to ensure that the bed is level Loosen locking nut to adjust bolt ...

Page 25: ...re that axes are checked from the appropriate side of the machine to better judge flatness PHOTOGRAPHS TAKEN FROM ABOVE View the movements in the X axis from the front of the machine View the movements in the Y axis from the sides of the machine BACK BACK FRONT FRONT ...

Page 26: ...hould not touch the bed Moving the extruder with the nozzle touching the bed will damage the nozzle and the bed If the nozzle touches the bed immediately lower the bed using the Z button Finally check the centre location of the bed by pressing Y This can be used to identify an excessively worn or warped print bed as the height in the middle will differ from the perimeter of the bed Press Escape to...

Page 27: ...lock the 3 bed bolts in position by tightening the lock nut under each using the 8mm spanner Whilst tightening the nut make sure that the bolt does not spin by holding it in position with the 3mm hex driver from the top side of the bed Tighten nut to lock bolt into position ...

Page 28: ...an page 20 Check the bed is level page 21 On the control panel select Settings Set Z Height function and press enter RUN FILE EXTRUDER MAPPING MANUAL MOVE EXTRUDER CONTROL HOME TOOL HEAD SETTINGS EXTRUDER OFFSETS LEVEL BED SET Z HEIGHT SET BED TYPE GENERAL SETTINGS Observe the gap between the nozzle and bed from the front of the machine Press and hold the Z buttons to move the bed Start with a gap...

Page 29: ...aution If the nozzle is pushed too hard against the bed the nozzle will be forced into the bed for the whole first layer of printing This will damage the nozzle and the bed Ensure that setting the nozzle against the bed does not compress the bed springs Bed spring ...

Page 30: ... D100253 30 Pressing Enter X will save the setting to the printer s memory which is retained when the power is turned off The Z offset value will be applied each time the printer is homed Pressing Escape will exit the function without saving the value ...

Page 31: ...l the end of the filament must be prepared to prevent damage to the delivery tubes This procedure is essential to prevent any damage to the delivery tubes which may in turn block a nozzle Cut the end of the filament at 45 from both sides to produce a point Using sandpaper remove all sharp edges The tip should feel smooth 1 2 3 4 ...

Page 32: ...ruder are indicated below Delivery tubes for each extruder run from right to left as indicated below Figure 5 Reel positions and delivery tubes Reel position for Extruder 1 Reel position for Extruder 2 Reel position for Extruder 3 Tube for Extruder 2 Tube for Extruder 3 Tube for Extruder 1 ...

Page 33: ...r of extruders in the BFB 3000 Material for Extruder 1 Material for Extruder 2 Material for Extruder 3 1 ABS or PLA 2 ABS PLA 3 ABS PLA Not needed in first print After positioning the reels 1 Insert the filaments into the appropriate delivery tubes identified in Figure 5 page 32 Feed filaments up to extruders 2 Example for this section BFB 3000 with two extruders PLA ABS ...

Page 34: ...B 3000 Set Up and Operations Manual Document No D100253 34 Check the filaments exit the tubes at the correct extruders Push filament out of the end of the delivery tube Extruder 2 Extruder 1 Extruder 3 3 ...

Page 35: ... No D100253 35 Use pliers to push the filaments into the white tube for each extruder as far as it will go approximately 10 cm 5 4 Remove the pressure bearings below on the extruders Use the 4mm hex driver from the toolkit Pressure bearing assembly ...

Page 36: ...ngs onto the extruders Ensure filaments run on the middle smaller pressure bearings If not move the bearings around using the nose of the pliers until they snap into position 6 7 8 Tighten the pressure bearing springs until they are fully bound they will be adjusted from this position later ...

Page 37: ...ANUAL MOVE EXTRUDER CONTROL HOME TOOL HEAD SETTINGS Extruder control manages one extruder at a time E1 E2 or E3 using the buttons on the control panel EXTRUDER CONTROL Cur Tgt RPM E3 E2 25C 0C 0 E1 259C 260C 0 indicates selected extruder E1 E2 or E3 are selected using the Z buttons Temperature at extruder nozzle C Target temperature at extruder nozzle C Use Y buttons to change Revolutions per minu...

Page 38: ...arings are fully compressed Compression needs to be adjusted from this setting Proceed by purging one extruder at a time Heat the extruder to the maximum temperature defined below depending on the material in the extruder Material Extrusion temperature C ABS 260 PLA 195 Once target temperature has been achieved turn the RPM up to 15 If the motor on the extruder stalls you will hear a clicking soun...

Page 39: ...o the extruder this could take several minutes Allow material to purge for a few seconds before reducing the RPM to 0 Repeat for each extruder Turn the machine off to allow the nozzles to cool As the extruders cool clean the nozzles see Check the hot end nozzles are clean page 20 Dispose of all waste filament from the nozzle Pressure bearing bolt Thin filament of plastic 4mm hex driver from toolki...

Page 40: ...run two test files documented in the following sections When asked to print a file you will need to follow the procedure below Insert the SD card into the BFB 3000 control box Turn the control box on Select Run file and press Enter RUN FILE EXTRUDER MAPPING MANUAL MOVE EXTRUDER CONTROL HOME TOOL HEAD SETTINGS Current file FILENAME BFB File 3 of 3 Press Enter to confirm and start the print The firs...

Page 41: ...tee a good build Therefore the height of the hot end nozzle over the bed for the first layer is critical If the nozzle is too far away from the bed the filament will not stick to the bed If the nozzle is too low it will not be able to extruder the filament and there is a risk of damage to the bed and the nozzle SIDE VIEW END VIEW Model Raft Nozzle Deposited Filament Bed Nozzle movement ...

Page 42: ...e filament into the bed therefore small contact area between filament and bed Raft may detach in mid print OK Filament pushed into the bed slightly to maximise surface area contact with bed but still maintain extrusion flow NOZZLE TOO LOW Not enough clearance for the filament to be extruded damaging either the extruder or the bed ...

Page 43: ...1 Follow the section Start a print page 40 to print the preloaded raft check file on the SD card supplied in your toolkit relevant to the material loaded into Extruder 1 see table below Remember only the first 6 characters of the filename will be displayed on the control box if the filename is longer than 8 characters Material type in Extruder 1 File to print ABS RaftABS_CheckFile PLA RaftPLA_Chec...

Page 44: ... 2 Examine the raft check file RAFT MAGNIFICATION NOTES NOZZLE TOO HIGH Wavey tracks or tracks narrower than 1 2 mm use vernier calipers to check See Perfect the raft page 46 NOZZLE TOO LOW Tracks sides pushed over neighbouring tracks See Perfect the raft page 46 OK ...

Page 45: ...me imperfections in the raft but that the process is very forgiving and even the images shown below will generally not spoil a full print 6 11 3 1 Track ripping 6 11 3 2 Purge deposit Track ripping can be caused by a dirty nozzle snagging a track and ripping it in the direction of the extruder See Perfect the raft page 46 Purge deposit can be caused by a dirty nozzle leaving its plastic behind on ...

Page 46: ...e bed is referenced to the extruder nozzles page 28 to adjust the height at which the nozzle starts printing Nozzle to low See Check the bed is referenced to the extruder nozzles page 28 to adjust the height at which the nozzle starts printing Nozzle heights appear inconsistent across a single print Check the bed is level page 21 Track ripping Check the hot end nozzles are clean page 20 Purge depo...

Page 47: ...e number of extruders on your BFB 3000 see table below Remember only the first 6 characters of the filename will be displayed on the control box if the filename is longer than 8 characters Number of extruders File name 1 ABS Duck1A_E1_ABS bfb 1 PLA Duck1P_E1_PLA bfb 2 Duck2_E1_ABSraft_E2_PLAbuild bfb 3 Duck2_E1_ABSraft_E2_PLAbuild bfb same as above After printing follow procedure detailed in Remov...

Page 48: ...ownwards even slightly turn the bed over page 15 and 16 to point the bow of the bed upwards for the next print as shown below The next print will restore the bed s flatness maintaining a flat bed If the bed is turned over Check the bed is fitted correctly page 14 Check the bed is level page 21 Check the bed is referenced to the extruder nozzles page 28 Printing with bed bowed down Slight bowing ca...

Page 49: ...waste bin After each print you will need to empty the nozzle wipe box Lower the bed see Manual move page 18 to access the nozzle wipe box Remove the waste box from the machine and dispose of the plastic deposits Re install the waste box back into the machine ready for your next print ...

Page 50: ...0 8 Further printing Now your printer is set up you will need to visit our website at www bitsfrombytes com to Download and install Axon software illustrated in page 9 Check for free updates we issue updates regularly to continually improve printing performance ...

Page 51: ...g pliers After removing the remaining filament follow the instructions in the Load the extruders section page 31 to load a new filament Purge the extruder page 38 until the old material is completely flushed out See caution note below about purge temperature If a new material is being loaded in to the extruder purge at the temperature of the material which has the highest melting point E g if PLA ...

Page 52: ...sible to use different materials for the build and the support This is configured in Axon By using ABS build and PLA support PLA support can be dissolved by Leaving the model in an ultra sonic tank with a small amount of caustic soda Time and concentration depends on the volume of the material needed to dissolve Leave the model in water at 80 C for over 48 hours 9 3 3 Storage All polymers degrade ...

Page 53: ...e main menu The following sections describe all the functions 9 4 1 Run file See Start a print page 40 9 4 2 Extruder mapping Extruder mapping allows you to swap the extruders specified in your BFB files generated in Axon onto physical extruders on the machine E g you can map the extruder specified in the BFB file as extruder 1 onto physical extruder 2 Swapping extruders is useful if you want to a...

Page 54: ...t in the print solely using physical extruder 2 Physical extruder 1 will be unused Remapping extruders is achieved by going to Settings Extruder Mapping Identify what each extruder is used for in the Gcode determine which physical extruder you want them to map to Pressing X will change Gcode extruder 1 mapping Pressing Y moves the menu cursor between Gcode extruder 1 2 It is not possible to select...

Page 55: ...n Make sure the bed is in position before homing the tool head The bed contains a sensor necessary for homing Without the sensor the machine will drive the bed frame into the waste disposal stand offs Repeated collisions will damage the machine 9 4 6 Settings Push Enter to enter the Settings menu EXTRUDER OFFSETS LEVEL BED SET Z HEIGHT SET BED TYPE GENERAL SETTINGS See the following sections for d...

Page 56: ...our website to download the calibration procedure and determine the offsets values Extruder 2 X 44 30 Extruder 2 Y 0 00 Extruder 3 X 88 60 Extruder 3 Y 0 00 Use the Z buttons to select the extruders Use the Y buttons to alter the values Press X to save or Escape to quit without saving Incorrect values will severely affect print quality 9 4 6 2 Level bed See Check the bed is level page 21 9 4 7 Set...

Page 57: ...e bed design in the machine dictates how the machine operates V2 Black composite V1 Clear perspex Use the Z buttons to select the bed type Press X to save or Escape to quit without saving If the wrong bed is selected the machine will be unable to home its z axis and will damage itself ...

Page 58: ...nore G92 Yes Enable Hopping Yes Use the Z buttons to select the option Press X to save or Escape to quit without saving Incorrect general settings will severely affect the BFB 3000 print quality Do not change any general settings without fully understanding each setting first See the following sections for general setting explanations ...

Page 59: ... extruder offsets from the Gcode file and into the printer When the printer utilises extruder 2 it reads the offsets from memory When the extruder offsets are loaded from memory the Axon generated G92 commands in the Gcode file must be ignored by the printer Otherwise the Axon generated G92 extruder offsets will be applied in addition to the printer memory extruder offsets resulting in print failu...

Page 60: ...s may include Firmware the software inside the control box Hardware mechanical improvements 9 5 2 Adjusting the nozzle wipe The nozzle wipe should sit slightly higher than the height of the nozzle tip so that when the nozzle is moved over the wipe the wipe brushes over the nozzle tip Use Manual move page 55 to position the nozzle over the nozzle wipe box Nozzle Nozzle wipe Nozzle wipe box ...

Page 61: ... wipe box and loosen the M3 nuts and bolts on the back of the wipe using the 2 5mm hex driver supplied in the toolkit Use the reference holes to gauge the adjustment and ensure that the nozzle wipe is horizontal Retighten the M3 nuts replace the nozzle wipe box and re check nozzle wipe position Reference holes M3 nuts ...

Page 62: ...es are not level with respect to the flat and level bed proceed as follows The remainder of this procedure will level the nozzles by sanding the tips down This is a permanent change ensure that it is necessary by thoroughly checking all the preceding steps before continuing as the process cannot be reversed Make sure that the nozzle has plastic loaded into the tip This reduces the burring on the i...

Page 63: ...anually turn the ø 0 5 mm drill bit supplied in the toolkit 2 revolutions to remove any burrs in the orifice from the sanding process You will need to use Extruder control page 37 to melt the plastic inside the nozzle to insert the drill bit Caution When heating up nozzles to melt plastic do not touch the nozzle tips with your fingers Extruders will burn if touched when hot Make sure the ø 0 5 mm ...

Page 64: ...o the bed the back of the filament may be ground out by the extruder drive shaft The drive shaft will then be unable to push the filament down into the nozzle preventing the extruder from extruding This is normally indicated by a fast build up of plastic dust around the pressure bearing If the nozzle is not extruding a build up of plastic dust can indicate a ground out filament Remove pressure bea...

Page 65: ...ruder control page 37 Examine the removed filament to confirm the cause Reload the filament as per Load the extruders page 31 taking care to prepare the tip of the filament as specified Cut filament using side cutters Remove loaded section using pliers Normal drive shaft teeth marks Ground out section ...

Page 66: ... filament snaps in more than one place in the delivery tube the tube needs to be flushed of any trapped broken sections before the filament can be reloaded Also remove filament from extruder end as per Handling a ground out filament page 64 Broken section of filament Remove all readily available sections of filament ...

Page 67: ...B 3000 Set Up and Operations Manual Document No D100253 67 Unclip delivery tube from back panel at all points Pull out delivery tube full out of bottom bracket Bring delivery tube up to top of the machine ...

Page 68: ... extruder end completely removing it from the machine Prepare an end of filament from the reel rounding the edges as per standard filament loading procedure page 31 Energy chain This will be used to push any trapped segments out of the delivery tube and support the tube when re threading back into the machine ...

Page 69: ...e in a coil to match the natural bend of the filament making it easier to push out the trapped segments of filament Once all the trapped segments have been pushed out continue to push the reel filament through so that approximately 5 cm protrudes at both ends Then cut the reel filament to detach the arrangement from the reel ...

Page 70: ...on non nut end of the tube so that the filament cannot move in the tube Insert the taped end back down inside the energy chain from the extruder end Push the tube all the way back down the energy chain You may need to move the extruders around to massage the tube through ...

Page 71: ...p and Operations Manual Document No D100253 71 On exiting the energy chain remove the tape Run the delivery tube under the second steel bar at the back of the machine Re clip the delivery tube against the back panel ...

Page 72: ...tions Manual Document No D100253 72 Position the nut end of the tube so that the nut sits comfortably on the extruder body Remove the support filament from the delivery tube Finally reload filament as Load the filament page 31 ...

Page 73: ...e visit our website at www bitsfrombytes com to use our troubleshooting guides 9 7 Troubleshooting Please visit our website at www bitsfrombytes com to raise a support ticket 9 8 Specifications Please visit our website at www bitsfrombytes com to view specification sheets on the BFB 3000 ...