Acrylic plattform upgrade for the Replicator
Description
The benefit of PLA printing on an acrylic surface is that it bonds better to it, then to painters tape. This will reduce the risc of curling and warping considerably. Also, since the acrylic sheet ment to be used with this clamps is only 3 mm thick, after the print is done, you remove the sheet and gently bend it in different direction to loosen the print from the surface. That should make it easy to snap it off with your fingers.
Also, if you happen to run the extruders into the plattform, a acrylic sheet is much cheaper to replace then the aluminium platform.
Further more, since temperature and distance between nozzle and acrylic sheet matters, with this mod, you can actually get more control over how hard the part is bonded to the buildplate! That means for instance that you can print supported structures without a raft ( just reduce the space between the nozzle and buildplate alittle ) and the supportstructure still wont fall over.
Also, you cant control thoose really stubborn prints that never seem to stop curling. Just close the gap even further, and it will bond like nothing else.
Enjoy!
Instructions
In order to make room for the 3 mm acrylic sheet, you need to use the long piece and push it down on the wooden edge that makes contact with the Z-endstop when the machine goes to home axis. Look at the first picture and you will see the distance piece in place next to the Z-screw. Make sure it has a tight fit so they wont come loose by vibrations. You should also trim all surfaces on these printed parts, so the are without obstructions, smooth and wont catch on something. It is also a good idea to sand down the edges of the acrylic sheet alittle, to make it easier to push on the four clamps to hold it in place.
As for the position of the four clamps, you can put them anywhere they fit, but be careful not to put them in a place where the nozzles can collide with them, otherwise you might damage your machine. My recommendation is at positions 3 o'clock, 5 o'clock, 9 o'clock and 11 o'clock. If you find the nuts underneath the platform being in the way, just choose the closest place. This should probably work most of the time, but keep in mind, the location of these clamps depends on how the extruders will move during the print.
Finally, give the nozzle some extra room over the platform, extruding too close to the acrylic will fuse the PLA into the acryllic and it wont come out again. Like ever. Start at twice the distance you normally have, and the tighten carefully between each attempted print to find the sweet spot. And as always, make sure your platform surface is properly degreased!
When your unwarped, uncurled, beutiful print is done, just remove the acrylic sheet, bend it genlty in different directions until you hear cracking noises, and just snap off the print with your fingers.
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By coincidence, I tried printing using PLA on Acrylic this weekend, and the prints stuck to the point where I had to cut them off. Is there a particular formulation/brand of Acrylic? Or is there some other trick?
Update:
Yes, different brands of acrylic sheets matters. Im currently using an acrylic sheet labeled "Perspex", so you could start trying that brand. However, im not sure that all "Perspex" acrylic sheets are the same, so you might need to try different sources. All i know is that some of the acrylic sheets are crap and will permenantly weld itself to your printed part. You basically have to grind it away to get it off :/ So try different brand, starting with the "Perspex" brand.
As i wrote above, you must make the distance between the nozzle and the plattform larger the normal. I roughly have twice the distance. Being to close will couse the PLA to fuse into the acrylic sheet, and then youll never get it out. Try again, but this time, fold the Makerbot Industries buisnesscard in two so its twice as thick before you use it to calibrate the nozzle height at Z home position.
They recommended removing and bending the sheet until it pops off willingly. did you try that?
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Would unplugging the HBP be a reasonable safeguard against forgetting to turn the heat off?
..Because if so, maybe we could figure out a way to clamp the acrylic to the hbp at the outlet. That way, you'll always remember to unplug it if youre clamping the acrylic on.