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Surface Finish Calibration Test Shape

by whpthomas, published

Surface Finish Calibration Test Shape by whpthomas Dec 24, 2012

Description

If you are having problems with uneven surface finish in things with curved surfaces, this calibration shape provides a quick print shape with a diversity of surfaces to check. I made this as an alternative to the standard 20 x 20 x 10 calibration cube.

UPDATE (Feb 7th 2013)
New Slic3r Config files for the Replicator 2. You still need to use ReplicatorG to load the sliced gcode files and export as x3g to print. Scroll to the bottom of Instructions below for installation guide.

I have also recently added a new 340 micron profile for when you just want to print something quickly, and a new 340 ZERO FILL to make it easier to create Stretchlet Bracelets like emmett's thingiverse.com/thing:13505

Version 6 profiles have been tweaked for the new 7.0 firmware. I have also described all the key changes I have made in these profiles so you know what I have changes and why, so you can experiment yourselves. I have tried to be a bit conservative with the settings in the profiles provided here, so read the comments below to tweak them even further if you feel the need to.

Because a few of you have asked - Paypal donations graciously accepted - whpthomas at yahoo dot com

Recent Comments

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Hi, thanks a lot for your Replicator Slic3er profile(s)!!! I'm currently adjusting them a bit to get them working with Flash Forge Creator Dual-Extruder. But I'm stuck at one of the gcode start lines. The one is "G1 X-137 Y-70 Z0.1 F1000.0 ;Slow wipe"....what does it do? As Flashforge dimensions are lower than those of the Replicator, I guess this lines makes my device create noise (ratatatkrkrk). Everything else workes fine. After I'm dine, I will surely upload the profiles as a remix of yours! :-) Once more, thanks!

There are a couple of things you will have to check. The packing density for ABS is 0.85 whereas PLA is 0.97. The retraction distance for ABS is probably less.

Would these profiles (for SF and Slic3r) work on a Replicator 1, dual, out of the box? Or there's something fundamentally different, eg. the start / end gcode or other things? Thanks!

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Instructions

print, review, tweak, calibrate...

ReplicatorG Profiles

I have included my best Replicator 2 profiles for 0.1 and 0.2 mm layer heights in ReplicatorG. To install them, select an existing profile you have already duplicated, then in the ReplicatorG menu select GCode->Edit Slicing Profiles... and click on the Locate button. On my mac this opens up ~/.replicatorg/sf_50_profiles/... with the folder of the currently selected profile highlighted. Select the parent directory i.e. ~/.replicatorg/sf_50_profiles and unzip the profile files in that parent folder. They should turn up in the GCode->Edit Slicing Profiles... and Generate next time you run ReplicatorG.

If you are using the latest version of Makerware, download the Makerware_profiles-xx.zip and unzip them into your ~/Things/Profiles folder. For more info on using these scroll down to the bottom.

These profiles were saved from my Mac, so if you unzip on a PC, check in the skeinforge Alteration Module to ensure the start and end code file names are correct as well as the Home Module. Sometimes these will be blank - so copy the filenames over form a working Replicator 2 profile if they are missing.

Make sure to measure each roll of filament you load and enter the diameter under Print-O-Matic->Plastic, if you can't 1.75 is a good starting point.

100 micron print settings

Infill 30%
Layer Height 0.1mm
Number of shells 3
Feedrate 80 mm/s
Travel Feedrate 150 mm/s
Print Temprature 230c (*)

200 micron print settings

Infill 20%
Layer Height 0.2 to 0.3 mm
Number of shells 1
Feedrate 80 mm/s
Travel Feedrate 150 mm/s
Print Temprature 230c (*)

The 200 micron profile uses the Skin Module to print the outside layer at half the layer height i.e. 100 micron for a 0.2mm layer height, however the surface finish is not as good as the 100 micron profile, but it prints twice as fast!

340 micron print settings

Infill 10%
Layer Height 0.34 mm
Number of shells 1
Feedrate 80 mm/s
Travel Feedrate 150 mm/s
Print Temprature 230c (*)

*If you are in a hot humid climate like me (34c & 90%) and having problems with stalls, droping the print temperature a few degrees can help.

340 micron zero fill (for Stretchlet Bracelets)

Infill 0%
Layer Height 0.34 mm
Number of shells 0
Feedrate 80 mm/s
Travel Feedrate 150 mm/s
Print Temprature 240c

SKIENFORGE SETTINGS

These are the Skeinforge settings I modify - and why.

Material

Firstly the material is set as ABS - I know, the Replicator 2 only prints PLA - WTF? However its just the way it has been setup, changing the material to PLA seems to break everything, so better to leave well enough alone - promise to have a go at 'correcting' this some time in the future.

Clip

Clip Over Perimeter Width = 0.2

This helps to reduce the little blobs or zits that form where the nozzle loops start.

Cool

Minimum Layer Time = 2

This is supposed to help endure that small layers don't melt. But if the nozzle slows down too much, it just sits there and melts the thing it is trying to cool.

Dimension

Extruder Retraction Speed = 20

Filament Diameter = 1.75

Filament Packing Density = 0.97

I have tried values between 0.93 and 1.0 but I think 0.97 is the most reliable. If you are getting too much plastic, 1.0 may be better, however if inter-layer adhesion is an issue drop down to 0.93. I have also found that clear and white PLA prefer higher packing densities like 1.0, whereas black and grey prefer lower numbers like 0.95.

Retraction Distance = 0.5

This helps to get rid of excessive strings. However too much retraction and too much heat can lead to jams as it sucks in air bubbles.

Restart Extra Distance = 0 to -0.1

This will also reduce the little blobs or zits that form where the nozzle loops start by relieving back pressure. However make sure this is a very small negative number - larger numbers can cause printing gaps, or worse unload your filament mid print if there are too many islands, and positive numbers will increase back pressure and lead to jams.

Fill

Extra Shells on Base Layers = 2

Helps to stitch overlapping layers to the perimeter. Use in conjunction with either 1 or >= 3 extra shells in Print-O-Matic

Grid Rectangular

I think this is both the fastest and strongest infill pattern, and it works with both 0% and 100% Print-O-Matic settings

Solid Surface Thickness = 3 for 200 micron and 6 for 100 micron

Sets the number of layers printed for the top and bottom layers.

Start From Choice = Nearest

Stops all the little blobs and zits forming in the Lower Lefthand Corner.

Loops -> Perimeter -> Infill

Ensures the best surface quality on the outer perimeter shell.

Inset

Infill in Direction of Bridge

Generally I leave this feature on, to ensure overhanging bridges are filled in the right direction. However, if you have a shape where the first layer is the bottom of a curved surface that is protruding outward this will result all the base layers printing in the same direction, so if you notice this happening, turning off this feature will correct it.

Jitter

Jitter Over Perimeter Width = 2 or 10 to 15

Alters the perimeter starting point (called the zipper) - spreads imperfections around so they are not all in the one place. Although sometime you want this to be 2 so its in one discrete line that is hidden in a crevice somewhere.

Skin

For my 200 micron prints I activate this module.

Horizontal Infil Divisions = 2
Horisontal Perimeter Divisions = 1
Vertical Divisions = 2

This gives your 0.2 mm layer height prints a 0.1 mm skin - so you get twice the print
speed with a surface finish almost as good as 100 micron.

Skirt

Convex enabled
Gap over Perimeter Width = 10

Runs a bead of filament around your base layer before it starts so as to prime the
extruder and ensure your base layer gets off to a good start.

Speed

Having problems with the first layer sticking too hard to the build plate

Object First Layer Feed Rate Infill Multiplier = 0.9
Object First Layer Feed Rate Perimeter Multiplier = 0.9
Object First Layer Flow Rate Infill Multiplier = 0.8
Object First Layer Flow Rate Perimeter Multiplier = 0.9

Having problems getting the first layer to stick

Object First Layer Feed Rate Infill Multiplier = 0.6
Object First Layer Feed Rate Perimeter Multiplier = 0.6
Object First Layer Flow Rate Infill Multiplier = 0.53
Object First Layer Flow Rate Perimeter Multiplier = 0.6

If you are printing directly onto your acrylic build plate, and having problems with PLA sticking too well, a light dab of olive oil and polish with a tissue to create a very thin film will help. With a light sheen of vegetable oil objects will still stick, but also snap off easily. If you put too much on, rub down with a bit of mentholated spirits or rubbing alcohol.

Perimeter Feed Rate Multiplier = 0.5
Perimeter Flow Rate Multiplier = 0.5

For mechanical parts with fine tolerances - particularly small parts, setting the Perimeter to 0.4 or even 0.3 can improve surface accuracy and remove ringing artefacts.

USING MAKERWARE CUSTOM PROFILES

In MakerWare there is no Print-O-Matic for custom profiles - so this is where you find those settings in skeinforge.

Infill (%) = Fill->Infill Solidity (ratio)

With this one, make sure to divide the Infill percentage you usually use by 100 to get the ratio.

Number of Shells = Fill->Extra Shells on Alternating Solid Layer
Layer Height = Carve->Layer Height
Temperature->Extruder = Temperature...
Speed while extruding = Speed->Feed Rate and Speed->Flow Rate Setting
Speed while traveling = Speed->Travel Feed Rate

Filament Diameter = Dimension->Filament Diameter

INSTALLING SLIC3R CONFIGS

Use the Flle->Load Config to set each configuration. Save a 'Replicator 2' printer settings, 'PLA 1.75' filament setting (and maybe one for any other filament sizes you have eg. 1.69) and one print setting for each config (100, 200, 340 micron). You still need to use ReplicatorG to load the sliced gcode files to export the x3g file to print from your SD card.

Slic3r can be downloaded from here slic3r.org its OSX, Windows and Linux compatible. Slic3r is a fast slicer, and the default infill pattern also prints fast. You can also make hollow objects like vases really easily.

Comments

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debel on Nov 17, 2013 said:

Hi, thanks a lot for your Replicator Slic3er profile(s)!!! I'm currently adjusting them a bit to get them working with Flash Forge Creator Dual-Extruder. But I'm stuck at one of the gcode start lines. The one is "G1 X-137 Y-70 Z0.1 F1000.0 ;Slow wipe"....what does it do? As Flashforge dimensions are lower than those of the Replicator, I guess this lines makes my device create noise (ratatatkrkrk). Everything else workes fine. After I'm dine, I will surely upload the profiles as a remix of yours! :-) Once more, thanks!

bbence on Oct 7, 2013 said:

Would these profiles (for SF and Slic3r) work on a Replicator 1, dual, out of the box? Or there's something fundamentally different, eg. the start / end gcode or other things? Thanks!

whpthomas on Oct 7, 2013 said:

There are a couple of things you will have to check. The packing density for ABS is 0.85 whereas PLA is 0.97. The retraction distance for ABS is probably less.

AmazingSpanoMan on May 2, 2013 said:

So I've seen someone printing at .05 layer height. Has anyone had any experience with this? I'm not sure if there would be a noticeable difference from .1

michaelladt on Mar 14, 2013 said:

Hey whpthomas, I love these profiles(I met have said this before) but are you seeing or hearing of any issues since the new makerware release or new firmware? I am having problems when I use your profiles in makerware now

MrPlastic on Mar 4, 2013 said:

I have not had a successful print with Makerware in about a month. I am waiting on the replacement plunger from makerbot to arrive.

HOWEVER, I installed these profiles and switched over to rep G. I have had nothing but successful prints all day.

thank you so much for these, and for your informative videos on youtube. You legend!

michaelladt on Mar 14, 2013 said:

MrPlastic, are you familiar with whpthomas's extruder upgrade/delrin plunger replacement? In terms of people having problems, it has fixed everyone's... If you can't print it just search on ebay like "makerbot replicator 2" a few people are selling the kits

GregFisk25 on Mar 3, 2013 said:

Are these profiles the same for the sailfish firmware as well? What speeds would you recommend for 100micron with sailfish?

GregFisk25 on Mar 1, 2013 said:

I have always used your profiles with great sucess until this morning I upgrade my makerware, and now RepG is not updating the extrude temperature in the gcode, it is starting from the right corner instead of the left, and it is trying to heat the bed. Any suggestions???

whpthomas on Mar 1, 2013 said:

Is the correct printer type selected? Try doing a factory reset of the onboard preferences under machine in ReplicatorG.

Stick-Tec on Feb 8, 2013 said:

I made this thing with your makerbot profiles. The 200 & 340 seems to be good, but the 100 has a very rough surface. I'm totally new in 3d printing, so i dont know why?

whpthomas on Feb 8, 2013 said:

Clear PLA is trouble - you may have to drop the temperature a few degrees, or measure your filament diameter and enter the correct value in Print-O-Matic under plastic. From memory, my MBI clear PLA was about 1.80mm

camstuff on Feb 8, 2013 said:

What bots do you have other then Rep 2 ? I am looking at a replicator and wondered if these profiles will work for it as we'll.

whpthomas on Feb 8, 2013 said:

Only a Replicator 2 :(

camstuff on Jan 30, 2013 said:

How do I install this using MakerWare? dying to try it out.

whpthomas on Jan 31, 2013 said:

Download the Makerware_profiles-xx.zip and unzip them into your ~/Things/Profiles folder

wheeleyum on Jan 25, 2013 said:

Can I activate the skin module in makerware through the edit profile menu? Thank you for your contribution!!

whpthomas on Jan 25, 2013 said:

Yes. But only for the skeinforge (high quality) slicer not MiracleGrue.

Fused3D on Jan 20, 2013 said:

Thanks a bunch, I put these into practice and the first 100micron print worked perfect, where makerware failed everytime.

majorplatypus on Jan 16, 2013 said:

I'm having the same issue as Kevinkevin. When I go in to edit the profile, it looks like it is defaulted set to ABS as the material. I'm using PLA. Should I change it there? I tried that, and it seemed to radically change what I was looking at...

whpthomas on Jan 19, 2013 said:

Hi Major,
I have corrected this by creating a separate set of profiles for Makerware - not sure what was causing the incompatibility.

Kalibre46 on Jan 15, 2013 said:

Just used the 100 micron profile on a Rep2 that was mis-behaving, so far so good! Thanks.

Kevinkevin on Jan 15, 2013 said:

I'm having difficulties using these profiles through Makerware (latest version). The slice gets to 100%, then I get a message saying the slice has failed (although the machine still starts up). The Rep2 display also gives me an error saying that it received a command for a heated build platform. Any idea why I could be getting these errors? Heading into month 2 of trying to get my machine to work beyond medium default settings, any help is greatly appreciated.

whpthomas on Jan 19, 2013 said:

Hi Kevin,

I have created a separate set of profiles for Makerware - you can download them as a zip file.

SimonWhite on Jan 13, 2013 said:

I assume I am doing something wrong. I tried slicing with your new profiles in makerware 1.1.0.51 and the slicing hangs on 100%. However, going through your changes and making a new profile manually means it works fine (prints are great by the way). I also thank you for your contributions!

whpthomas on Jan 14, 2013 said:

Are you on a Mac or PC?

fanmw on Jan 12, 2013 said:

Great piece of advice! Thanks for your contributions here and in Google Groups!

DrGlassDPM on Jan 7, 2013 said:

I used this profile and it works GREAT! Thanks for sharing.

PeteJM on Jan 6, 2013 said:

I had a slight issue with the 100 micron profile and it adhering to the build platform. I re-set the bottom.py from .1 altitude to 0 and it seemed to resolve this however. For the 200 Micron profile I had a issue where I was getting way to much filament blob in the starting lower left area. So I set it to nearest and it seemed to fix this as well. The start area on the 100 micron profile has this issue as well, so you can try it for that too :)

whpthomas on Jan 6, 2013 said:

All good suggestions. On my Replicator 2 I level with a 0.1 mm feeler gauge for some reason I need the 0.1 altitude. The nearest fill setting is a good change too.

suade907 on Dec 31, 2012 said:

Hi thanks for the settings but I'm having a few issues with my replicator 2 and them. First off at the end of the program I get a temp error on the replicator 2 lcd when the program ends right after it plays the ta da song and I hit a key to exit. Also I'm getting feedrate too high on the 200 micron settings. I'm getting lines like this G1 X-0.1 Y-20.38 Z71.05 F59940.0

Any tips?

whpthomas on Jan 1, 2013 said:

The feedrate problem can be ignored as it will be on the z axis, not sure what is causing the temperature error though - check that the end.gcode filename in alterations module is correct.

Thugorp on Dec 30, 2012 said:

So, I don't have a makerbot, or the softwear talked about above. I do have a Printrbot(Printrbot Jr. actually), and I use slic3r. Will this be of any use to me?

Tikigod on Dec 29, 2012 said:

Profiles are fantastic - getting great results - better than anything I've tried so far - thanks!

camstuff on Dec 28, 2012 said:

OK new to this... how do I install the new profiles in the software?

whpthomas on Dec 28, 2012 said:

As stated above - To install them, select the ReplicatorG menu GCode->Edit Slicing Profiles... Then click on the Locate button. Unzip the files in this folder.

isaacsmeke on Dec 27, 2012 said:

Really nice setting, thanks!!

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