Test driving a new – old – host program on a big 3D print

Pronterface screen, 3D printing - Kevin Caron's 3D printing blogDealing with sudden, inexplicable fails got me to try some new things. I don’t know which, if any, are related to why my Cerberus 3D Gigante 3D printer just stopped cold without apparent reason, but it sent me back to play with a host program I’d only used once or twice before.

In fact, when my 3D printing guru suggested I use Pronterface instead of Repetier, which we thought might be the problem, I remembered I had a version of it. It was old, so the first thing I did was download the latest version of this venerable – well, for 3D printing! – host program.

Pronterface is apparently one of the most common interfaces used by 3D printer software. It can move and home all 3 axes independently, as well as offering a temperature graph, extrude and retract buttons, a window showing the current layer’s tool path, and a window to enter G-code. Some users complain that it’s too basic or don’t like the program’s look and feel, but it seems very clean and easy to use to me.

The big question is whether and how it works ….

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3D printing jewelry adds color & and complexity

BackFlip 3D printed earrings - Kevin CaronOne of the many things 3D printing has allowed me to do is make jewelry.

I’ve always loved jewelry – my wife likes to brag that I had her favorite jewelry store on my speed dial (which is true) – but I could never work that small in metal.

But suddenly, with 3D printing, I am able to create beautiful jewelry – and open a whole new side of my business.

Some of my designs are smaller reproductions of large sculptures – more on that in a moment – while others are original designs for the jewelry that I just may create in full-size metal sculptures someday.

Like most things, though, creating a jewelry line is not as simple as it may seem, and certainly not as simple as I thought it’d be!

For instance, none of my three 3D printers is able to print in small enough resolution to reproduce my designs as earrings or necklaces. There are other aspects of the learning curve to create jewelry, too ….

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3D Printing Mystery Continues…

Troubleshooting - Kevin CaronWouldn’t it be awesome if things just worked?

Yeah, they do sometimes, but especially in these early days of 3D printing, there are so many variables and things change so quickly that it seems there are myriad things that can and do go wrong.

Lately I’ve been battling a problem with both of my deltabot 3D printers, and I still haven’t figured out what is causing it.

The result is ugly: they just stop printing. For no apparent reason. Everything is going well, and then the hotend just stops moving.

Aaaargh!

I can’t just give up – it isn’t in my nature.

So I’ve been doing what I always do when troubleshooting any problem ….

I work through a process of elimination, testing and ruling out various possibilities.

Here’s what I’ve done thus far:

  1. Confirmed that it isn’t on just one 3D printer. It seems that I’m having the same problem with both deltabots.
  2. Confirmed that it isn’t Windows 10. That’s because it’s also happening on a computer that is running Windows 7. If it were just Windows 10, that’d be one thing, but the other computer hasn’t had an update in years and ran just fine.
  3. Confirmed that it isn’t the host program. I’m having the problem with both Repetier – two different versions of it – and Simplify. I’ve checked Simplify’s log and see it says the firmware is unresponsive, which brought me to my latest hunch (below).
  4. Removed the host program from the equation altogether. I put the file directly into the Gigante (yes, I used a ladder to do it). Same problem.
  5. Confirmed that it isn’t a power problem. One of the computers is plugged directly into the wall, while the other runs through an uninterrupted power supply.
  6. Ruled out the file itself. This has happened with several files, so it isn’t the design.
  7. Made sure it isn’t a filament bulge problem. It’s happened with various filaments, including two different diameters (3 millimeter and 1.75).
  8. Noted that it has happened shortly after the print started and just before it finished. If it were related to the file length, you’d think that would be more consistent.

At this point, I’m thinking it might be the controller board. I believe both 3D printers have Smoothie boards, so that might be it.

So I’ll just keep poking around on forums, talking to people, consulting my expert, and eliminating problems, hoping that one of them is the solution that gets me back up and 3D printing again.

And if this is just a test of my patience, I hope I have already passed!

 

What do you do with a failed 3D print?

endtable-croppedAnyone who works with 3D printing – other than on the very high end – has likely pondered what to do with prints that don’t make it.

Early on, I asked it a lot. Between hardware, software and filament problems, I had a lot of fails.

Often a fail is unsalvageable. I mean, really, what can anyone do with a rat’s nest of filament?! (Maybe find a homeless rat?)

My hope is that the Protocycler will finally be completed. I invested in this Indiegogo-fueled project that grinds up old filament so it can be reconstituted to fresh filament, but at this point it seems like it’s still a pipe dream. (And I’m now really reluctant to invest in any crowdsourced project without a lot of scrutiny!)

But some failed projects got far enough that a little imagination might lead to something worthwhile. Take for instance, the print that failed after more than two days of printing (right) because of a power outage ….

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Double trouble: Is it original or a print?

Multiples of Sunscraper, a 3D printed fine art sculpture - Kevin Caron Most people who have wondered if 3D printed sculptures are art have now realized that 3D printers themselves are simply tools, like paintbrushes, potters’ wheels and cameras.

With 3D printing, however, some people continue to fear that once artists create their original CAD designs, they will then simply print popular sculptures over and over, creating the sort of “copies” 2D artists make with offset prints and giclees. Many in the art world are bothered when artists offer inexpensive (or sometimes not so inexpensive) copies of their work this way.

For me, although it is, of course, technically possible to print multiples, whether to do so is really a philosophical issue. I had to consciously consider and develop this philosophy as a lodestar for my 3D-printed creations.

Sure, once a design has proven popular, I could simply reprint multiples, but that isn’t something I choose to do any more than I do it when I create sculptures in metal. In metal, it is a little trickier to recreate a form exactly, which would be quite easy with 3D printing. Still, I think there are issues for patrons if they feel they are not really buying an original.

My philosophy is straightforward, but took a little time to think through ….

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String theory: removing strings from a 3D printed sculpture

Close up of 3D printed sculpture Love and Marriage - Kevin CaronPrinting big sculptures on my 8-foot-tall Cerberus 3D Gigante printer is a balance of heat and cool.

As discussed in a previous post, I installed a heated bed on the printer, which helps keep the base of my large format 3D-printed sculptures adhered to the bed during the multiple days of many prints. (Some prints have taken four days. Keeping an eye on a print that long 24 hours a day, switching out spools of filament, adjusting speeds, etc., is definitely not for the faint of heart!)

As the sculptures print, though, I cool them down with fans. My fan of choice right now is a 4-foot-tall oscillating tower fan.

The cooling is especially important when the upper sections of a sculpture narrow, as many of mine do. When they narrow like that, I also turn down print speed to avoid burning on any edges.

The result is spiderweb like strings, or threads, that cool as the hotend moves. They sometimes run between sections almost like the warp, or horizontal threads, in a weaving ….

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3D Printing Filament Comes Out of the Closet

The Point, a 3D-printed bronze sculpture - Kevin CaronI’ve written about applying finishes to the surface of a 3D-printed resin sculpture, but today there are a lot more options for types of the resin filament itself.

Nearly everyone has heard about exotic 3D printing that use biomaterials, titanium, etc. but I’m talking here about filament that mere mortals like me can use in their own 3D printers.

I have 3D-printed in bronze, as you can see at right in my 26″ tall sculpture The Point. That filament is 80% bronze and 20% resin. I’ve printed both a small version of this form on my Cerberus 3D 250 and the larger version on my 8-foot-tall Cerberus 3D Gigante 3D printer.

I don’t have as many choices for my Gigante, though, which requires 5-pound spools of filament for my large prints – unless I want to “weld” together filament from 1-pound spools – providing I can get 3 millimeter filament in that type – and rewind it , which isn’t an entirely crazy idea.

Yet the new materials you can actually print in are staggering. And they aren’t just facsimiles, either. The filaments are actually a mixture of the material and resin, so you are literally printing in these amazing materials ….
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Let there be light (with 3D printed translucent filament)

Sunscraper, a 3D printed contemporary art sculpture - Kevin CaronIn February during my one-person show devoted to my 3D-printed sculptures, I heard many interesting comments and questions.

One thing I was asked repeatedly is whether I’d ever put lights into a 3D printed sculpture.

This undoubtedly grew out of them seeing the luminous translucent filaments I’ve used, including ice blue (for the sculpture Easy In), red (several sculptures, including Redhead and Love and Marriage), purple (Twin Peaks and Love and Marriage) and – my favorite – yellow (SunScraper, right). The yellow just really lights up!

BTW, I’ve tried green “translucent” filament, too, which wasn’t really translucent and was, honestly, just pretty ugly.

The subject came up so often, in fact, that, of course, my mind got going ….

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The Strange Case of the 3D printed Geared Ball

Geared sphere - 3D printed by Kevin CaronIf you read my last blog post, you know I’ve been playing around with some cool designs from Thingiverse.

Both are geared – one is a cube, the other a ball. You can see me playing with them in that last blog post – several people have remarked they are like a modern Rubik’s Cube. I’ve taken a geared cube to events and people just can’t stop handling it.

Lately, I’ve been having fun enlarging the designs to print on my 8-foot-tall Cerberus 3D Gigante 3D printer, something that was a whole lot harder than I thought it would be – it isn’t just a matter of scaling up mathematically.

I’ve also been adding stripes to cubes while printing (another good reason to check out last week’s post to see me manipulate one).

But the point of this post is the strange thing I discovered after I printed the large black geared ball (right) ….

When you 3D print a geared cube, you print all the pieces at the same time. With the geared balls, you print all nine pieces – four large ones, four small ones and a middle – separately.

Difference between PLA and ABS 3D printed filament - Kevin CaronUsing my 3D Systems CubeX 3D printer, I had printed six of the pieces in black ABS filament for this 5″ geared ball when I realized I wasn’t going to have enough to print the last three pieces.

So I found some black 1.71 mm PLA filament, which is what the CubeX runs, and figured, “What the hell – filament is filament.”

After the last three pieces printed, I bought some 1/4 x 20 Allen bolts to assemble it, just as I’d done with a 2-1/2″ gray version I’d printed earlier.

But the black geared ball just wouldn’t go together. It probably took me two hours to assemble the gray one, but the black one probably took me three.

Finally, I realized that the three pieces I printed in PLA resin were slightly larger – the photo at right shows one of the smaller pieces protruding slightly.

I’d heard that PLA resin shrinks less, and this seems to prove it.

I want to try playing with this some more, comparing PLA to ABS, but since I finally got the black geared ball together, I’m happy for now.

Boys Just Gotta Have Fun

Thingiverse homepageYeah, girls have to have fun, but so do boys!

If you’re a regular reader, you know that not everything I make on my 3D printers is a sculpture. Every now and then, I make a part or something we need around the house, and I have plenty more of those kind of projects to work on.

Recently. though, I’ve also been playing with some designs from Thingiverse.

If you’re not familiar with Makerbot’s huge community of makers, members have uploaded more than 564,000 3D models and are adding more every day.

The cool thing is that you can upload your own designs as well as download whatever you want.

I like to browse Thingiverse like I browse for new books to read, and one day I found some intriguing designs that I couldn’t wait to play with ….

 

Of all the designs I found there, the geared cubes and spheres really caught my eye. Well, really, it’s my brother-in-law Bill‘s fault – he’s the one who got me hooked on 3D printing, in part because he sent me a geared cube. Once I found the geared cube, then I also found a geared sphere.

These are really cool designs – I give huge credit to the designers.

Of course, I couldn’t stop there. I enlarged the designs and also began adding stripes to them. The stripes are super cool when you start twisting the cubes because they then make their own designs.

So here, for your entertainment, are some videos showing me playing with these giant geared toys:

A geared sphere …. #3Dprinted #3dprinting

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