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3D Printing

3D Printing Resources

Maintenance

Here are tips for regular maintenance that should help the printing process run smoothly. 

  • Clean the build plate
    • When there are layers of old glue on the glass build plate, it will become very difficult to remove finished models from the printer.  After printing is complete, scrape the used glue with a metal spatula, then wipe the glass with a paper towel and some glass cleaner solution.  Starting every print with a clean build plate will make it much easier to remove the model.  
  • Make sure software settings are consistent with hardware settings
    • Make sure the nozzle setting in Ultimaker Cura is consistent with the nozzle that is installed in the machine.  In other words, if you slice a 3D model with the nozzle size set to 0.6mm, make sure the 0.6mm nozzle is actually installed before attempting to print that model.  
    • Likewise, make sure the material setting is consistent with the material that is installed in the machine.  If you change the type of material in the printer, make sure you change the material setting in Ultimaker Cura before slicing a 3D model.

Here are tips for regular maintenance that should help the printing process run smoothly. 

  • Inspect build platform
    • Maintain the cleanliness of the build platform by inspecting it after every print job. Remove any sticky or solid resin from the platform using isopropyl alcohol and paper towels.
  • Do not use expired resin tanks
    • The resin tank is a consumable product that has a finite lifespan. The flexible film on the underside of the tank is vulnerable to corrosion and friction and can cause spills or other issues if used beyond its expiration date. The exact lifespan depends on the type of resin it contains and the amount of time spent printing, but the Form 3's automated sensors will notify you when the tank needs replacing. Find more detailed information about monitoring your resin tank's lifetime here.
  • Use a separate designated resin tank for every type of resin
    • Every type of resin that you print with should have its own designated resin tank. When you change out the cartridge from one resin type to another, remember to install the corresponding resin tank as well. When not in use, store resin tanks in their own protective cases and label the cases with the type of resin they contain. When you install a new resin tank for the first time, the printer will automatically calibrate the tank to associate it with a specific resin type. If you happen to miss-match the resin cartridge and its designated tank, the printer should sense it and warn you of the error. 
  • FormWash filled to minimum level
    • The FormWash machine must be filled to a minimum level with isopropyl alcohol so it can completely submerge 3D parts during the wash. Alcohol evaporates fairly quickly, so the level will need to be topped off once in a while by Innovation Lab staff. If the level goes below the minimum, your parts will not be completely washed and will come out with sticky resin remaining. 
  • Replace solvent in FormWash 
    • The alcohol inside the FormWash will need to be completely replaced on an occasional basis whenever it becomes too saturated with liquid resin. Find instructions for safely changing the alcohol here. 

Print Failure

When in doubt, always ask Innovation Lab staff for assistance if the 3D printer behaves abnormally.  Here are some common problems that you may encounter.

  • Plastic is not extruding at the beginning of a print
    • Make sure the nozzle has been heated to the correct temperature to melt the plastic (200-220 degrees C for PLA plastic).  Sometimes the printer won't heat the nozzle automatically, meaning the filament isn't melting and cannot come out of the nozzle. You can raise the temperature manually by navigating on the screen to "Tune" and then "Temperature" and then cranking up the target temperature.
    • The filament might be jammed, either inside the feeder (back of the machine) or inside the extruder (top of the machine).  In either case, it is best to ask staff for help.  They might need to manually push the tip of the filament through the extruder, or they might need to remove and reinsert the filament into the feeder.  
  • Plastic stops extruding during a print
    • The spool behind the machine might be tangled and jammed.  Usually the only solution is to abort the print, free the tangled filament by hand, and start the print over again.  Freeing the filament might just require rotating the spool to free up some slack, or you might need to remove the spool to untangle the filament. 
  • Plastic is not sticking to the build plate
    • Remember to apply glue to the glass build plate shortly before the print begins.  The first layer of plastic needs glue so it can stick to the glass.
    • If you have used glue and you are sure the filament is extruding properly, but the first layer still isn't sticking, You might need to re-level the build plate. The glass is too close to the nozzle and is simply blocking the hole where the plastic should be coming out.  By calibrating the build plate, you are creating a little bit of space between the nozzle and the plate, so the plastic has room to come out.  Ask staff for assistance. 
  • Model has ugly texture on downward-facing surfaces
    • The 3D model likely needs support structure.  Slice the .stl model again in Ultimaker Cura and be sure to enable supports.  The software will automatically generate structure to support overhanging surfaces.  The supports can be removed by hand or with tools after printing is complete.  
  • Support structure is problematic
    • Supports will be necessary anywhere the 3D model overhangs with nothing underneath.  This is because the 3D printer "draws" every layer of plastic on top of the previous layer from the bottom up. Highly detailed models with a lot of inner surfaces might not be right for the Ultimaker printer.  
  • Model has abnormal holes or structures
    • The digital 3D model might have holes or other surface errors that are invisible but cause problems when printing.  Import the .stl file into a mesh repair program like Meshmixer and repair the model and then slice the model again in Ultimaker Cura.  Find mesh repair resources and tutorials here. 

When in doubt, always ask Innovation Lab staff for assistance if the 3D printer behaves abnormally.  Here are some common problems that you may encounter.

  • Printer says the resin tank is not installed
    • If you have recently replaced the resin tank, it's possible it has not clicked into place all the way and is not making contact with the automated sensors. Push the tank straight toward the back of the machine with some force until you hear it click, then the screen should indicate that the tank is installed.
  • Cartridge is not dispensing resin into the tank
    • Make sure the vent cap on top of the cartridge is open. If the vent is open but the resin is still not dispensing, the problem might be the release valve at the bottom of the cartridge. Close the vent cap, remove the cartridge from the printer, and hold it upside down to view the rubber bite valve. Squeeze the bite valve until the opening fully unseals, then reinstall the cartridge and remember to open the vent cap again.  
  • Non-adherence
    • Prints may become partially or completely separated from the build platform if their supports or orientation are inadequate for good adhesion. Check the support settings in PreForm and reorient the model as needed. Although custom settings may be desirable for some print jobs, a safe bet is to use PreForm's "One-click-print" function to automatically generate optimal supports and orientation. 
    • If a model has completely separated from the platform and fallen into the resin tank, carefully remove all solid pieces from the tank to prevent them from interfering with future prints.  
  • Incomplete or damaged parts
    • There are a range of different surface defects that can occur in resin printed parts such as holes, cuts, craters, and other abnormal structures which may be caused by a combination of factors. To decrease the likelihood of these defects, always make sure that the resin tank and build platform are clear of debris, that the resin tank has not expired, and that your PreForm settings are adequate. Find more detailed information on diagnosing print failures here.