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foehnsturm

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Everything posted by foehnsturm

  1. Mark2 is an asymmetrical multi-extrusion upgrade for the Ultimaker 2, based on Foehnsturm's magnetic tool changer. It offers some unique features compared to conventional approaches. Keep it smart and simple The Mark2 upgrade doesn't require to modify or even disassemble the well-working single extrusion setup. Instead it adds a detachable second extruder. This leaves you with several benefits. Powerful - print quality on par with eg. the UM3 or BCN3D Sigma Flexible - use whatever you want: Olsson ruby, 3Dsolex block / nozzles, ... Cost-efficient - all you need is a second drive train, some magnets and screws Simple - all tried-and tested standard components Smart - Z-offset managed by firmware, calibration wizards Open & scalable - a non-extrusion tool head, a 3rd extruder ... all possible Mark2 is an Ultimaker community project, we don't offer a complete kit but we can help you out with a package, including all the parts you need, besides the second drive train. See it live Probably the best way to get an impression of the usability and print quality is to watch a few videos. https://www.youtube.com/watch?v=PLeNzDYMnqAqIeZHWU9iOWnj_2OaemupQG Full Cura 2.5 integration Mark2 comes with a set of Cura definition files and can be added as a pre-configured printer. Tried and tested Mark2 setups have been printing for more than 5.000 hrs now, which equals more than 500.000 tool changes. Beta-testers and co-developers include well-known guys here like Tinkergnome, Ultiarjan and many more. The Mark2 website ultimaker-mark2.com is the place where you find all the information you need for doing this upgrade. ... and The Mark2 Dual Extrusion Project Contest is still running.
  2. This is a project by a group of community members which was also involved in the Mark2 dual extrusion upgrade. More precisely, it's me coming up with an outside the box approach / weird idea for a certain unresolved problem. Smart people like @gr5, @Anders Olsson, @Dim3nsioneer, @rooiejoris throwing in ideas and @tinkergnome who implants the stuff into firmware. My impression of the current state of development when I started this was as follows. There have been filament monitor projects since the beginning of reprap. Only very few made it to some kind of product state, like the one by Aaron Tunell. Manufacturers like Prusa and others recently introduced some kind of filament monitors, with mixed success / reliability issues. The Duet3D guys set their hardware research (laser-based and rotating) on hold because they were experiencing inaccuracies of +/-20%. Well and then there was Ultimaker ... until yesterday with the S5 All these efforts have been or still are struggling to fulfill the most important objective: NO FALSE ALERTS. Otherwise any filament sensor would quickly render itself useless. What we want to achieve Objectives, the obvious part: zero false alerts detect filament runout ("nothing there") detect filament grinding ("nothing/very little moves") Objectives, the challenging part: detect first layer issues (see video below) detect when real flow leaves a certain safe process window and starts to compromise part quality (first, inter layer adhesion will suffer, then classical under extrusion will be visible) and try to counteract, that's where the real fun starts ... Current state of development We chose an encoder and there's a reliably working prototype for an easy to attach external flow sensor, mounted to the entry side of the feeder. Resolution is in the range of 0.015 mm. It's integrated in Tinkerware with a dedicated menu and we (well, he) implemented a gcode command: M591 T0 S1 E0.5000 L0.01695 R35:130 A0.3 P100.00 I leave the parameter interpretation as a little quiz here. Right now I'm working on a modified design which, besides the encoder, doesn't need some parts which cannot be printed and are in the +30€ range to have them manufactured. But most likely some parts will still not be FFF printable. How can I get this? First give us some more time to test and evaluate. If everything works like intended we might proceed like with the Mark2 project. If we should offer this as a product I'd expect a price tag between 70-100 €. And the UM3? That's the BIG question. Like @Daid recently stated their main market is already different. And indeed, has anyone seen any kind of (hardware) upgrade for the UM3 so far? Feeders are the same, mechanically our sensor fits. Electronics, not sure. Ultimaker originally wanted to use a serial interface on the UM3. For the UM2+ we simply connect the sensor's quadrature output signal to free I/O pins, there are enough left (4) for two sensors for a Mark2 dual extrusion UM2. Ultimaker won't do anything to support a sensor on the UM3. Anyway, if a large number of UM3 users would show interest, they might at least not impede a development ...
  3. Hi, Glad to have you here. Please check the power budget settings and search for that topic here. This is a rather common issue and, due to individual hardware variations, the solution is not perfectly straightforward but a requires some tinkering.
  4. Test assembly, now casting silicone, then final assembly and test.
  5. @jffry7, any news on a possible UM3 integration?
  6. @laverda @henry-tong @Ace1992 @wimismith @3dprinting_guy @Ramzes777 Please send me a PM with your address details and add a remark if you want more than one sensor.
  7. Update, you guys want one: @laverda @henry-tong @Ace1992 @wimismith @3dprinting_guy @Ramzes777 Correct? I'm going to order parts by the end of next week.
  8. Hey guys, sorry for not beeing responsive lately. So, currently interested: @laverda @wimismith @3dprinting_guy Please feel free to correct or add yourself to the list.
  9. foehnsturm

    Another take on ringing

    Could a few people share short (ideally < 1hr) real life prints where they experienced serious ringing issues with the UM3 and the settings they used? Or the other way round, prints that suffered from the massive reduction of accelleration and jerk (rounded corners etc.) I'm testing a UM3 mod and the usual ringing tests show some improvement. But real life prints might be a whole different story.
  10. foehnsturm

    Another take on ringing

    Printed at 50mm/s, 30mm/s jerk; bottom half: 20mm square, top half: same square with tiny bulging / ringing corrections. Could a slicer or even a post-processing plugin apply those corrections to the path in a generic way? I think yes!
  11. foehnsturm

    Another take on ringing

    Well, at and least in theory, you could counteract against the ringing with smarter slicing. If you know the resonance frequency / wavelength, the slicer could alter the path in a way that e.g. at at corner it stops the moving axis like 0.1mm earlier to compensate for the belt stretch and then add this 0.1mm to the axis position again after half of the resonance wavelength to compensate the back swing / contraction of the belt.
  12. foehnsturm

    Another take on ringing

    Here is what I found so far: The resonance (ringing) frequency of my UM3 is around 26 hz; corner bulging and ringing is affected by wall speed and jerk; you can mostly ignore acceleration, as (at least with usual settings) it happens in a different time scale. As commonly known, the bulging happens due to overpressure in the hotend. This will inevitably (pressure advance algotrithms could probably help here) build up when printing with more than very modest speed (like 20-30mm/s). "Slow" deceleration doesn't help to release the pressure, because our "slow" like 500mm/s2 or even 100mm/s2 is way too fast. Deceleration still happens in a timescale of less than 0.1 sec, which is one or two magnitudes too fast to show any helpful effect on the extrusion system. So, if you want to print with more than very low speed, you're like going downhill in a car with very weak breaks. If you want to go fast straight you have also to corner fast: I got the same perfect, almost bulging-free pre-cornering surface with standard 20/5 speed/jerk as with 50/30. With a speed-jerk difference above 20 the bulging starts, irrespective of acceleration (tried from 100 mm/s2 to 2000mm/s2). But fast direction changes will produce ringing after the corner. The printhead and the belts form kind of a resonating mass-spring system. The amount of "bad" energy stored there, again monstly depends on the speed difference between the two adjacent paths, which is defined by the jerk setting. However, there's is some positve effect (less stored ernergy) when decelerating very slowly but this is ruined by the increased bulging. The ringing may possibly be reduced by some kind of hardware measures for low frequency damping. E.g. somehow decouple the belt vibrations from the printhead. Another approach, which could show some positive effect, is to measure the ringing frequency (print speed / distance between the ripples) and find a specific deceleration rate as explained in the Duet3D forum. Left (standard): wall speed 20/30mm, acceleration 500/1000, jerk 5/10 | 30 min Right: wall speed 40/50, acceleration 526/789, jerk 20/20 | 22 min
  13. I check if I can do a test on the UM3 with 0.6
  14. To my experience with different nozzle sizes, it's - unfortunately - almost impossible to compare different sizes. It's not just the reduced resolution with bigger nozzles, but the entire extrusion system loses some controllability, especially with 0.8 and above.
  15. could you share a link to your test part file (stl, step)?
  16. As for the material question.Its operation temperature should provide a reasonable safety margin to the bed temperature you are typically using. E.g. if you print ABS with the bed at 100°C you should look for something with a really high softening point. Other requirements are not that demanding, but as the magnets are glued, the material should work well with serious glue.
  17. @3dprinting_guy, for an UM2GO with the old black feeder you would have to design an adapter. Not sure about the firmware (@tinkergnome ?).
  18. Hi guys, holdays are over here now. Any experiences with the sensor to share so far? @cjs, @conny_g, @fbrc8-erin, @Dim3nsioneer, @jffry7
  19. Super nice.? I already knew, you're well very organized person. ?
  20. A hall effect encoder instead of the AMT is doable but would require to attach a magnetic target to the shaft and some kind of mount and housing for the PCB. The encoder you are linking to seems to be discontinued, I'm not sure if there is a newer alternative which provides the same interface.
  21. foehnsturm

    Mark2 Firmware

    Thank you. I made some corrections. There's no separate "mark2 for Ultimaker2 Extended" definition. I think the only important thing the Extended defintion files are overriding is the machine_height setting.
  22. foehnsturm

    Mark2 Firmware

    It should be there somewhere but I had no luck with a quick search. So: Tinker-Mark2-dual -> Standard UM2(+) Mark2 but without the tiny Mark2 PCB Tinker-Mark2-expansion-board -> UM2(+) Mark2 with the Mark2 PCB --- extended --- > same for UM2(+) Extended printers I assume you don't have the PCB as you had to extend cables.
  23. Here are some basic operating instructions Unscrew the lower screw that holds the feeder cover, mount the adapter (use a longer screw in case). Push the flow sensor into the mount and rotate 90°. It's a very good idea to use a filament guide together with the sensor. There are a lot of designs available which are mounted to the screw some 7 cm below the feeder which secures the XY stepper cover. It's vital that the flow sensor wheel moves with almost no resistance when there's no filament present. Connect the cable as shown here. Implemented Gcode M591 T - extruder number T0 or T1 (default=active extruder) S - S0 = disable filament monitoring, S1 = enable filament monitoring E - extrusion length for each comparison (default 0.20mm) A - smoothing factor for exponential floating average (0.05) L - filament movement per pulse in mm (1 / steps, default 66) R - min/max percentage (print will be paused if the average is outside of these values) P - set value for the average percentage All parameters are optional. E and R are global (the same for both extruders) Complete example: M591 T0 S1 E0.2000 A0.05 L0.015 R40:130 P100.00 Basic settings You can set the "L" value via the screen menu as well: Advanced / settings / filament sensor. Use "move filament", there it displays the number of encoder steps and the calculated percentage as well. Move like 10 mm and use the number of pulses to calculate the movement per pulse (most likely in the range of 0.015 to 0.017). The default E and A settings: E is quite short (0.2mm) and A low (0.05). That means the average is calculated every 0.2mm but in the way that the new measured value only influences the result by 5%. For calibration I use high E like 2.0 and A1.0. Then, encoder pulses and percentage match immediately. Fo regular printing I found values like E0.5 and A0.3 to work well. Tinkerware firmware for standard, single extrusion UM2+ Tinker-MarlinUltimaker2plus-18_07.zip Tinkerware firmware for dual extrusion UM2+ Mark2 Tinker-Mark2-18.03.4.zip The original 18.03.4 works well but after a pause and resume due to a flow sensor alert it doesn't reset the calculated flow average. This is usually hidden by the retract and prime move which helps to increase the average again. But sometimes it stays low enough to immediately trigger the next alarm. Here's the link to a slightly modified firmware. Tinker-Mark2-expansion-board-18.03.4fs.hex
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