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another UMS5 print accuracy problem thread


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Posted · another UMS5 print accuracy problem thread

Hello,

 

I've been using a Prusa i3 mk3s for about 6 months making custom IC shipping containers and decided to upgrade to an S5 a little under a month ago. I've had issues with interlocking prints being oversized, which is pretty well documented around this forum. Most people recommend simply using a negative horizontal expansion value to bring the print size closer to the .STL size. While I have some success using a -0.1mm horizontal expansion value for outer dimensions, my model has some fine 0.4 mm wide lines on the surface which get completely removed by using this horizontal expansion value. I have to say, this is very disappointing. I will echo the many other reports I have seen of people running into XY dimensional accuracy issues with this printer and say that I am very surprised a Prusa mk3s produces much more accurate prints with less work. At this point I would not recommend anyone purchase the S5 if dimensional accuracy is important to them.

 

It seems like a software or firmware fix would be appropriate to solve this issue; does UM plan to address this issue, or are there any plugins that will adjust outer and inner walls only and leave single wall features alone?

 

Thank you,

 

Gabriel

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  • 3 months later...
Posted (edited) · another UMS5 print accuracy problem thread

Having the same issue here. I'll have to find the right settings. I guess It'll take a little more work to achieve the accuracy I need.

Edited by Cloud-Forge
written on the spur of the moment, wasn't necessarily constructive
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    Posted · another UMS5 print accuracy problem thread

    Hi, we're sorry to hear that you are struggling to reach the level of accuracy with your Ultimaker that you are looking for. Perhaps it would help if you could share some specific elements that you need help with, instead of 'it is not good and not accurate'. 

     

    We have an engineering profile that should give you pretty good results, and plenty of features in Cura that allow you to print outer walls before inner walls, or the other way around. There is horizontal expansion you can use, and speed settings you can optimise for optimal results. 

     

    Plenty to configure and I'm sure with the right settings you can reach the accuracy you are looking for. 

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    Posted (edited) · another UMS5 print accuracy problem thread
    58 minutes ago, SandervG said:

    Hi, we're sorry to hear that you are struggling to reach the level of accuracy with your Ultimaker that you are looking for. Perhaps it would help if you could share some specific elements that you need help with, instead of 'it is not good and not accurate'. 

     

    We have an engineering profile that should give you pretty good results, and plenty of features in Cura that allow you to print outer walls before inner walls, or the other way around. There is horizontal expansion you can use, and speed settings you can optimise for optimal results. 

     

    Plenty to configure and I'm sure with the right settings you can reach the accuracy you are looking for. 

     

    Yeah sorry about that.. I agree it is not a good start. But I was feeling a bit let down after my few first prints.

    The handling of the machine and the startup was close to flawless, so I had really high expectations for the printing results.

     

    Now, I just got the printer less than a week ago, so I guess I'll have to find the right settings.

     

    To answer your questions:

    I use PLA tough (Ultimaker).

     

     

    I used the following settings I have found on an other thread about accuracy (I did left jerks as default) :

    Line width: 0.4
    Wall thickness: 1.2
    Top/Bottom thickness: 1.2
    Speeds: 40
    Jerks: 30
    Horizontal expansion: -0.03
    walls: 3 

     

    Also I use Engineering profile with 0.1 height.

     

    Now the pieces fit better,

    but I still struggle to screw them together.

    After I clean the burr line.

     

    What are the right settings for tough PLA for best accuracy  ?

     

    Thanks.

     

     

     

    Edited by Cloud-Forge
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    Posted · another UMS5 print accuracy problem thread

    Thank you, by heart I think those settings you have listed are pretty much the same that are in the engineering profile. Without taking any specific details about your model into account, default engineering profile should provide you with the best dimensional accuracy. Now if your model has any distinct features you want to take some additional settings into account. 

     

    What is the difficulties with screwing? Do you have difficulties of driving the screw in? I imagine you want to have some friction to ensure a tight fit, but if it is too much you could look into the 'Hole horizontal expansion' feature. Similar as horizontal layer expansion, you can apply a factor to each hole in your model. 

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    Posted (edited) · another UMS5 print accuracy problem thread

    Thanks you.

     

    After some tests, trials and errors, I can now print whit the accuracy I need !

     

    The settings I use are the one above with jerks at 20, retraction at every layers. 

    I use the engineer profile at 1.5.

    Now my prints don't expand. 

    The settings that help is Horizontal Expansion : -0.16

    (For Ultimaker PLA Tough and Ultimaker PLA)

     

    Hope it help others as well.

     

    I got scared for a while,

    but the problem was the guy in front of the printer not the machine.

     

     

    Edited by Cloud-Forge
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    Posted · another UMS5 print accuracy problem thread
    2 hours ago, Cloud-Forge said:

    but the problem was the guy in front of the printer not the machine.

    🙂 - let's better say it was a mix of a lot of options in Cura with difficult requirements.

     

    Thanks for the feedback, and happy that it is now working for you!

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    Posted (edited) · another UMS5 print accuracy problem thread

    Hi All,

     

    Here is an update: 

     

    The rounded corner issue is due to the bowden feed system and can be remedied by using the correct print settings. This is pretty well documented around the forum and elsewhere online.

     

    We had issues printing fine single wall details (0.5mm wide single layer line features on a surface) where the printed lines had extremely variable widths. I suspect this is also caused by the bowden feed system not regulating pressure in the print head well. We remedied this issue by using a 0.25mm print head which was adequate to get the single wall feature accuracy we needed.

     

    In an attempt to fix the various and hard to understand dimensional accuracy issues which made interlocking parts not fit together, we meticulously modified and test printed our model file one line width at a time so that it would print patterns that do fit together. After this was accomplished and some test prints had the correct printed dimensions, we rotated the model 90 degrees on the print bed only to find that the model has systematically shifted its dimensions. We get a distortion of up to 0.75mm between X and Y oriented prints for a dimension that should be approximately 100mm using the ESD PETG required for our application and tech support recommended print settings, and a systematic 0.5mm distortion using toughPLA with Ultimaker engineering profiles. Printing the same part on different parts of the print bed also results in variations in dimensional accuracy, but we have not done extensive characterization of this effect.

     

    I suspect the significant distortions between the X and Y axes were causing a lot of our headache when trying to tune an interlocking print model on the S5.

     

    After doing a lot of test prints and debugging with Ultimaker support, they have determined that our printer is working as intended. For a comparison, we have printed over 600 of these interlocking parts on the Prusa we used as a proof of concept machine with few problems and predictable model file vs measured print dimensions. We wanted to upgrade to a printer with easily replaced modular components and better build quality, but these tolerance issues are enough to dissuade me from moving our printing program onto the S5 platform. So, I am returning the S5 and taking a hit on return shipping and a restock fee.

     

    There is a lot to like about the S5 - the modular print heads, large print area, robust cable management, nice enclosure and air manager system, etc. If you do not need very precise and accurate prints, it may serve you well and live up to it's reputation. Unfortunately that isn't the case here and we did end up spending a lot of time and money with little to gain.

     

    As an afterthought, I do wonder if printers with large build area tend to have more XY accuracy problems generally. There is another thread here where users with a lot of Ultimaker experience claim the smaller format printers have better accuracy and I imagine the S3 and S5 have a lot of design similarities.

     

    Gabriel

    Edited by ganadyne
    just added an afterthought
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