e3d v.6 print success

Remark: The E3D v.6 hot end has dramatically improved my print quality with increased productivity and reliability.

Yet another positive post on the change. I will provide a basic overview of the original failures of my robo 3d and the modifications to my printer, along with short commentary on the process. I also wanted to show a successful start of a challenging prototype. This is from the viewpoint of a moderately skilled 3D printing enthusiast and I hope it will benefit someone new.

Issues with original:

-plastic shards at hobbed bolt
-mostly inconsistent extrusion and failed extrusion after prolonged printing
-eventual clog, and final "fatal" clog
(should have switched to aftermarket hot end sooner)

Modifications:

1. new spool holder to feed filament from directly above (thingiverse) - [however i switched back and forth between this and the original side mount with varying performance]

2. new hobbed bolt - http://www.ebay.co.uk/itm/RepRap-Hobbed-bolt-Wade-Mendel-Huxlel-3D-PrinterExtruder/311019715458_trksid=p2047675.c100011.m1850&_trkparms=aid%3D222007%26algo%3DSIC.MBE%26ao%3D1%26asc%3D20140107083358%26meid%3D2a20d38fd2734079862488f2010263d3%26pid%3D100011%26prg%3D20140107083358%26rk%3D2%26rkt%3D10%26sd%3D310965918835
-50mm, shallow, asked for robo 3d specifically
-Filament fed much better but hot end issues continued despite any improvements.

3. E3D v.6 hot end - 1.75 universal - .4 mm and .8 mm nozzles - Assembled hot end per E3D instructions and re-used molex connection between hot end and printer to minimize work. The following are forum links that helped me with firmware changes, electronics, installation, etc.
- http://forums.robo3dprinter.com/index.php?threads/e3d-upgrade-firmware-changes.2716/#post-21595
- http://forums.robo3dprinter.com/index.php?threads/marlin-firmware-update-3-14-14.1857/page-2
- https://docs.google.com/document/d/...qHU0iFY7uVRF3sFx0/edit#heading=h.2lb1da6657u4
- http://forums.robo3dprinter.com/index.php?threads/e3d-v6-is-out-lots-of-improvements.2542/
- http://forums.robo3dprinter.com/index.php?threads/e3d-installation-question.1380/page-2#post-9917

4. While waiting on the hot end to arrive I customized my shell structure. The only interesting thing to note is my filament spool orientation - this has been working very well. I am also using Z-axis stabilizers but the new ones don't show.



Print Examples:

This form did not make it very far with the stock set up. You can see in my only other posts the issues I was having. I went through countless settings and made small progress just to fail again.

The E3D hot end successfully completed the prototype first print, without a parts fan. I know that contradicts most PLA suggestions and I have experienced/agree that you should have a parts fan. But for the first couple of prints I couldn't resist to let it go. Some stringing for sure but I'm happy with the high quality baseline and can refine from here.

1. Settings - Repetier-Host Mac w/ Slic3r v. 1.1.6 - Rhinoceros modeling
- Layer height: .18 mm \\ Perimeters: 2 \\ Solid layers: 6 Bottom \\ Fill density: 0
- Speeds - Perimeters/Small perimeters/Ext perimeters: 50 mm/s \\ Travel: 90 mm/s \\ Acceleration: All 400 mm/s*s
- Filament Settings - Extruder Temp: 220 C/220 C
- Printer Settings - Nozzle diameter: .8 mm \\ Retraction length: 3 mm \\ Lift Z: 2 mm \\ Speed:30 mm/s
- Time -11 hours \\ 584 layers

The combination of the wide nozzle and larger layer height have dealt with this shape surprisingly well, and cut the print time in half. This was a good find for me because I kept thinking that the only way to do the overhangs without support would be minimal layer height. The lower resolution may bother some of you but for me, and this project in particular, the surface texture is great. Another variable to play with. The OD of the part is precise to .15 mm.










This is just a simple beginning to utilizing the full capabilities of the E3D. Please ask any questions and I will try to direct you to the trouble shooting resource I used. I've learned a lot but there are many other experts already available. I will post more results as I continue to print.

 

Hi,
did you change your threaded rods to mertric? (or at least changed the Z-axis behaviour in the firmware?)
I think you have ribbing from this (can't see if it's not wobble so maybe I'm wrong). I had the same, but after the changes I can't see them anymore (though it can have other reasons and not all profit the same amount).