Differences

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--- 3devo_extruder:3devo_extruder [2020/09/10 05:25] – formlab
+++ 3devo_extruder:3devo_extruder [2021/09/30 07:32] (current) – [Troubleshooting] formlab
@@ Line 2: / Line 2: @@
 {{:3devo_extruder:3devo_next_filament_extruder.jpg?nolink&200|}}
+[[https://support.3devo.com/]]
 ===== Filament width specifications =====
-±0,1mm deviation is in spec:\\
+±0,1mm deviation is in spec //(± means both + and -)//\\
 Bad: < 2.75mm\\
@@ Line 25: / Line 27: @@
 ===== Dry filament =====
-  * 4-6 hours @70-80°C.
+  * 4-6 hours @70-80°C. Stir regularly.
-  * Other sources say to stay below 40°C
@@ Line 50: / Line 51: @@
 This is a simple methodology to get you started.
-Source of info in [[https://www.youtube.com/watch?v=uxp2iuypDAo&feature=youtu.be|this video]]
+{{:3devo_extruder:schematic-overview-of-extrusion-system.png?400|}}
   * Enter dimensions of spool into the settings panel
+  * Make a stable environment
+    * no wind or temperature fluctuations
   * Set initial parameters
     * All heaters: 10% above the melting temperature (see datasheet of the material)
@@ Line 58: / Line 61: @@
     * Fan: 50%. Changes to the cooling have a big impact on the filament.
   * Apply the settings
-  * Start logging with Devovision
+  * Start logging with [[https://3devo.com/devovision/download/|DevoVision]]
-  * Test extrusion.
+  * Start extrusion.
     * Check for unmelted particles (too cold)
     * If filament is too viscous, lower the temperature
     * If there are bubbles, the filament needs drying
-  * Start adjusting the temperature in 10 to 20°C steps. Wait 10 minutes for the change to take effect. Patience is key.
+  * Set all heaters to the same temperature. Find out ideal temperature iteratively
+    * Adjust the temperature in 10 to 30°C steps. Wait 10 minutes for the change to take effect. Patience is key.
+      * for example: 200°C: too runny --> 170°C: a bit too solid --> 180°C sweet spot
+    * Check the logs
   * When sweet spot is found, set up the **temperature profile**
-    * Bell shape: heater 1, 2 and 3 increase the temperature. Heater 4 has a lower temperature
+    * Increasing shape: All heaters heat up to increasing temperatures. This causes more compression in the screw due to material being more solid at the beginning.
-    * //Unclear how to determine a profile, or why it's necessary instead of using all heaters at the same temperature.//
+    * Bell shape: the first 3 heaters increase the temperature. The last heater has a lower temperature.
+    * //It's yet unclear to me how to determine a profile, or why it's necessary instead of using all heaters at the same temperature.//
+  * If you are dealing with **filament deviation**, the first temperatures to experiment with are the temperatures of heater 1 and 4. Also make sure that the material will be fully melted when entering the metering zone of the extruder.
+  * check if your granulate is pure. Contaminants (a pellet of a different polymer for example) might partially block the flow.
+  * Purge the machine with DevoClean might make the extrusion more consistent.
+  * Feed material regularly. Avoid big changes in hopper loading.
+Cooling:
+  * too much cooling makes the filament too rigid. This makes it impossible to control the diameter
+Extruder RPM:
+  * output rate of the material
+  * If the extruder speed is inconsistent, so will the material output rate. It will be very difficult for the puller mechanism to maintain a consistent filament thickness when the extrusion rate is inconsistent.
+  * Extruder speed inconsistency can be caused by different things:
+    * Wrong temperature profile;
+    * Material feeding issues;
+    * Material contamination;
+    * Polymer degradation
+  * Reducing the Extruder speed gives the puller mechanism more time to react, which results in more stable extrusion
+Winder mechanism:
+  * needs to be easily stoppable with 1 finger (adjust slip clutch on the back). If it pulls too hard, it overrides the control of the puller mechanism.
+Source of info
+  * [[https://www.youtube.com/watch?v=uxp2iuypDAo&feature=youtu.be]]
+  * [[https://support.3devo.com/filament-thickness-deviation-inconsistent-diameter]]
+===== Recycling plastic =====
+  * keep waste plastic waste away from moisture, UV light, dust or grease
+  * sort different polymers. Only work with 1 kind at a time
+  * shred
+  * dry (if the polymer is hygroscopic)
+  * extrude
+  * print
+Source:
+  * [[https://www.youtube.com/watch?v=l9OuNUuVbdI|link]]
+===== Powder based pigments / fillers =====
+  * The Pigment Dunaliella Salina comes in a range of particle sizes. When mixing with PLA pellets, shake the batch well, then repetitively move the pot back and for on a table so the large particles sink down and the fine ones stick to the pellets on top. The fine powder colours the PLA darker orange and the filament has almost no speckles. Filament batches from further down the mixture are more yellow with more speckles. **Make sure to only very lightly coat the PLA pellets with pigment powder. Too much powder and the extrusion won't be consistent.**
+===== Troubleshooting =====
+  * **The diameter never settles and is way too big and then too small.**
+  * **The filament feels rather stiff when handling.**
+  * **Sometimes blobs of pure pigment appear, throwing off the diameter sensor.**
+If this happens with fillers (Plastic pellets with added non-plastic parts, for example Algae powder pigments), **reduce the amount of powder** added to the PLA pellets. I used 25g of Dunaliella Salina for 750g PLA. But this was too concentrated. For every 100g coated PLA pellets, I added 120g clean PLA pellets. Then I mixed them for a few minutes thoroughly with a spoon. The extruded filament is dimensionally stable and feels much more supple when handling.