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"MSN" can refer to several things. Which do you mean? - **MSN the website/portal**: Microsoft's news, email (Outlook.com), and search homepage - **MSN Messenger**: the instant messaging app, retired in 2013 and succeeded by Skype and later Microsoft Teams - **Master of Science in Nursing**: a graduate nursing degree - **Madison, Wisconsin airport**: the airport code MSN (Dane County Regional Airport) Or if you meant something else, tell me more about what you're looking for.


2012
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The Makerbot and RepRap both printing nicely. Found nothing worthwhile to to publish here. Most of the stuff I made is published on Thingiverse.

Best wishes for 2012!


PLA
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Switched from PEEK to PTFE for the insulator so, finally, the RepRap can print PLA as well.

The new nozzle is a RepRap nozzle derivative. Without the PEEK mounting plate and with NiCr. The combination of NiCr wire and Chamois clay I prefer over the wire-wound resistor approach.

Construction details you find on the RepRap website.


Impatience
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Feeling more confident now the RepRap is operational too, I ordered coloured ABS with RepRapSource.
The first black ABS print is a RepRap brutstruder backup. But, well, the black ABS did not stick to the HBP as good as the uncoloured did. Next prints, with HBP temperature set to 120°C, all failed with missing x-y steps after the first ten or so layers. The usual suspects, such as Z-axis blocking, were not the cause. My calibration seems to have been done too hastily and sloppy as a little too much ABS was put down every layer. Recalibrating resulted in a 5mm/s feedrate increase and a successful print.



Btw, the Skeinforge parameters set when calibrating the printer I save in this spreadsheet. The printed calibration cubes I label and saved as well.


Night before Christmas
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'Twas the night before Christmas, when all through the house
Not a creature was stirring, not even a mouse;
...
When, what to my wondering eyes should appear, but the BfB RapMan running!
Yes, this relates to the 2008 version 2 RapMan, a Darwin RepRap I never got printing successfully.

Now, with the Geared Brutstruder and a heater construction of my own, it is running. Some additional tweaks in the Firmware and Host for the final printing touch.


Details
Firmware: Gen2OnABoardFiveD_GCode_Interpreter
Extruder: Brutstruder with Wades Gears
Host: ReplicatorG-0009 (patched so that spaces are not removed from cmd string:
SerialPassthroughDriver.java, comment out line #173 clean = clean.replaceAll(" ", "");

For those interested in the final Firmware and hardware design used, leave a comment and I will post the files as well.


Moved
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At the time I started this Blog to register my 3D printer stuff in, I thought Blogger was a nice and easy starting point. Now I changed my mind.
Not that Blogger in particular is not the "right thing" to do. It is more the idea of being dependent on one of these "free" services for which you will pay eventually in some way.I just felt like publishing this on my own weblog.

So to keep this a short entry, I moved most of the things I valued worthwhile, to Chaos Geordend. Which is my personal business site which (now) has partly Dutch and partly English content.

Any future Makerbot and/or RepRap stuff I may still log here.

That's it!

PS Yes, it is a matter of paying so either you or your readers are not covered with advertisements. Otoh, eventually we all pay some way or another, if it isn't only Google, to reach content :-)


RepRap revisited
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The successfull MakerBot prints gave me enough confidence and motivation to pick up the, last year abandoned, RepRap project. After some days of tough fights with the software, the RR is now in control! Finally I can test the extruder and hopefully the RR will be printing this year :-)

Follows a list of blocking issues:
1. Arduino had a HardwareSerial issue in the Sanguino (Atmega644P) library, solved in Arduino 0018. Mark that you clean up the firmware objects (FiveD_GCode_Interpreter/applet) to ensure a clean object recompiled with the proper libraries;
2. ReplicatorG SerialPassthroughDriver.java removes spaces from the commandstring, patched as follows;

public String clean(String str) {
String clean = str;
// trim whitespace
clean = clean.trim();
// remove spaces
// 2010.04.04 JvO DON'T clean = clean.replaceAll(" ", "");
return clean;
}

3. FiveD Firmware, byte datatype tested for -1 unsigned byte;
4. FiveD Firmware, cartesian_dda.can_step() code is incorrect for Max endstops, patched as follows;

bool cartesian_dda::can_step(byte min_pin, byte max_pin, long current, long target, byte dir)
{
bool canStep = true; // 2009.08.27 JvO
//stop us if we're on target
if (target == current)
canStep = false;
#if ENDSTOPS_MIN_ENABLED == 1
//stop us if we're home and still going
if(min_pin >= 0 && min_pin != 255) // JvO byte datatype is unsigned
{
if (read_switch(min_pin) && !dir)
canStep = false;
}
#endif
#if ENDSTOPS_MAX_ENABLED == 1
//stop us if we're at max and still going
if(max_pin >= 0 && max_pin != 255) // JvO byte datatype is unsigned
{
if (read_switch(max_pin) && dir)
canStep = false;
}
#endif
// All OK - we can step
return canStep;
}


Finite Element Modeling
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Reading my way through the "Finite Element Method" by Michael R.Gosz, ISBN 0-8493-3407-1. An excellent book to go with FreeFEM++ and FreeFEM3D.


Finite Element Modeling
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My first, modest, steps in modeling the heaterbarrel. Starting with a 2D model. Not taking into account real-life stuff such as convection, radiation and other effects (I am probably not even aware of :-)







First tried to get ElmerFEM to compile on Intel Mac to find out it crashed anyway. Then recently I found FreeFEM++ which is perfectly suited for this purpose.

Before I can add some more sensible comments to this post I have to re-read some old math and physics textbooks first. Partial differential equations, thermal diffusivitiy. All this may take some time ;-)

Please mail me your findings on your 3D printing heaterbarrel FEM approach.

Todays' update; 3D image (FreeFEM3D icw medit) of the heaterbarrel and NiCr Heater coil model.


Oh, the joy of 3D printing
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There is calibration to do, and repositioning of the Z-plane rods. Despite all this I printed (a kind of) PTFE retainer.
The first rafts didn't stick at all. Then they did but the extruder would stop or the print would be fudgy so the nozzle got stuck. Then despair came. And today I managed to complete the thing.



And, well err, it does resemble most of the design ;-)


Jim, it's alive!
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The MakerBot is built and indeed it prints.



The first print ever, a testcube



Now back to my wishlist of things to print. For tweaking and operational MB stuff I keep an eye on the MakerBot Operators Blog.


MakerBot body assembly
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In november I ordered a MakerBot Cupcake printer, to have at least some results with a 3D Printer this year ;-) Last week the package arrived and this week I started assembling the MB body.




Lost directions
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Aaaaargh, finally found why the max stops didn't work, where they were dearly needed!
Escaped from Java Host to replicatorG and Eriks' 3D-to-5D script. Though building here sends all axis way beond the Max!
Anyhow, this is the code adjustment made in cartesian_dda.pde (svn #3252):
bool cartesian_dda::can_step(byte min_pin, byte max_pin, long current, long target, byte dir)
{
bool canStep = true; // 2009.08.27 JvO
//stop us if we're on target
if (target == current)
canStep = false;
#if ENDSTOPS_MIN_ENABLED == 1
//stop us if we're home and still going
if(min_pin >= 0)
{
if (read_switch(min_pin) && !dir)
canStep = false;
}
#endif
#if ENDSTOPS_MAX_ENABLED == 1
//stop us if we're at max and still going
if(max_pin >= 0)
{
if (read_switch(max_pin) && dir)
canStep = false;
}
#endif
// All OK - we can step
return canStep;
}
And next on the list is why the extruder stepper doesn't extrude. It does work in the stepperdriver test.


Infinite series and beyond
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So I spent again too much time on the FiveD Gcode and Java Host. For some reason the FiveD does see the MIN stops but refuses to recognize the MAX. Debugging the code gives me no clue whatsoever. Yeah, disabled the max stops.

Aside from the Mac Java Host stil failing with "gnu.io.PortInUseException", the latest Java Host (compiled with NetBeans) does not communicate with the FiveD properly. Despite tweaking baudspeeds and what not. The first command is sent and the next read returns "o" or "k" but no "ok". Maybe this is related to the Java Serial stuff. But why does the very same environment work well with the old GCode / Java host combination?

It's time to give RepRap the Java Host a break. In the meantime things may mature. Chances are I get an idea for the solution. But right now the Mac Intel, Java, NetBeans, Arduino, C-code, G-code, Extrusion, Heater construction and so on is too much to chew. It spoils my temper. True though, I learned a lot.

So that's it for now.


Arduino Serial monitor and carriage returns
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Struggling to get the latest Java Host to talk to the firmware I checked the FiveD Gcode using Arduino's Serial Monitor. It failed the test and then I spent quite some time hours on this to learn that the Serial Monitor does not send the carriage return at the end of the line. Google turned up this Bitlash readme document. Bitlash being another project using the Arduino platform.
As a work-around, tweaked the firmware process_g_code:
// Get a command and process it
void get_and_do_command()
{
//read in characters if we got them.
if (Serial.available())
{
c = Serial.read();
#ifdef JVO_CR_DOT
if(c == '\r' || c == '.')
#else
if(c == '\r')
#end if
c = '\n';

Example of how you can test the firmware by entering the appropriate command, terminated by a dot, in the Arduino Serial Monitor:

M105. ; read the temperature
G1X10. ; position X
G0 X-99. ; X go home
G0 X-99. ; Y go home

See the RepRap wiki for more on G-Codes.
The minimum stops are seen now, for the maximum endstops I have yet to find out why these are not seen by the FW.
To conclude today with the reassuring (?) knowledge that the firmware seems to be ok so the Java Host is next in line.


Nanotec stepperdriver breakout
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Hm, the glorious extrusion turned out to be unsustainable. Unreliable at the best. Hence preparing for the last resort,the pinchwheel drive.
Now working on a small breakout board for the Nanotec microsteppercontroller.

For those interested, you can download the Eagle files (beta version) (If you don't use stripboard, remove the holes and move all top tracks cq wires to the bottom layer, or ripup and autoroute all over again).


And then there was Extrusion!
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Extrusion, glorious extrusion. Ah, this is Extrusion in its purest form!
;-)
After assembly of the improved BfB heater nozzle, finally succeeded in usefull extrusion speed! And that with the BfB boltdrive. Renoirs' item led me to give the original drive another chance.

So now production begins. The wishlist off things to be RepRapped, after having printed the minimug of course:
- curtain hook
- kitchen mixer tap handle
- motorbike (Yamaha xj900s) choke handle
- steppercontroller board (for the future stepper-extruder) mount

PS
Hm, it's becoming a flat minimug so rotate it prior to printing...


Digital Storage Oscilloscope on the iMac
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Finally the DSO software is running on the iMac!
It is a Voltcraft (i.e. Hantek) model 2090 DSO. HantekDSO (Linux) software from Oleg Khudyakov.


Having KDE installed anyway, here is an example of what KDE looks like on the iMac.


Digital Storage Scope on OS X
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A short preliminary publication :-) for the few who consider using a Digital Storage Oscilloscope on Mac OS X.

Syscompdesign has a simple DSO and OSS software that works on OS X. The 2MHz bandwith I consider too low for my use though.

In search for other suitable DSO's I found none other. What I did find was the HantekDSO package Oleg K is currently working on. This opens up the Hantek (Voltcraft and the like) DSO for use under Linux. In short, I managed to compile HantekDSO under OS X (10.5.7) and right now waiting for Hantek 2090 delivery to test the combination. If successfull I will followup and figure out how to create a MacPorts portfile.


Protostruder
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With help of the Protospace FabLab I managed to cut an improved pinchwheel extruder from 8mm acrylic. Mounted the old BfB heater so it is ready to go, but for one gear, electronics and the steppermotor software... Anyway, Erik dB achieved promising results with this pinchwheel concept.
Pictures follow.


Pinchwheelextruder out of stock :-(
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First of all, thanks for your comments on the previous post. After some productive weeks I am now back to tinkering at the RepRap hardware.

Migrated to Leopard, which is a breeze unless you have a mount of X-windows apps to compile and test. which I do. Studied Tcl/Tk which may be of interest for a digital scope application ( I hope syscompdesign will soon launch a 20Mhz digital scope.) Made my first 3D drawing, yes it is but a drawer, watertight so it could be printed by ShapeWays. Furthermore an attempt for a lasercut Sumi-e brushstand. To begin with started drawing a basic one.

Anyway all this single-handed :-p and now back as I have both hands free again!

Wanted to order the Makerbot pinchwheel extruder but it's out of stock :-(
This is a somewhat compensated as I received today the BfB kit with a new heaterbarrel design. This in preparation of an attempt to get the BfB extruder to work.

At the instigation of ProtoSpace I ordered Nanotech microstepping boards for future refinement of the RR. In particular usefull with the BfB lasercut RR as this has quite a number of bolts and nuts to shake apart.


Dem bones (not the song)
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Yeah, just when things got interesting I broke my collarbone. Being an allweather biker for over twenty years I reckoned something like this could happen someday. That day was yesterday.
The pain is bearable, there's enough things to do to do BUT any tinkering. Which will not be possible the coming weeks...
Status 9 april, btw this is is a comminuted fracture


Z-Flanges
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The BfB kit (v2.0.1) has starshaped Z-Flanges. Material economics outweighed the construction requirements here. In my case the toothed belt realigns in continuous flip-flopping along the flange fingers and occasionally runs off from the gear.
I replaced these with full flanges cut from 5mm acrylic. With help of the FabLab and their Lasercutter. Now the belt runs much more smooth and does not roll off anymore.


Nozzle reconstruction
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Took the heater barrel apart and reconstructed, now with help of the BfB tutorial video
The result is a slightly improved, not to say less worse, extrusion. Now without hand-force, it extrudes very slowly. That is no more than four odd millimeters per minute.
Think I leave the RR arest for a while until I have an idea how to improve extrusion. As the sun shines today, it's time to go out and play.

Similar report
Renoir's coach bolt solutio
Zach Hoeken's Pinchwheel Extruder prototype


Foie gras
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For some reason the current extrusion progress makes me think of force-fed geese and Pate foie gras.
Anyway, pulled the extruder apart to replace the PTFE insulator with a PEEK version. Realigned and now the extruder does extrude. Though very slow and only by hand-force helping the extruder feed :-(
So things are not allright yet. Looks very similar to the Detroit RepRap builders' experience.
Ordered a heater barrel set at BfB to give it another try.


Throw in the towel
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Spent my RR Saturday on improving the heater barrel isolation using glasswool. Then lost quite some time on figuring out why the extruder motor would not work anymore. Finally backed out to Gcode_interpreter SVN version #2483. I suspect the preparations for stepper motor extruders to be the culprit so I will leave the code in development a while for what it is.

Anyway, I tried to get the extruder to work and did not succeed. Better isolation of the barrel only slightly helped in that a little more HDPE comes out of the nozzle now. Tweaking the thermistor lookup table (with createTemperatureLookup.py and setting Beta to 6000 :-) to achieve higher temperatures which didn't help much either. Btw, the heater shouldn't get too hot for the PTFE insulator.

I conclude I did not build the heater barrel correctly. So, I mailed BfB for a new heater barrel kit :-( and for that matter, a second extruder for future (two material) use.

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