Equipment/Stratasys FDM 1650: Difference between revisions

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==Background==
{{EquipmentInfobox
|name=Stratasys 3D printer<!-- Do not change! Takes name from the name of the wiki page it is on. -->
|image=stratasys.jpg <!-- Image of the item. Leave with placeholder image if none exists. -->
|category=Equipment <!-- Main category. Please leave alone to keep item in this category -->
|subcat=Defunct <!-- Sub-category if one exists. Please check main listing to see other categories contained within the main one -->
|status=Scrapped
|consumables=Printer filament <!-- Any items used up in normal operation, such as; ink, paper, saw-blades, cutting disks, oil, etc.. -->
|accessories=<!-- Any items associated with the equipment but not consumable, such as; drill bits, safety gloves, goggles, etc.. -->
|reqtraining=Yes <!-- Is training required to use this equipment? Yes or no. -->
|trainlink=[[#Training & instruction]]<!-- If training is required, provide a link to training signup or contact page. Otherwise leave blank. -->
|acnode=Yes
|owner=LHS <!-- Provide a link to owners members page if other than LHS -->
|origin=Donation <!-- If via pledge, please link to the completed pledge page on the wiki -->
|location=3D printer area, Ground floor <!-- Floor, room/zone and location within that area -->
|maintainers=Hipster <!-- If an individual is nominated as managing the upkeep of this item, please list them here. -->
|itemId=<!-- Item ID code if available -->
|template_ver=1.0 <!-- Please do not change. Used for tracking out-of-date templates -->
}}
=Description=
The Stratasys is a commercial-grade 3D printer that was [http://groups.google.com/group/london-hack-space/browse_thread/thread/a4088a8560511d67 donated to the LHS by Imperial College London]. It was repaired for a time, but is currently undergoing an extensive refurbishment to bring the electronics up to modern standards and properly convert it to non-vendor-specific feedstock.


http://groups.google.com/group/london-hack-space/browse_thread/thread/a4088a8560511d67


'''DISPOSAL: Notice of Disposal applied by Tgreer on 11/12/2016. Scrapped & gutted sometime over xmas period by Hipster.'''


==TODO==
== Pictures ==


===Hardware===
{|
| [[File:FDM_1650.JPG|thumb|What it could look like, one day.]]
| [[File:Stratasys_controls.jpg|thumb|The control panel for the Stratasys.]]
| [[File:Stratasys_side.jpg|thumb|A side view of the Stratasys.]]
|}


*Driver boards reported to be faulty
=Specification & documentation=
**but all axes move - it's not clear that any repairs are needed.


*Self-test starts to work, but runs extruder into left hand side. Be cautious
*Usable Print Area: 270mm x 270mm x 300mm
**homing operation appears to work in X/Y if done separately
*Top Print Speed: 20mm/sec (Yes its slow)
**investigate setup limits
*Print Tolerance: 0.05mm in X and Y axes. Z axis is dependent on layer thickness
*Layer Thickness: 0.05mm to 0.2mm
*Supported Materials: ABS and PLA plastic filaments
*Usable Filament Sizes: standard 1.75mm


*Homing Z tries to run substrate into extruder
** Examine Z axis for reference or limit switches, diagnose.


*Contact Ally to find out details of common faults
=Training & instruction=


* Possibly document connections from the automove unit -- at some point, we're going to need to figure out how to drive the heaters/extruder from the automove.  Might as well do as much as possible now, while it's open anyway.
Training '''IS REQUIRED''' and is being carried out voluntarily by the current maintainers, more info on the separate [[3dprinter_training|training page]]
** Is anything connected to the 38v coil drivers, the DE-9?
** What is connected to the digital I/O connector, the 36-pin female "printer" port?


===Operations===
Please do not use the printer if you have not been trained, even if you think you know how to use it.


* Calibrate
==Consumables==
**Find documentation for this
Only filament provided by the maintainers can be used in the Stratasys. This is to prevent any issues with poor quality filament. If we're running low on filament (or tape), ro recommended alternative providers, let them know (via the [[mailing list]]).
*Measure positioning precision
*Find out if drivers are microstepping.
*Find out stepper motor drive levels (current and voltage)
**Stepper motor signals rest at 20V - is this the supply ?


===Software===
Filament options (3.0mm)
*ABS (lego brick plastic - prints at 190-230 DegC, requires heated bed at 100-110 DegC)
*PLA (biodegradable , based on food starch - prints at 185-190 DegC, optional heated bed, not hotter than 60 DegC)
*There are other 'specialist' filament, like wood effect, stone effect, nylon (can be coloured by clothes dye), etc


*Run original software and capture the commands it's sending.
== 3D printing process ==
**Doesn't really matter if this works as long as the data is sent
[[File:3D_Print_process.png ]]
**Disconnect stepper motors if it seems likely to exceed permitted travel
**Determine normal move sequences
**Note any non-XY operations to determine Z positioning and extruder control


*Write simple sequences to test understanding of ACL
=Log=
==Original use==
For pre-refurbishment logs, see the legacy sub-page here: [[Stratasys_FDM_1650/Legacy#Logs]]


==Refurbishment==
===TODO===


*If we wanted to use the stratasys with skeinforge, we'd need to get skeinforge to output appropriate movement commands or, perhaps more maintainably, translate the G-code output into ACL. This might not be too difficult : skeinforge seems to use a very limited section of G and M codes, notably
*1. <s>Remove all the unnecessary wiring, including the old heater tubes.</s> 16-05-2013
*2. <s>Identify the wiring on the steppers (these are wired differently to normal).</s> 16-05-2013
*3. <s>Connect the motors to the 4pi (http://wiki.arcol.hu/blog:4pi) and calibrate the settings.</s>
*4. <s>Redesign the head end for 2 hot-ends and extruders.</s>
*5. <s>Connected hot ends and run heat and thermistor checks. </s>
*6. <s>Head end redesign complete, waiting for aluminium part for mounting hot-ends</s>
*7. <s>Filament path checks.</s>
*8. Install Raspberry Pi with Octoprint and touch-screen.
*9. Dual head calibration test print.
*10. Heated chamber (required for ABS), phase 2.


G1 linear move
==Updates==
G2 cw arc
===1-6-2014===
G3 ccw arc
After providing spare hands to tgreer in trying to get the new controller wired in for the open-day, I noticed both motor connector plastics are extremely perished. Sockets and plugs. The Y-axis (?) stepper connector has previously been bodged. Pins no longer make good electrical contact with bodged SIL connector. This is both due to bent pins that have apparently been forced, but also the SIL socket terminals sliding freely in their plastics. Pins on stepper are also able to move into the motor body when pressed! Attempting to press another connector onto them will likely push them all the way into the motor housing, rendering the motor useless.
G21 set units to mm
As the motor pins still pass continuity tests, this severely damaged connection seems the likely reason for the motor skipping phases.
G28 home
My recomendation is that flying leads are soldered directly to the damaged pins and connected to a seperate connector that can be fixed to the chassis. Possibly a DB9.
G90 set absolute distance mode
Replacing the steppers entirely is a possibility, but will be tricky due to the capstan-drive. Removing the stepper will probably mean re-winding and re-tensioning the system.
G91 set incremental distance mode
M101 extruder on
M103 extruder off
M104-108 extruder temperature control
M110 filament height ?
M113 duty cycle ?


*Write translator to perform the above conversion
The capstan drums seem at risk already however, as the (nylon?) coating on the steel cable is severely deteriorated, cracked and flaking off. Once the coating fails sufficiently to expose the cable, the cable will begin to eat into the surface of the aluminium capstan drums, ruining them. The drums are not likely to be easily replaced, the motors and cable are.


==DONE==
While the cable is fine for testing use, if the Statasys is going to be used frequently, new cable should be sourced as a priority.
* Power up normally.  Are there any bad-looking lights on the front panel?  If so, something is stuck.
  DONE! - It's fine.


* Power up with left and right buttons pressed, should start self-test run.  It will loop, power-off or hit reset to stop it.
- Sci
  DONE! - It works as expected. Ran through all the self-tests, and they came out ok.
  They're all in the service manual. Have a look.


* Connect the serial port up.  Document how to reach it on this wiki page.
===27-11-2013===
* Open her up, document the position of the switches on the back of the automove unit.
The milled parts should arrive any day now and, once installed, we should be ready for a first test print.
* Determine serial parameters from the dip switches, see page 9 of [http://www-car.asymtek.com/support/manuals/70_0045_20_C.pdf the automove operation manual].
  DONE!  [[Equipment:Stratasys_FDM_1650#COM1_Settings]]


* Using [http://www.nordson.com/en-us/divisions/asymtek/documents/manuals/76_cs02_01_acl_manual.pdf the acl docs], find the current values of the personality parameters, document them here.  This will hopefully keep us from losing them by accident later, and tell us a bit about how the machine is set up.  You'll want the OP command, page 3-50, and the list of personality parameters, page 14-1.
As far as I am concerned, based on the investment by members, a successful print of any description, using both extruders or not, is proof of working.  Having experimented with Dual Extruders, the configuration too complicated to include this by the (self imposed) deadline.
  DONE! [[Equipment:Stratasys_FDM_1650#Initial_Conditions]]


==Current Status - 17/10/11==
Thanks
Ian


*Moved out of alcove and tried a few basic things.
*Self-test ran (aborted) after restoring front panel connector.
*All axes capable of movement using arrow pad.
*Remaining parameters dumped and entered in wiki
*Feed Home command works
*Z home using buttons appears not to stop (aborted, looked dangerous)
*ACL manual reports that microstepping is used (but is that for a different controller ?)




==Current Status - 6/10/11==


(Billy posted this to the mailing list)
===01-11-2013===
Currently the Stratasys is moving and the hot-ends/extruders are working.  We are waiting for the aluminium to mount the hot-ends in.


Ally, one of Dean's friends, has said that she's happy to help us
Once this is completed, it shouldn't take much longer to have this completed and working.
repair it. She's worked on older versions of the Stratasys printers,
and she's already had a look at the electronics. She's happy to to
show people what needs doing, and how to do it, though she'll need her
expenses covering for travel. I think it's inside the M25.


I'll pass along the contact details.
However, as I mentioned on IRC, if we cannot have a completed print by Christmas, I think this project should be marked as 'not completable' (if there is such as word) and we call it a day...


As for the state of the Stratasys. The transport mechanisms work fine.
Thanks
Both extruders seem to work. The temperature control  mechanisms seem
Ian
to work, though the machine has the tendency to run for a while, then
shut down instantly.


From what Ally said, this is usually due to either leaking capacitors,
===16-05-2013===
or two-legged transistors. Usually simple enough to replace, but this
To the mailing list:
project went waaaaaaaay past my skill levels in electronics a long
time ago... :))


The server sitting next to the Stratasys is set up with the OS and
<code>
software needed. We can communicate with the control boards happily.
Hey all.


==Current status - 2011-07-01==
Right, finally got time today to do a thorough check-up on the stratasys. As I have rpreviously said, all internal mechanics (including the steppers) are in full working order, especially as I performed a strip and clean to it pre-move.


The rackmount machine on the floor is now running XP again; somebody, likely Billy, reinstalled the system without updating this page.
After a quick talk with Ian on Wednesday, I have traced all the cables and found all the documentation for the parts, ferrous detecting end-stops, x-y controller pin outs, steppers etc. I have removed the old and power hungry heaters and flourescent lights.


I've installed speedfan, and disconnected some of the non-software-controllable fans.  This makes it somewhat less horribly loud.
I have paird the stepper cables and made ready for the 4-wire board. Also gave another clean


I've also started documenting the initial parameters below.
Basically it is ready to be connected to control board and ready to run.  


The correct serial settings are 9600 7E1 (that is, even parity, 7 data bits, 1 stop bit). Other settings work, but ESC.E gives errors.
All we need now are to nice tourqey nema17 steppers, 2 j-hotends (ian has offered to source and will start pledge, less than £100). Once these have turned up and I've cad modeled them, i will design a nice clean and easily accesable mount for them in the existing hot end housing (also been cleaned).  


==Current status - 2011-06-23==
Charles will need to add a ACNode and it'll be up and running as a tool for the space. But like the laser cutter and charles, I will be its main care-taker/daddy lol.


The rackmount machine on the floor under the terminal to the right of the stratasys is named capak (the man who coined the term "robot").  The user is hackspace/hackspace.  Please use sudo for root.  (The root password is also hackspace.)
Hope this has cleared up any concerns or apprensions about having a fully working, accurate, industrial 3D printer in the space to be used by people with training.


If you know why the monitor is nigh-unreadable, please fix it.
Regards
Hipster
</code>


It should be possible to ssh to it from within the space.  (Use capak.local.)


==Current Status - 10/06/11==
=Links=
 
It's kind of functional.
 
There's an computer connected to it and we can get a serial port connection on COM1.
 
At the moment it's only returning error messages.
 
The automated tools can connect happily.
 
IT STILL NEEDS CALIBRATION BEFORE USE!!!
 
Please do this first, and let us know what happened.
 
There are two printed manuals, a printed service manual, and the rest of the docs are on the desktop in the Stratasys folder.
 
I'm in the middle of setting up the software. It's NOT usable yet!
 
I'll be back later tonight to finish setting it up...
 
==Information==
 
UK reseller is http://www.laserlines.co.uk/.  This one may have come direct from Stratasys, though.
 
* [http://3d4u.org/MyFDM/ Extensive blog on the 1650 and 2000]
** Manuals for an FDM 2000 (includes description of Quickslice 5.0 - 1997):
*** [http://3d4u.org/MyFDM/wp-content/uploads/2010/12/2000APPL.pdf Applications]
*** [http://3d4u.org/MyFDM/wp-content/uploads/2010/12/2000UTIL.pdf Utilities]
*** [http://3d4u.org/MyFDM/wp-content/uploads/2010/12/2000INTR.pdf Manual]
*** [http://3d4u.org/MyFDM/wp-content/uploads/2010/12/2000PROC.pdf Procedures]
** [http://3d4u.org/MyFDM/?p=29 Page referencing these] and C:\QuickSliceV64-qsni
** [http://www.3d4u.org/MyFDM_Files/cb12abs-sml-101211.txt Calibration file]
** [http://3d4u.org/MyFDM/?p=708 Webcams]
* [http://haveblue.org/ Another 1650 owner]
* [http://www.incredilution.com/2011/01/engineering-to-save-5000/ Repairing an FDM 2000]
 
* [http://support.knowlton.ohio-state.edu/files/InsightUserGuide.pdf Insight User guide] (2005)
 
* [http://replay.web.archive.org/19990221032334/http://www.stratasys.com/1600.HTM Stratasys product page] (1999)
* [http://www.hive76.org/fdm2000-progress Philadelphia hackspace] with an FDM 2000


==Training==
==Training==
Line 185: Line 149:
* [http://www.ipd.anl.gov/anlpubs/2001/05/39420.pdf Modification for makerbot-style self-supporting objects]
* [http://www.ipd.anl.gov/anlpubs/2001/05/39420.pdf Modification for makerbot-style self-supporting objects]
* [http://wiki.makerbot.com/forum/t-284930 Using makerbot parts]
* [http://wiki.makerbot.com/forum/t-284930 Using makerbot parts]
==Software==
Quickslice known versions are 5.0, [http://replay.web.archive.org/19990224223330/http://www.stratasys.com/PR061298.HTML 6.0], 6.1, 6.2, 6.4
Insight known version are 3.4.1, 4.2, 6.0, 7.0.  Only 4.2 and below works with the 1650[http://jcflowers1.iweb.bsu.edu/rlo/fdm.htm].
Answers from Stratasys to emails:
: We stop supporting this system a couple years ago, so getting the software for this system is not possible because it cannot be purchased and is only available through a maintenance contract. We are not aware of any third party or open source application that would work on this system.
: Quickslice might be archived somewhere, however, we have to adhere to company policy.


==Reverse engineering==
==Reverse engineering==
Line 201: Line 157:
* [http://utwired.utexas.edu/lff/symposium/proceedingsArchive/pubs/Manuscripts/1998/1998-28-Bertoldi.pdf Some guys at UTexas] managed to cope with it
* [http://utwired.utexas.edu/lff/symposium/proceedingsArchive/pubs/Manuscripts/1998/1998-28-Bertoldi.pdf Some guys at UTexas] managed to cope with it
* [http://utwired.utexas.edu/lff/symposium/proceedingsArchive/pubs/Manuscripts/1998/1998-28-Bertoldi.pdf Some guys at UChicago] did too
* [http://utwired.utexas.edu/lff/symposium/proceedingsArchive/pubs/Manuscripts/1998/1998-28-Bertoldi.pdf Some guys at UChicago] did too
==Initial conditions==
Firmware Version is 9.01
OF: Calibration factors: 1.0027,1.0028
OI: AUTOMOVE REV 3.60/3.60
OL: travel limits: 0,0, 12000, 12000
ON: digital inputs state: 0
OO: origin : 0,0
OP: Personality parameters:  (enter OP<space>n; or OP<space>nn;)
1: Arrow Single Step Delay: 3000 (factory)
2: Arrow slow step delay: 100 (factory)
3: Arrow Fast Step Delay: 3 (factory)
4: X Arrow Direction Swap: 0 (factory)
5: 0
6: 0
7: 250
8: 2
9: 2
10: 100
11: 100
12: 100
13: 100
14: 32767
15: 32767
16: 32767
17: -15
18: -15
19: 1.0027
20: 1.0028
21: 8
22: 8
23: 0
24: 0
25: 12000
26: 12000
27: 16504
28: 16504
29: 1
30: 0
31: 1
32: 40
33: 10000
34: 40
35: 10000
36: 0
37: 0
38: 255
39: -1
40: 200
41: 25
42: 1
43: 0
44: 100
45: 32767
46: 0
47: 200
48: 0
49: 0
50: -1
51: 500
52: 0
53: 150
54: 400
55: 400
56: 10
57: 1
58: 0
59: 0
60: 0
==COM1 Settings==
Bits per second : 9600 <BR>
Data Bits      : 7<BR>
Parity          : None<BR>
Stop Bits      : 1<BR>
Flow Control    : Xon/Xoff<BR>
These settings are stored in a Hyperterminal session called FDM1650.

Latest revision as of 15:09, 31 December 2016

Stratasys 3D printer
Stratasys.jpg
Sub-category Defunct
Status Scrapped
Consumables Printer filament
Training requirement Yes
Training link #Training & instruction
ACnode Yes
Owner LHS
Origin Donation
Location 3D printer area, Ground floor
Maintainers Hipster

Description

The Stratasys is a commercial-grade 3D printer that was donated to the LHS by Imperial College London. It was repaired for a time, but is currently undergoing an extensive refurbishment to bring the electronics up to modern standards and properly convert it to non-vendor-specific feedstock.


DISPOSAL: Notice of Disposal applied by Tgreer on 11/12/2016. Scrapped & gutted sometime over xmas period by Hipster.

Pictures

What it could look like, one day.
The control panel for the Stratasys.
A side view of the Stratasys.

Specification & documentation

  • Usable Print Area: 270mm x 270mm x 300mm
  • Top Print Speed: 20mm/sec (Yes its slow)
  • Print Tolerance: 0.05mm in X and Y axes. Z axis is dependent on layer thickness
  • Layer Thickness: 0.05mm to 0.2mm
  • Supported Materials: ABS and PLA plastic filaments
  • Usable Filament Sizes: standard 1.75mm


Training & instruction

Training IS REQUIRED and is being carried out voluntarily by the current maintainers, more info on the separate training page

Please do not use the printer if you have not been trained, even if you think you know how to use it.

Consumables

Only filament provided by the maintainers can be used in the Stratasys. This is to prevent any issues with poor quality filament. If we're running low on filament (or tape), ro recommended alternative providers, let them know (via the mailing list).

Filament options (3.0mm)

  • ABS (lego brick plastic - prints at 190-230 DegC, requires heated bed at 100-110 DegC)
  • PLA (biodegradable , based on food starch - prints at 185-190 DegC, optional heated bed, not hotter than 60 DegC)
  • There are other 'specialist' filament, like wood effect, stone effect, nylon (can be coloured by clothes dye), etc

3D printing process

3D Print process.png

Log

Original use

For pre-refurbishment logs, see the legacy sub-page here: Stratasys_FDM_1650/Legacy#Logs

Refurbishment

TODO

  • 1. Remove all the unnecessary wiring, including the old heater tubes. 16-05-2013
  • 2. Identify the wiring on the steppers (these are wired differently to normal). 16-05-2013
  • 3. Connect the motors to the 4pi (http://wiki.arcol.hu/blog:4pi) and calibrate the settings.
  • 4. Redesign the head end for 2 hot-ends and extruders.
  • 5. Connected hot ends and run heat and thermistor checks.
  • 6. Head end redesign complete, waiting for aluminium part for mounting hot-ends
  • 7. Filament path checks.
  • 8. Install Raspberry Pi with Octoprint and touch-screen.
  • 9. Dual head calibration test print.
  • 10. Heated chamber (required for ABS), phase 2.

Updates

1-6-2014

After providing spare hands to tgreer in trying to get the new controller wired in for the open-day, I noticed both motor connector plastics are extremely perished. Sockets and plugs. The Y-axis (?) stepper connector has previously been bodged. Pins no longer make good electrical contact with bodged SIL connector. This is both due to bent pins that have apparently been forced, but also the SIL socket terminals sliding freely in their plastics. Pins on stepper are also able to move into the motor body when pressed! Attempting to press another connector onto them will likely push them all the way into the motor housing, rendering the motor useless. As the motor pins still pass continuity tests, this severely damaged connection seems the likely reason for the motor skipping phases. My recomendation is that flying leads are soldered directly to the damaged pins and connected to a seperate connector that can be fixed to the chassis. Possibly a DB9. Replacing the steppers entirely is a possibility, but will be tricky due to the capstan-drive. Removing the stepper will probably mean re-winding and re-tensioning the system.

The capstan drums seem at risk already however, as the (nylon?) coating on the steel cable is severely deteriorated, cracked and flaking off. Once the coating fails sufficiently to expose the cable, the cable will begin to eat into the surface of the aluminium capstan drums, ruining them. The drums are not likely to be easily replaced, the motors and cable are.

While the cable is fine for testing use, if the Statasys is going to be used frequently, new cable should be sourced as a priority.

- Sci

27-11-2013

The milled parts should arrive any day now and, once installed, we should be ready for a first test print.

As far as I am concerned, based on the investment by members, a successful print of any description, using both extruders or not, is proof of working. Having experimented with Dual Extruders, the configuration too complicated to include this by the (self imposed) deadline.

Thanks Ian



01-11-2013

Currently the Stratasys is moving and the hot-ends/extruders are working. We are waiting for the aluminium to mount the hot-ends in.

Once this is completed, it shouldn't take much longer to have this completed and working.

However, as I mentioned on IRC, if we cannot have a completed print by Christmas, I think this project should be marked as 'not completable' (if there is such as word) and we call it a day...

Thanks Ian

16-05-2013

To the mailing list:

Hey all.

Right, finally got time today to do a thorough check-up on the stratasys. As I have rpreviously said, all internal mechanics (including the steppers) are in full working order, especially as I performed a strip and clean to it pre-move.

After a quick talk with Ian on Wednesday, I have traced all the cables and found all the documentation for the parts, ferrous detecting end-stops, x-y controller pin outs, steppers etc. I have removed the old and power hungry heaters and flourescent lights.

I have paird the stepper cables and made ready for the 4-wire board. Also gave another clean

Basically it is ready to be connected to control board and ready to run.

All we need now are to nice tourqey nema17 steppers, 2 j-hotends (ian has offered to source and will start pledge, less than £100). Once these have turned up and I've cad modeled them, i will design a nice clean and easily accesable mount for them in the existing hot end housing (also been cleaned).

Charles will need to add a ACNode and it'll be up and running as a tool for the space. But like the laser cutter and charles, I will be its main care-taker/daddy lol.

Hope this has cleared up any concerns or apprensions about having a fully working, accurate, industrial 3D printer in the space to be used by people with training.

Regards Hipster


Links

Training

Modification

Reverse engineering

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