MakerBot Replicator 1

A few steps to keep the MakerBot running smoothly and continously.

Files

• MakerBot SD card August 2012 - zip archive of the included SD card

Mechanical setup

The basic setup of the MakerBot replicator is quite simple, below is a compressed version of the official guide.

1. Open and remove the top large cardboard piece along with the user manual and take the entire Replicator out of the box
2. Slide out the large accessories box and open it to take out the extruder and place it on the extruder platform
3. Move the build platform up by pulling on both of the inner back supports of the build platform to remove the cardboard piece and the two filament spools
4. In the accessories box, find the two black hex screws and fasten the extruder (the washers are for the extruder plunger maintenance)
5. Add the rubber feet to the side panels under the bot to dampen the vibrations and increase friction on the MakerBot's working surface
6. Refit the heated build platform cable below the platform to the bottom plate, adjust position of the cable to limit slack
7. Press the black filament guide tubes onto the extruder holders and clip the guides in place on the back
8. Hook the spool supports to the back of the MakerBot, with the top tap going in upwards
9. Unpack the filament spools and put them onto the support with the filament pointing from the bottom and up towards the center of the backpanel, cut the bent end using a plier and feed them through the guides till they hit the extruder
10. Find, or use the supplied US, power cord and plug it into the adapter and the other end to the four pin socket on the Replicator
11. Lastly, flip the power switch to power up the bot and and skip to the next section to perform the software calibration

First-time calibration

The first run experience steps below tunes and sets up the build platform and extruder.

1. An automatic setup script will be displayed on the LCD display, press the middle 'H' to continue
2. Tighten the thumb screws on the underside of the build platform to make sure the platform does not hit the extruder tips/heads
3. Adjust the height of the platform by loosening two screws at a time as per the instructions
4. Heat the extruder and wait for it to hit 220 degrees C
5. Load the filaments by pressing it until the extruder motor hook onto the feed
6. A find string of plastic will start to collect on the build platform, when it is finished remove the extruded plastic
7. Now, it is time to print a complete model, from the menu pick a model (not starting with acc_*)
8. Congratulations, the preliminary calibration of the Replicator is done!

Software setup

The Replicator can be controlled both from the on-board MakerBot user controls and the ReplicatorG printer software. Models can be loaded via USB or from the SD card. To prepare a SDL model, use ReplicatorG to create the necessary Gcode bot instructions file.

The steps below can also be found on the official Replicator software page.

1. Download the latest build of the open source ReplicatorG software
2. Perform the installation and setup Python if necessary
3. From the Machine -> Machine Type (Driver) menu pick Replocator single or dual
4. Pick the correct serial port from Machine -> Connection (Serial Port)
5. Open the Control Panel to get to know the functionality of the bot
6. Select an SDL file from the File menu and scale, rotate or move the model to put it in the center of the build platform
7. Hit Generate Gcode and then Build, or put the file on an SD card, to print the model!

Improvements

• Add blue thread-lock to all grubscrews on all the axis to prevent them to fall out [1]
• Use Triflow or similar PTFE lubricant to all metal-to-metal mechanical motion [2]
• Replace the system fan with a large 80x80 mm fan to reduce noise
• Add a adhesive label on the right side of the joy-pad to indicate the insertion point for the SD card
• Remove the ABS residue from the drive gear regularly [3]
• Fit side and top covers to prevent dust from settling on the extruder and internal components
• Enable accelerated prints to increase the print speed and efficiency, see below

Accelerated prints

A new feature which appeared on community 3D printers early in 2012 was the ability to accelerated the printing process. What this means is that instead of linearly moving the position by instantaneously starting and stopping the motors, the travel speed is gradually increased and decreased. While this method is slower when using the same travel feedrate as before, it will be faster when increasing, or doubling, the travel feedrate. The bot will not shake and vibrate as violently and work smoothly. But make sure to use high resolution models/gcode.

• MakerBot accelerated prints