Over the last few months, our engineering team has made some iterative design changes to both our Gigabot 3+ and Gigabot X 3D Printers.
Parts modified are:
Gigabot 3+
Gigabot X
View the video below to find out how they’ve changed!
Below is a repost produced by 3DPrint.com last year, which highlighted our first peer reviewed paper on Gigabot X. You can view download the research, along with other papers under the Gigabot X section at https://re3d.org/gigabot.
In an attempt to mitigate the environmental impact of 3D printing, several organizations have taken to creating recycled filament, made not only from failed prints but from water bottles and other garbage. Inexpensive filament extruders are also available to allow makers to make their own filament from recyclable materials. Not only does recycled filament help the environment, but it also helps 3D printer users to save money and be more self-sufficient, making the technology more viable in remote communities.
3D printer manufacturer re:3D has been working on making their Gigabot 3D printer capable of printing with recycled materials, for the purpose of helping those in remote communities to become more self-sufficient. In a college paper entitled “Fused Particle Fabrication 3-D Printing: Recycled Materials’ Optimization and Mechanical Properties,” a team of researchers used an open source prototype Gigabot X 3D printer to test and optimize recycled 3D printing materials.
In the study, virgin PLA pellets and prints were analyzed and compared to four recycled polymers: PLA, ABS, PET and PP.
The Gigabot X showed itself to be able to print materials 6.5 to 13 times faster than conventional 3D printers depending on the material, with no significant reduction in mechanical properties. This is significant because each time a polymer is heated and extruded, whether during the filament creation process or the 3D printing process, its mechanical properties are degraded. One option to reduce degradation, the researchers explain, is to 3D print directly from scraps, or particles, of recycled plastic.
The Gigabot X was also capable of 3D printing with a wide range of particle sizes and distributions, which opens up more possibilities for the use of materials other than pellets and filament. The processing of the materials was minimal – they only needed to be cleaned and ground or shredded. Mechanical testing using tensile strength was performed and showed that the polymer properties were not degraded; however, the researchers suggest that further mechanical testing should be performed to test properties such as compression, impact resistance, fracture toughness, creep testing, fatigue testing, and flexural strength.
There are a few limitations with the prototype Gigabot X, including lower than normal resolution in the XY plane. Due to the high heat transfer rates from the large contact area of the printer’s hotend, parts that are less than 20 mm x 20 mm cannot be 3D printed reliably. The Gigabot X also currently lacks a part cooling system, so it is limited in the geometries of parts that it can print. However, it is still a prototype, and so can be considered a work in progress.
Authors of the paper include Aubrey L. Woern, Dennis J. Byard, Robert B. Oakley, Matthew J. Fiedler, Samantha L. Snabes and Joshua M. Pearce.
re:3D’s Research and Development team never stands still, and while we’re developing the next generation of your Gigabot® and Gigabot® X 3D Printers, we’re continually looking for ways to refine the current iteration’s user experience, precision, and quality. As of October 1, 2019, all new Gigabot®3+ 3D printers ship with the below enhancements. Current Gigabot® owners can order these as replacement parts that are fully compatible with previous versions.
To enhance user comfort and safety, we’ve created a full length 3D printed cover that fits over the top of the front-mounted LED light strip.
Our Unibody Extruder design, which was released this past spring, as well as our Filament Detection units now features numerical hot end indicator labels for a visual aid for filament loading. Additionally, these and many other 3D printed parts now include part and revision numbers. Not sure what a part is called? Search our store using the part number or share the part number with customer support to help streamline troubleshooting communication.
FIRMWARE RELEASE VERSION 4.2.3
Our newest iteration of Gigabot®3+ firmware has been posted at re3d.zendesk.com along with instructions for how to flash your firmware. This firmware update includes the following changes:
Fit and Strength Adjustments for Polycarbonate 3D Printed Parts
The following parts have had material added for improved strength and durability:
The below parts have had their designs modified for better fit or print quality:
We’ve upped the durability and longevity of our head cable and added 3D printed wire separators inside the cable carrier to protect the electrical wiring as it rolls and unrolls during normal Gigabot® operation.
Under the category of non-3D printed parts, we’ve thickened our bed plates to improve strength and rigidity. The square, left and right leveling blocks attached to the bed frame have had fit adjustments. We’ve also adjusted hole spacing for Gigabox Enclosure panels and split the top panel on the Gigabox Enclosure into two pieces. This improves manufacturing quality as well as increases modularity, as one piece can now be removed for venting or other customizations.
Do you have an improvement or a design change you’d like to see for this or future versions of Gigabot®? Fill out our New Feature Request form and share your ideas with us!
Charlotte craff
Blog Post Author
This month we have tested a variety of printing materials with the GBX, including recycled PET pellets, grocery store bags, plastic Starbucks cups, and polycarbonate manufacturing waste. And our in-house failed prints and supports? Instead of going into the trash, we’re granulating them into PETG, PLA, and polycarbonate regrind for GBX printing.
A big hurdle for printing with regrind is identifying particle characteristics– size, sphericity, etc– for optimal printing. Using the open source software ImageJ, we’ve determined the ideal particle size to be around 3mm in length, but further testing still needs to be done. For more information on the particle analysis and feed tests, check out our forum posts: ImageJ Particle Analysis and ImageJ Circularity Analysis and Feed Tests
Helen Little
Blog Post Author
This post is a follow-up to this one on the Gigabot X pellet printer. If you haven’t checked it out or watched the video, start there!
We know you’ve been dying to know what on Earth our Gigabot X pellet printer prototype was printing in the last update video, so we’re here to deliver!
Without further ado, the reveal.
The slick design was dreamt and drawn up by one of the students working on Gigabot X material validation at Michigan Tech University. Our team was really excited about the idea of printing the board using one of our favorite new materials we’ve been testing: recycled PET.
Giving water bottles a second lease on life as a fun, functional object? As Robert put it, “You know, we had to do it.”
We went through a few trials of the board, snapping a couple of the earlier prints due to the design being a little too thin or not printing it with enough infill. We thickened up the design and increased the infill percentage to make the board a little sturdier, leaving us with a roughly six and a half hour, five pound print.
After popping on some trucks and wheels, re:3D Engineer & Resident Skater Jeric Bautista took the board for a spin behind the Houston office.
Morgan Hamel
Blog Post Author
The first Gigabot X prototype took a trip up to Michigan and is currently residing at Michigan Tech University, where a group of students are performing material testing research as a collaboration supported by our NSF SBIR Phase I. Some of the materials they’ve been validating include PLA, PET, polypropylene, and ABS, in both recycled and virgin forms. One of our favorites we’ve been printing with is recycled PET, better known as the common disposable water bottle.
Morgan Hamel
Blog Post Author
Here at re:3D, we are results driven and want to provide the best possible product for our customers. Before the release of the new Gigabot Firmware 4.2.0, we wanted to put the new feature, Linear Advance, to the test. Referenced from the Marlin website, Linear Advance allows users to print more dimensionally accurate parts. Under normal conditions, the extruder gear movement is a linear proportion to all other axes. However, the pressure buildup in the nozzle is not proportional to other axes and this leads to extra material being extruded at the end of each movement.
To solve this issue, linear advance changes the extrusion rate whenever the extruder slows down or speed up, creating an even extrusion line no matter the speed or change in direction. The K value has units of mm of filament compression needed per 1 mm/s extrusion speed [mm/(mm/s)]
The advantages of this feature are as follows:
A total of 48 test specimens were printed at a different layer height, speed and K value. Each of the 25mm squares were printed individually to decrease the effects of other variables. A circular indentation was added to the middle of the model to increase the number of changes in travel direction, emphasizing the effects of Linear Advance. Shown in Figure 1, are a set of test pieces printed at 0.31 layer height, 120mm/s and a K value of 0.0, 0.05, 0.1, and 0.15 from left to right.
Each test specimen was measured with a caliper. In Table 1, the dimensions of all of the test squares are shown. The highlighted boxes show the test specimen that had the most accurate dimensional reading in its group. As linear advance decouples the extrusion motor from other axis, the print quality is visually and quantitatively improved. Shown in Figure 1, Linear Advance significantly reduces the extrusion of extra material on the outer edges at higher print speeds and larger layer heights. As print speed decreases, the addition of Linear Advance has less of an impact on the quality, however, it is still beneficial with a delta of 0.2 at 40mm/s and 0.15 layer height. These results showed to be consistent with expectations because as flow rate increases, the more buildup of pressure and potential for extra material to come out of the nozzle. With 8 test samples of 0.1 K value and 4 samples of 0.05 K value excelling in accuracy, a weighted average of K= 0.08 provides a good value to improve print quality across the board.
If you are interested in using this feature on your Gigabot, please visit the full feature list of the new Gigabot Firmware 4.2.0 here
Noah Pan
Blog Post Author
Introducing the new Gigabot Firmware 4.2.0. This new firmware release features the latest version of Marlin 1.1.8 and is packed with new features that will elevate the user’s experience with the Gigabot.
Notice: This Gigabot Firmware is only for users with the Azteeg X3 Pro (GB-371 and up) with the dual limit switch kit. This version will not work for bots with single Y limit switches.
Here are the links to purchase the upgrade kit, new Simplify3D profiles, and to Download the Firmware
Table of Contents:
Continuous Printing After Filament Change
Babystepping for Perfect 1st Layer
Other Links
A New Look
The changes in the new firmware can immediately be noticed on the main info screen of the Gigabot. The larger font makes it easier to read and navigate. (Figure 1.)
The contents and item order of the Prepare Menu have also changed to create an easier and more accessible experience. The preheat option is placed on the top so a target temperature can be set quickly. A new and improved Change Filament routine item is shown followed by the Move Axis menu plus three axis homing actions. (Figure 2.)
About Printer is the newest addition to the screen menu (Figure 3). This menu displays useful information about the printer, such as the model number, firmware upload date, prints completed/ failed, total print time and longest print job completed. This data can be used to keep track of a regular maintenance schedule for your Gigabot.
Dual Y Axis Homing Switch
A major feature of the new firmware is the support for dual Y-axis homing switches. This feature provides more consistent performance and a higher degree of dimensionally accurate printed parts out of the Gigabot.
Previously, a single homing switch existed on the left Y motor, resulting in a carriage that was not consistently parallel to the machine frame. During a filament change, it was possible for an accidental displacement of the carriage, losing positional accuracy (Figure 4).
With dual Y axis homing switches, the machine is guaranteed to be squared to the frame every time the machine is homed (Figure 5). This will provide more consistent performance and accuracy for all prints. Paired with the new filament change routine, the Gigabot will show precise repeatability.
Shown in Figure 6 is a print completed to torture test the dual homing switch feature. A line of gcode was inserted after each layer incrementation to move the extruder aside, disengage the stepper motors, rehome, and continue printing. The results show the consist carriage squaring that the dual homing switch provides. After over 1000 layers, the tower shows homogenous layer quality with no layer shifts.
Linear Advance
Do your prints ever look like the image in Figure 7? Linear Advance is a new feature that allows users to print more dimensionally accurate parts. Under normal conditions, the extruder gear moves linearly in proportion to all other axes. However, the pressure buildup in the nozzle is not proportional to other axes and this leads to extra material being extruded at the end of each movement.
To solve this issue, Linear Advance changes the extrusion rate whenever the extruder slows down or speeds up, creating an even extrusion line regardless of the speed or change in direction.
The advantages of this feature are listed on the Marlin website and are as follows:
re:3D performed an extensive test on this new feature to determine the optimal K value for different layer heights and printing speeds. Shown in Figure 8, is a set of test specimens printed with different K values. Figure 9. shows the improved dimensional accuracy from a specific K value.
A weighted average value of K= 0.08 was chosen, improving print quality for a number of different print settings.
Check the blog post for more information:
Ditto Printing
Duplicate nozzle printing (aka. Ditto Printing) allows the user to print with both nozzles at the same time. It can produce two identical parts with the only constraint that the X length of the object is smaller than the hotend offset (~55mm on the Gigabot). This feature is particularly useful when mass producing parts, cutting printing time in half which can be very beneficial. To enable this feature, download the new 4.3 Simplify Profile for Gigabot, choose PLA Duplicate Nozzle or PC-Max Duplicate Nozzle under the Auto-configure for Material tab and Duplicate Extruders under the Auto-Configure Extruders tab. In the slicer, place only one model on the build platform and start the print. The bot will produce two identical parts.
(Note that this feature works by mirroring the left extruder to the right. Only the left filament runout sensor will be active and the right will be inactive.)
re:3D uses this feature to increase the speed of printing in-house production parts (Figure 11,12).
This feature can also be used to infuse parts together! Like this crazy dual color infused Marvin or 3DBenchy boat shown in Figure 13 & 14.
Filament Change Routine
The new filament change routine provides a series of walk-through interfaces that guides the user through the entire process. The user first selects the extruder and material type that needs to be changed. (Figure 15)
Shown in Figure 16 are a series of walkthrough LCD screens. The Gigabot will first heat the desired nozzle, then automatically unload the filament. The LCD will then direct the user to unload the filament and insert new filament. The filament will automatically purge and ask the user if they want to purge more or continue printing. There are also added safety features that will unheat the nozzle if the machine has been idle for a minute.
Previously, filament changes were tedious with the cable chain obstructing the workspace. With the new firmware, the nozzle park position is on the right side, avoiding all obstructions and allowing for easier filament changes. (Figure 17.)
Please Note: For filament changes from high-temperature material to lower temperature materials (Ex. Polycarbonate to PLA), Please manually heat the nozzle up to the melting temperature of the higher temperature material, switch materials, then purge 200mm of filament and lower the temperature down for the second material. This will clear out the nozzle of any previous material to prevent jamming.
Continuous Printing After Filament Change
Continuous printing after filament change is a feature specifically designed for the long prints that the Gigabot produces. Often times, the Gigabot uses an entire spool of filament and upon filament runout, the machine pauses and waits for the user to change filament. Production time will dramatically increase if the user is unavailable.
With the new Continuous Printing feature, the user loads two spools of the same filament into both extruders. When the first spool runs out, the Gigabot will automatically unload the filament, load and prime the second nozzle, and continue printing. This feature is listed under Controls> Filament> Filament Runout (Figure 18). The user can choose between two filament runout features, pause for change or continuous printing. These options are also available during mid-print so the user can change settings as any given time.
For very long prints, once the second filament spool starts printing with the left nozzle, it is suggested to pause the print and load another spool of filament into the right nozzle.
Shown in Figure 19 & 20 are some of the largest prints that re3D has done. The print time could have been dramatically shortened with the use of continuous printing after filament runout.
Babystepping for Perfect 1st Layer
Babystepping allows the user to adjust the Z height at very small increments to achieve a higher quality first layer. To use this feature, double click the encoder during the first layer of your print until the LCD screen displays the Babystepping screen as shown in Figure 21. Scroll the knob to move the Z up or down (clockwise to move the nozzle away and counterclockwise to move the nozzle closer). Babystepping can also be activated through a M290 gcode. Look at that perfect first layer in Figure 22!
re:3D uses this feature to accommodate for the expansion of the heated bed during high temperature prints such as polycarbonate. A M290 Z0.25 moves the nozzle 0.25mm away from the bed and M290 Z-0.25 moves the nozzle 0.25mm towards the bed.
As seen in Figure 23, Babystepping can dramatically improve the first layer quality. At the start of this print, the nozzle was too far from the bed and the babystepping was adjusted to -0.217mm. After the adjustment, a perfect layer line was achieved.
Other Links
Please contact support if you have issue with the new Gigabot Firmware. For general questions, please post them in the forum. To view instructions, please go to the re3D wiki. For source code, please visit our Github page.
Notice: Please download the latest Simplify3D profile on our wiki to fully take advantage of all these great new features!
References:
Thanks and Acknowledgements:
Mike Stewart
The Marlin Team
Known Issues:
Machine Power Cycles when the user homes the machine and initialized change filament routine simultaneously
If using Ditto Printing, only the left filament sensor will trigger. The right sensor will be inactive. If the left filament sensor is triggered, the machine will eject filament from both extruders and only with the left extruder when printing resumes.
Noah Pan
Blog Post Author
Fall is in the air and re:3D is very excited to introduce you to the latest updates for Gigabot. Over the past year we have been working hard to provide you with enhancements for Gigabot to print at a higher resolution, faster, and with better quality. Additionally, we have improved the user interface, made it easier to change filament and level the print bed. Here are the upgrades you have been waiting for!
Wow, I know that is quite a bit of upgrade for the new 3+ and I am super excited for all of you to see the REAL benefits! To make sure that none of our customers are being left out we are offering all the upgrades as a bolt-on package starting next month. Happy Printing!
Matthew Fiedler
Blog Post Author
As I sit on a plane flying in the opposite direction of Aruba I feel there is nothing more important than finding a way back. You see, Samantha & I spent the past three days as co-founders immersed in a new culture with new people and pitching an idea that is new and maybe just ahead of it’s time. The event that brought us all together is Atech2016. There exist in the paradise of an island nation of Aruba a group of inspiring founders who for the second year now have decided to put their money on the table. These visionaries invite tech savvy entrepreneurs and guest speakers to discuss thoughts and ideas on topics ranging from mobile banking & blockchain technology. I’m just glad we did research into sites like https://beincrypto.com/tag/coinbase/, as this meant that we were kept up to date with all things relating to the blockchain industry. We even looked into wearable tech & social inclusion from the perspective of Burning Man to inspire each other as well as the local Arubans how we as a society maintain relevance in the age of acceleration that we are living.
Gatherings like Atech2016 are really the nexus, bringing together in one place a group of young individuals with passion, focus, and hunger for change. With connections made, and new ideas formed we are all contemplating our next steps as we fly in the opposite direction of Aruba. We feel honored to have been part of such an event and encouraged by many Arubans who resonated with re:3D’s vision and our pitch for the Atech and Aruban communities. We were stoked to be named finalists in the pitch competition, and, while we didn’t win left more determined than when we arrived.
Several things became clear to us in the few short days we spent on the island:
Our goal and dream, that which we pitched to Aruba, was that re:3D would engineer and manufacture the prototype hardware needed to take the first step in 3D printing useful objects from plastic trash. During our few short days at the conference, we reached out to community leaders, local entrepreneurs, Aruban schools and universities and well as hotels to partner in the effort of recycling, re-using and re: imagining the possibilities to own their our factory as well as the supply chain. The response was super positive and affirmed for us first – hand there was a HUGE opportunity to leverage trash for a more circular economy.
While we left Aruba affirmed that 3D printing from waste is inherently right, we unfortunately did not secure the resources we needed to complete a prototype to leverage reclaimed plastic using Gigabot. Stayed tuned to upcoming blogs in our series as we continue to share our vision in future competitions and pursue partners to donate post-manufacturing waste streams to test. With a little luck, we will raise enough support to partner with Aruba on a pilot!
~Happy Printing!
Matthew Fiedler
Blog Post Author
re:3D’s Headquarters is Moving to Austin! Delivery will be delayed until June 2024 for orders placed after May 1, 2024. LEARN MORE