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FDM + SLA – Testing 3D Printers for FIRE !!! Safety in 2021





Transcript

Hello everybody and welcome to another video. Today we’ll be looking at a collection of machines that I currently own and explore some of the safety issues that they may have. Today we’ll be checking the machines for Thermal Runaway Protection as well tinned wires on the terminals. I’ll be evaluating not only my FDM machines, but also my SLA printers at the same time. As always the information you see represents my own opinions and no money has exchanged hands. Try this at your own risk.

After having watched the 3D printing Nerds video on the CR30 along with the Thomas Sanladerer’s video on thermal runaway, I felt that expanding on this topic might be of use to some of you. You see, I’ve been using quite a few FDM and SLA printers non-stop and decided to show you guys just how many of my personal machines have issues out of the box.

To start things off, I’ll be looking at 3 of my FDM as well as 3 of my SLA printers, for a total of 6 machines. These machines include the CR10 V3, Ender 3 V2, CR30, Anycubic Photon, Voxelab Polaris and the Elegoo Saturn. Unfortunately, at the time of recording this video, my two Anycubic Machines required maintenance, so I will not be including these in this video. It should also be noted that I had modded those two machines so extensively over the years that most of these issues have already been addressed.

Let's begin with the machine that started this whole inquiry, which in this case is the CR30 by Creality. For the most part this machine is very well though out, however I have had to do several adjustments after extensive use, and I’ll be covering those issues in a future video. For today however, I did check the machine for tinned wires. When I opened up the machine, I did indeed discover that most of the wires connections to the terminals were all tinned. I therefore replaced those with ferrules.

The next machine was the Ender 3 and in this case we once again have tinned wires at the terminals connections. After replacing those, I then started working on the testing the thermal runaway on this machine. All 3 tests were successful and indeed this machine did have a properly implemented thermal runaway protection. Although error messages weren’t always generated, the machine did on each occasion turn off the hot end. If you're testing out your own machine, you’ll want to keep in mind that the test for removing the connection wire to the heater cartridge does take a while to trigger, depending on the machine.

Let’s take a look at the modified CR10 V3, which does have an updated firmware, which was created with the source code that Creality had on its website. When I recently went to check for those files I did find them harder to located, however they are still available after doing some digging. Now similar to the Ender 3 and CR30 the wires were tinned at the terminals and had to be updated to included ferrules. To do this, I used a Ferrule crimping tool and automatic wires strippers, although you can just use a pair of pliers to do the same thing. Now the wiring for the hot end is a little more complicated since it uses a hub to provide power to most of the hot end components. Therefore, testing will most likely more difficult if you are attempting this at home. This machine passed all the thermal runaway tests with flying colours and had the appropriate warnings pop up on each occasion. As mentioned previously, I was using my own modified stock firmware, which can be found on my website.

Now, all these FDM printers did have mosfets to help cool the motherboard, which is a very important feature to have. Since so much power is being drawn to the hot end and the build plate, having those will help cool those connections and keep them from burning out. On my I3 Mega and Mega S these were not present, and I had to add them to it separately. The Creality machines all have these built into the motherboard and so long as they’ve been properly installed, they will keep cooling the motherboard and prevent the wires from overheating. You can see that on my Anycubic, although the connection did overheat, the damaged was contained to the mosfet. In this case the damage was caused because of the tinned wires which were still present at the time.

The SLA printers were all pretty surprising in themselves, with the Elegoo Saturn being the most complicated. Out of all these machines, all of them had tinned wires at their terminals. Thermal runaway isn’t an issue in this regard since we aren’t dealing with a hot end or heated build plate. Out of all the machines, the most difficult one to check and repair is the Anycubic Photon, since it required the most awkward of dissembles. While the Elegoo Saturn did take time to do disassemble, all parts are fairly easily accessible, although you’ll have multiple connections which are tinned. It’s for this reason that I’ll be releasing an additional video going over this in more detail for the Elegoo Saturn. In the end, the easiest printer to access all the components was the Voxelab Polaris. Voxelab opted to create a more open design, which should make upgrades or repairs easier in the future.

So with all of this information taking into account how did all of these machines do in the end? Well, none of these 3d printers had proper ferrule terminal connections, which is disappointing to say the least and should be the very first thing a user should check upon receiving their machine. Out of the FMD printers by Creality all of them did have thermal runaway protection. The CR30 is still to be tested as we speak, so you’ll have to keep an eye out for that video when it comes out. Out of all machines, only the Anycubic Photon was extremely difficult to access the internal components and is something that I would like to see them solve in the future. By far the easiest to disassemble, was the Polaris, which clearly had a focus on repairability because of the open design. While the Ender 3 is still easy to open up, you do have to be careful when putting back on the panel. Since the CR10V3 has a separate case for the electronics, repairs are easier since you can simply remove this portion. I hope this video illustrations how important it is to check your machine when you get it, since you never know how seriously a company has taken safety into account. As someone who was once bought a device which didn’t have thermal runaway enabled, I say just how serious of an issue this could be and just how thankful I am when it’s properly implemented. In future however, I would like to see companies stop using tinned wires in their terminal connections since this does represent a significant safety issue and is definitely something I will be watching for in the future.

Grim Evolution – 2D to 3D Printed and Back – Grim Reaper Design





From 2d to 3d design, the grim reaper is transformed from a simple painting to a full 3d-printed model.  Each step represents the different stages that an artist can go through in the creation process.  Each part of the process can take several weeks to complete before they are ready for the next stage.

CR10-V3 – All Metal Upgrade + CR Touch





Link to download files: https://www.thingiverse.com/thing:4910392 (Please check the youtube video comments since most questions have already been addressed in that area)

Transcript

Hello everybody and welcome to another video tutorial. Today we’ll be upgrading the machine to use an all metal hot end thanks to a couple of mods that I designed myself as well as installing the new CR Touch which is crealities BLTouch alternative. Full disclaimer, this is not a paid sponsorship, I was sent the CR Touch free of charge for testing purposes and the opinions that you will see here are my own. Furthermore, undertake this at your own risk, and I’m in no way responsible if damages may occur as a result.

Before starting to design anything, I first needed to see how the hot end was mounted to the machine. So this meant dissembling the unit and seeing which portions could be reused and which one needed to be changed. For the components that I’m building today, I did find it easier to do the test prints with PLA, so long as I monitored the temperatures. I then used my SLA printer to print with engineering materials.

I went with the E3D V6 direct kit since even with the exchange rates it came to almost the same amount as a knockoff and I knew the quality that I was getting. Another benefit was the online resources that they provided to the user. They had diagrams which included important measurements and even had the steps for modifying the firmware. So I knew I was going to have the proper thermistor settings enabled without having to do additional research.

With all of this information, I began designing the adapter for the hot end itself. Now in the stock version, the main cooling fan was attached to an outer case which made nozzle changes more difficult because of the lack of access. So I knew ahead of time that I would need to keep this area as clear as possible. What I ended up modelling was an adapter which fit into the stock gear section of the filament feed and used a Zip tie to help ensure that it remained in place. Although the zip tie wasn’t necessary, it was an additional precaution to make sure that everything held together.

While the finished part was printing on the machine, I began making the changes to the firmware. I changed the thermistor type to number 5 which was the 100k thermistor -ATC Semitec 104GT-2. With that portion changed, it was now time to set the maximum Temperatures for the hot end. Because this was a higher temperature hot end, it was important to take into account how the firmware worked. For safety reason, the firmware automatically reduces the max temperature reading by 15 degrees on the LCD screen. So to fully tighten the nozzle, we’ll first have to increase the max temperature by this amount and lower it back down. With this hot end, the maximum temperature is 285 degrees Celsius. So if you do this, you’ll want to make sure that you turn back down the maximum to 285 degrees after properly tightening the nozzle. I made a previous video showing how to do nozzle changes on this machine, which I’ll include a link in the description below.

By this point I had already decided that I would mount the cooling fan to the same screws as the CR Touch, therefore I modelled and began testing this portion together as soon as possible. With the mount for the CR Touch, there’s a little of play involved, therefore it’s important to keep this in mind when installing your part. In my first design I created only one cooling fan however the parts weren’t cooling properly in overhanging areas, so I redesigned this to a secondary output that ran onto the other side of the nozzle and although the designs don’t necessarily match they do however allow for minimal material use and a more streamlined path for the air to flow.

At this point, I began installing the finalized parts that I had 3d printed and replacing the BLTouch with the CR Touch. One thing I noticed was that in my case, I had to use trial and error to manually set the Z-Offset for the machine. To do this, I’m going to level the bed by going to “Prepare” + “Bed Levelling”. Afterwards, I went to “Prepare” + “Move Axis” and lowered the nozzle to the zero mark. Next, I went to “Control” + “Motion” + “Z-Offset” and began tweaking the value until I got a perfect first layer. Just make sure to save your settings otherwise it won’t be stored, so go back one menu after setting the Z-offset and choose “Store Settings”. This meant quite a few failed test prints, but was the best solution I found given the issues I encountered. For some reason, the nozzle would hit the bed whenever I used the proper method of calibration. The only difference was that I had compiled by own version of the firmware by using the source code which had been provided by Creality. In future, I would like to see them update this source code to reflect the changes which may have occurred as well as updating Marlin to one of it’s more recent releases. Other than that, I didn’t have any problems with the CR Touch, so I’m hoping that they’ve addressed the quality control issues which were present with the aftermarket BLTouch.

Now, to make things easier for any of you who may wish to try it out for yourselves, I’m making both the files and the firmware available for download on my ThingIverse Page. So would I say that the CR Touch and Hot End Upgrade was worth it in the end. I would say that yes, depending on how you intend to use this machine. I’m personally swapping out materials fairly constantly, so not having to worry about the bed levelling because of the temperatures changes makes the CR Touch Worth it in my case. As for the hot end upgrade, well that depends on the materials you intend to use. I do want to use some of my higher temperature materials, and I’ve been unable to utilize because of the limitations of the hot end, so once again in my case this does become relevant.

Also, for those of you who actually want to use this video as a guide, keep in mind that I will be posting the transcript on my main website to make it easier to follow along. Alternatively, please feel free to slow down the video by hitting the gear icon on the bottom right-hand corner of your screen and to changing the speed settings.

If you want to support this channel, please feel free to check out some merch on my website. Thank you for watching, and I hope to see you guys soon. Thank you and take care.

Nozzle Change – CR10 V3 3D Printer





Transcript

Hello everybody and welcome to another video tutorial. Today we’ll be addressing the question that some of you had in the past as to how to change the nozzle on the CR10 V3 since the housing is very tight and difficult to disassemble. Well the good news is that you can do this pretty much as easily as any other machine if you know what to look out for in the process. As always, I am in no way responsible for any damages that may occur so do this at you’re own risk.

Before we even begin removing the existing nozzle we first need to clean out the hot end and there’s a very simply method that I prefer to use for this. The main method I use now days is commonly known as a “Cold pull”. Not only is this great for cleaning out your nozzle if it’s jamming, but it’s also great for clearing out the passageway when doing a nozzle change.

Although I do prefer to use some TPU while doing this, PLA will also work, but you’ll just have to be careful not to snap it in the process. To start things off, if you don’t have any filament already loading into your machine you’ll need to preheat the nozzle by going to “Prepare” + “Preheat PLA” and “Preheat PLA End”. Both PLA and TPU will both use the same temperature settings in this case. Now with TPU you have the option of tying the end into a knot which will make it easier to remove later on, so we’ll cut a piece off that’ll be long enough to feed through and feed it into the hot end. Just make sure that it’s a little longer so that it extrudes slightly. Remove the part that extruded from the hot end and begin cooling down the machine by going to “Prepare” + “Cooldown”. The hot end should be at its normal room temperature before continuing to the next step. Once it’s Cooldown completely you’ll restart the heating process while tugging on the filament at the same time. As the hot end heats up any residue will be dislodged when the filament is pulled out at a low temperature. As you can see I did this process with both TPU and PLA with the same results. Once again just make sure not to snap the filament while doing this step.

For the following steps here’s what I recommend you pick up for the nozzle change. While some of these are optional most are highly recommended. A ratchet with extender and bits, needle nose vice grips, magnetic tray, pipe joint tape and your replacement nozzle.

With the nozzle cleaned up we can now begin swapping the end so to do this will need some needle nose vice grips. Normally for most machines you don’t need this specific tool however because of how close the hot end assembly is to the components and the difficulty which can be experience in removing the outer shell I do highly recommend you pick this up. A small ratcheting socket set is also helpful however there are more specialized tools out there, so this one isn’t as necessary. You’ll want to take a close look underneath to check where the wiring is mainly located since the last thing we want to do is damage the thermistor or heater cartridge. To do this we’ll raise the hot end assembly up the Z axis by going through the menu system. Go to “Prepare” + “Move Axis” + “Move Z” and we’ll set the number high enough to easily access the hot end with our tools. As an extra precaution I would also recommend putting something on the glass bed just in case you drop a tool on the surface.

Anything after this point should be done with a minimum of one glove on your hand to keep from burning yourself. With your vice grips you’ll lock this onto the heater block while making sure to avoid any of the delicate wiring that’s on the inside. Luckily the design of the hot end assembly automatically places these components into an area where they’re less likely to get damaged. Here’s a picture of how this looks under my machine but double check just in case before clamping the vice grips in place. The nice thing about using a ratchet which has an extender on it is that the extender helps to defuse the heat far easier and prevents burning. So you’ll unscrew the nozzle carefully and remove it from the hot end assembly.

Before we begin putting on the replacement, we first want to add some pipe joint tape since this’ll help produce a greater seal within the threads and prevent material from oozing out. I personally prefer using the version which is thicker since it requires less wrapping, but that’ll depend on your preferences. This material can be found at any local hardware store or online depending on what’s more convenient. A very important note is to make sure that the hole isn’t in any way covered or that you get this material inside. This can cause some very bad nozzle jams so take care of this step. If it’s covered, simply use your tweezers to punch a small hole and roll the material around the edge of the thread. Now we simply screw back in the nozzle making sure to have it just tight enough to hold into place. Just as you’re getting close to finish tightening the hot end, you’ll hold onto the vice grips and tighten the hot end followed by slightly turning the vice grips to allow for a greater seal. DO NOT under any circumstances do not overtighten the nozzle since it can snap in the heater block. Simply remove the vice grips, and you’re ready to go.

Also, for those of you who actually want to use this video as guide keep in mind that I will be posting the transcript on my main website to make it easier to follow along. Alternatively please feel free to slow down the video by hitting the gear icon on the bottom right-hand corner of your screen and to change the speed settings.