Friday, 2 December 2016

Using the Diamond Hotend with DuetWifi

(Guest post by Ian Pegg, deckingman on the Duet3d forums and www.pegdecking.com)


Julia vase #11 Heatwave by Virtox
http://www.thingiverse.com/thing:126567/
Printed Ian Pegg


I have been using a Diamond hotend (3 inputs and one output) on my custom built CoreXY printer, controlled by the DuetWifi for some time now. This blog post is is documentation on how to setup the DuetWifi with a Diamond hotend however it can be generalized to other multiple input - single output hotends. They might use different configurations but the principles will be the same. I have taken the definition of a mixing hot end as one which has multiple filament inputs and a single output (nozzle), although see the "issues with mixing" section at the end.


Hardware requirements.


Assuming you have the necessary number of extruders for your particular hot end, you will need to be able to drive them all. The new Duet WiFi and the older Duet v0.8.5 both have support for 2 extruders. If you have 3 or more extruders, then you will need to procure an expansion board or use another method to connect additional stepper drivers to the Duet expansion connector.

Important note. A mixing hot end must have filament loaded into all inputs at all times. Failure to do this will mean that extruded filament will find it's way up into any unused inputs where it will cool and solidify causing a blockage which will be very difficult to clear. 

Software and Firmware requirements.


You should have a slicer that is capable of supporting multi part objects. Although some things can be done by post processing the gcode file, objects which share the same Z position, would be very difficult to deal with using this method. Also, the slicer and the printer firmware should ideally be capable of supporting firmware retraction (G10) – more on this later. At the time of writing, Slic3r (version 1.2.9) is known to support these features. David's (DC42) branch of RepRapFirmware supports firmware retraction as of version 1.10.  

Some slicers support multiple extruders but not necessarily multicoloured objects (although there may be workarounds). It is often possible to use different extruders (tools) for perimeters or infill or support materials.


Connections.


Refer to the Duet wiring diagrams and connect the first extruder motor to E0, the second to E1 and any others to the relevant connectors on the expansion board. I highly recommend that you put a label on each extruder at this time to act as a reminder of which is which when you come to load filament. Remember that the first extruder drive is always D0 (not D1). This may initially confuse you when you start using slic3r which uses D1 for the first tool instead of D0.


E0 and E1 Plugged into the DuetWifi

E1 Plugged into the Duex5
A mixing hot end will only have one heater so connect this to the first heater (marked E0). Similarly, connect the thermistor to the first thermistor connector (also E0). It's not strictly necessary to use these exact connections but if you decide to use some other terminals on the Duet board, make a note of what you have connected to where. Finally connect the hot end cooling fan to wherever you prefer. The most common configuration is to connect the fan to one of the “always on” terminals but my fan is very high air flow and so quite noisy. Therefore I prefer to have it connected to one of the PWM fan terminals and run it in thermostatic mode so that it only comes on when the hot end is above 45deg C.

Configuration settings – tool definitions.


The first thing to do is define the tools. To do this, it is necessary to edit the confg.g file which can be done using the web interface:
DuetWebControl Web interface allows easy editing of all configuration files.

There are a few different ways that you can define the tools. You will probably need a tool for each of the “solid” colours. That is to say, tools which will only use 100% of one filament. Then you will need a tool or tools that combine different filaments in various proportions.

So to define a tool which uses only one colour, it is only necessary to set which extruder and which heater it will use. The gcode to define a tool is M563. So for the first 3 tools you could use something like this;

M563 P0 D0 H1
M563 P1 D1 H1
M563 P2 D2 H1

This would define the first 3 tools (P0 to P2) to each use one of the extruders (D0 to D2) but the same heater (H1).

IMPORTANT. Be aware that Slic3r and perhaps other slicers, use a different numbering system and the first tool is defined as 1 not 0. This can be easily rectified by either defining tools starting with tool 1 and up, or by using the M563 S1 command in config.g to tell the firmware to add a 1 to every tools number

If we want to mix filaments, we'd need create more tools and turn on mixing. So, we might have another tool defined like so;

M563 P3 D0:1:2 H1 ; Define tool 3 (P3) to use all three extruders (D0:1:2) and heater 1
M568 P3 S1 ; Enable mixing for tool 3
M567 P3 E0.34:0.33:0.33 ; Set mixing ratio for tool 3.

What this does is to define the tool T3 to use all 3 extruders (D0:1:2) then it uses M568 to enable mixing for that tool. Finally, it sets the mixing ratio using M567. In this case roughly the same quantity of each of the 3 filaments. However, this mixing ratio should always add up to 1. So, I've used 0.34 of extruder 0, and 0.33 of extruders 1 and 2 (0.34+0.33+0.33 = 1.00).

We could also have other tools. Say for example we had Red filament in extruder 0 and Yellow in extruder 1, we could define another tool which would blend equal amounts of the tool to create Orange. It would look like this:

M563 P4 D0:1:2 H1 ; Define tool 4 (P4) to use all three extruders (D0:1:2) and heater 1
M568 P4 S1 ; Enable mixing for tool 4

M567 P4 E0.5:0.50:0.00 ; Set mixing ratio for tool 4.

Of course, we can define as many tools as we like. The upper limit of tool numbers is constrained only by the Duet's free memory so over 400 tools are possible on the DuetWifi.

Managing a large number of tools would become cumbersome though and there is another way. Once a tool has been defined to use all the extruders and mixing has been enabled, we can simply change the mixing ratio before or during the print. It can be done before the print commences by putting the mixing ratio into the start gcode file. It can also be done during a print by entering the required M567 command in the web interface or by post processing the gcode file that the slicer generates. In theory the tool mix ratio can be set differently for each gcode move.

So we can simply have one tool which is defined as a mixing tool. In practice, this won't work with slicers which expect different tools for different (coloured) parts of an object. So, I have found the best compromise is to just define 4 tools (or one more than the number of extruders), one for each of the primary filaments and one which is a combination of all three. Coincidentally, in slic3r, if you set your printer to have 3 extruders, it will give you 4 tools to choose from for any object.

Taking this a step further, it is still useful to be able to use any combination of filaments for any tool. For example I could have red green and blue filaments loaded but want to print with Cyan, Magenta and Yellow. So all of my tools are defined as mixing tools but the first three use 100% of only one filament (actually this is not strictly true but we need to consider retraction before I elaborate more). Then if I subsequently want to change a tool to use a different filament or combination of filaments, I can do so but simply changing the mixing ratio at the start of the gcode file, without having to bother with all the other configuration settings. It can also be done “on the fly” from the web interface. This can also be used if one wanted to print a number of copies of the same object but in different colours. Simply slice the object once, then edit the start of the gcode file to change the mixing ratio and/or tool number.

Here is what the tool configuration part of a config.G file might look like.

; Tools
M563 P0 D0:1:2 H1 ; Define tool 0
G10 P0 X0 Y0 ; Set tool 0 axis offsets
G10 P0 R0 S0 ; Set initial tool 0 active and standby temperatures to 0C
M568 P0 S1 ; Enable mixing for tool 0
M567 P0 E1:0:0 ; Set mixing ratios for tool 0
M563 P1 D0:1:2 H1 ; Define tool 1
G10 P1 X0 Y0 ; Set tool 1 axis offsets
G10 P1 R0 S0 ; Set initial tool 1 active and standby temperatures to 0C
M568 P1 S1 ; Enable mixing for tool 1
M567 P1 E0:1:0 ; Set mixing ratios for tool 1
M563 P2 D0:1:2 H1 ; Define tool 2
G10 P2 X0 Y0 ; Set tool 2 axis offsets
G10 P2 R0 S0 ; Set initial tool 2 active and standby temperatures to 0C
M568 P2 S1 ; Enable mixing for tool 2
M567 P2 E0:0:1 ; Set mixing ratios for tool 2
M563 P3 D0:1:2 H1 ; Define tool 3
G10 P3 X0 Y0 ; Set tool 3 axis offsets
G10 P3 R0 S0 ; Set initial tool 3 active and standby temperatures to 0C
M568 P3 S1 ; Enable mixing for tool 3

M567 P3 E0.34:0.33:0.33 ; Set mixing ratios for tool 3


This is not quite how I have my tools defined but to understand the reason for that, we need to look at extruder retraction which is discussed later in this document.

A view of the three e3d Tital Extruders suspended as a flying extruder above the diamond hotend.

Tool offsets


You will notice that in the above tool definitions, there is no X or Y offset, or more precisely the X and Y offsets are set to zero (G10 Pn X0 Y0). That is because there is only one nozzle. X and Y offsets are only necessary where there are more than one nozzle and where they are physically offset from each other. Theoretically these offsets should default to zero but I always like to set them to zero, just in case something should get changed in firmware which might affect the default settings. 

Heating and standby temperatures. 


You will also notice that in the tool definitions above, the initial active and standby temperatures are set to zero (G10 Pn R0 S0). That is because I don't want the hot end to start heating whenever a tool is selected. Instead, I have the heating and standby temperatures set in my start gcode where I can also put the specific temperature as needed for a specific filament.

With a mixing hot end, we only have one heater and one nozzle so if we are using the same type of filament in all 3 inputs, we can instantly switch between tools without having for the next one to warm up, or the previous one to cool down. Therefore, we can (should) set the tool active and standby temperatures to the same values.

This is what I have in my start gcode for PLA in all 3 inputs.

G10 P0 S195 R195     ; Set tool 0 operating and standby temperatures
G10 P1 S195 R195     ; Set tool 1 operating and standby temperatures
G10 P2 S195 R195     ; Set tool 2 operating and standby temperatures

G10 P3 S195 R195     ; Set tool 3 operating and standby temperatures


Then when the print runs and a tool change is needed it can be instantly switched with no warm up or cool down delay.  

Obviously, if we had different types of filament in one or more of the extruders, we would need to change these values for those extruders (tools).

Extruder retraction.


With “normal” retraction, only the “active” extruder will retract. That is to say that if we are only pushing one filament into a mixing nozzle, normal retraction will only pull that single filament back. In effect, all that happens is that filament is drawn from the unused inputs rather than from the nozzle tip. In practice, this is just like having no retraction at all.

What is needed is for all filaments to be retracted, regardless of whether they are actively in use or not. Fortunately Duet hardware and firmware give us the ability to accomplish this. It is done by using firmware retraction using the codes G10 (retract) and G11 (unretract). This might be slightly confusing because G10 is also used for tool offsets but without a tool number, it is used for firmware retraction.

G10 is used in conjunction with M207 to define the retraction amount and speed.
Here is what I have in my config.g file.


M207 S1.5 F3000       ;set firmware retraction

S is the amount in mm. F is the Feed rate mm/min (divide by /60 to get mm/sec).
Optionally one could also have R (additional length on unretract) and Z (additional Z lift in mm)

It is vitally important to use this firmware retraction with a mixing hot end so, the slicer software must also be configured to use this. In Slic3r this is simply a matter of ticking a check box which is in the Printer Settings tab under “General”. Whenever retraction is needed, Slic3r will insert a G10 command (and a G11 command to unretract). For other slicers, there is sometimes a facility to post process the gcode output and one could use this to replace whatever retraction codes was output with G10. Another option would be to use some sort of text editor to do a “search and replace”.    

Tool Definitions revisited. 


Now that we have set our firmware retraction to retract all 3 filaments simultaneously there is another little issue that will become apparent but can be avoided. With a mixing hot end we must have all the inputs loaded with filament at all times otherwise extruded filament will simply find it's way up into unused inputs where it will cool and solidify. We must also retract all filaments simultaneously for reasons discussed above. Therefore, when we print using just a single filament and extruder for a prolonged period of time, what happens is that on the unused inputs, the same piece of filament is constantly being retracted and unretracted. Eventually it will just get worn away and will cease to move and retraction stops working and our prints get stringy.

There is also another issue, which is that most filaments will degrade if reheated and cooled a number of times which is what will happen if we primarily use just a single filament for an extended period of time.

There are a couple of things which can help. The first one is, before starting a print heat the nozzle and extrude some filament from each of the extruders. This will ensure that there is a fresh piece of filament in each of the extruders which may well last for enough retract and unretract cycles without getting so worn that it fails to move.

The way that I prefer to do it is to define the tools so that every tool always uses the main filament plus a small proportion of all of the other filaments. In theory, one might think that this would result in muddy and muddled colours. In practice, it is hardly noticeable and it uses the main filament but just enough of the other inputs to keep them moving so that retraction isn't always moving the same piece of filament back and forth and the same piece of filament isn't being constantly reheated and cooled. Of course, if the colour was absolutely critical, one could always load the same filament into all 3 extruders but in my experience it's unlikely to be necessary.

Here is what my final tool definition section looks like.

; Tools
M563 P0 D0:1:2 H1 ; Define tool 0
G10 P0 X0 Y0 ; Set tool 0 axis offsets
G10 P0 R0 S0 ; Set initial tool 0 active and standby temperatures to 0C
M568 P0 S1 ; Enable mixing for tool 0
M567 P0 E0.90:0.05:0.05 ; Set mixing ratios for tool 0 (90%,5%,5%)
M563 P1 D0:1:2 H1 ; Define tool 1
G10 P1 X0 Y0 ; Set tool 1 axis offsets
G10 P1 R0 S0 ; Set initial tool 1 active and standby temperatures to 0C
M568 P1 S1 ; Enable mixing for tool 1
M567 P1 E0.05:0.90:0.05 ; Set mixing ratios for tool 1 (5%,90%,5%)
M563 P2 D0:1:2 H1 ; Define tool 2
G10 P2 X0 Y0 ; Set tool 2 axis offsets
G10 P2 R0 S0 ; Set initial tool 2 active and standby temperatures to 0C
M568 P2 S1 ; Enable mixing for tool 2
M567 P2 E0.05:0.05:0.90 ; Set mixing ratios for tool 2 (5%,5%,90%)
M563 P3 D0:1:2 H1 ; Define tool 3
G10 P3 X0 Y0 ; Set tool 3 axis offsets
G10 P3 R0 S0 ; Set initial tool 3 active and standby temperatures to 0C
M568 P3 S1 ; Enable mixing for tool 3

M567 P3 E0.34:0.33:0.33 ; Set mixing ratios for tool 3 (34%,33%,33%)


These are what my mixing ratios will always default to. If I want to print a 2 or 3 coloured object using "solid" colours with no mixing, then what I tend to do is simply add M567 commands to the start gcode which will override the default values that I set in my config.g file. i.e. M567 P0 E1.00:0.00:0.00, M567 P1 E0.00:1.00:0.00, M567 P2 E0.00:0.00:1.00.

For example the snowflakes were printed with White on Gold. In this case, I had two tools. Tool 1 was 100% Gold, Tool 2" was 100% White. The base and the flake are separate stls. I added the base (gold part) to Slic3R platter, then in settings set it to use Tool 1. Then I used "Add part" to add the flake and set it to use Tool 2. So, when it printed, the first part of the flake started out Gold until the White filament purged through but that was only about an eighth of the first layer and there are 3 layers of white.


Example of two colour printing with the Diamond Hotend.

Tuning and tweaking


With the exception of getting the mixing ratios right for whatever printed outcome is desired, there is very little tuning and tweaking necessary for a mixing hot end compared to a non-mixing hot end. The only thing that springs to mind is that, because we retract all filaments together, the retraction distance can be less.

On my particular machine, with Bowden tubes around 250mm long for PLA at 195 deg C and print speed of around 60mm/sec, retraction of 1.5 mm at 3000mm/min works well.

Of course, using firmware retraction makes setting it up a breeze. Simply print two small cubes spaced about 50 mm or more apart then during the print use Duet Web Control to change the retraction on the fly and observe the difference. Use M207 Sn.n Fnnn where S is the amount in mm and F is the speed (feed rate) in mm/min. Start with a small number and increase it slightly until signs of stringing disappear. Repeat for other materials, print speeds and temperature if necessary but you'll likely find one value that works well for most situations. 


Scripting mixing ratios


Another way to use a mixing hot end is to post process the gcode file to enter mixing commands at various places. I have a little python script which an M567 command after “n” layer changes. It runs through loops, each one progressively decreasing the mixing ratio for one filament and increasing another. So the colour changes throughout the height of the printed object from colour A to colour B, then colour B to colour C. This can be extended to go from C back to A and then the entire sequence repeated. This is how I produced the following objects:


Ian's vase
A big version of the Julia vase #11 Heatwave by Virtox
http://www.thingiverse.com/thing:126567/
Printed Ian Pegg
The big Julia vase is printed with Red, Yellow and Clear translucent filaments. Starting at 100% red, reducing the Red by 1% and increased the yellow until 100% Yellow, then repeat going from Yellow to Clear. The mixing is changed at every 5th layer to get one complete iteration over the height of the object. The smaller rainbow Julia vase shown at the beginning of this post used Red, Blue and Yellow and changed the mixing at every layer change so ended up with Red,Purple (Red and Blue), Blue, Green(Blue and Yellow),Yellow, Orange (Yellow and Red) then back to Red and repeat the sequence.

Thoughts and ideas.


Most people think of multi coloured objects but even if your slicer doesn't support multi part objects it may well support multiple extruders. This means that one could choose to use one extruder for the infill but a different extruder for the perimeters. One could then use an exotic or expensive material on the outside but cheaper “everyday” filament for the inside. Or possibly use a clear filament for the perimeters to give the object a clear coating.

Printing support material using a different extruder is another possibility that springs to mind.

Then there are other exotic materials such as electrically conductive filament. It could be possible to print an electrical circuit within an object.


Issues with mixing.


There is a fundamental restriction with the Diamond hot end. This is that there is no mixing chamber as such. The advantage of this is that when changing form one filament to another, the changeover period is very short. Usually, if the printer is set to have two perimeters, by the time the second perimeter is being printed, the transition from one filament to another is complete. Obviously this depends on the size of the object. The disadvantage is that when filaments are “mixed” they come out of the nozzle like stripy toothpaste. So the colour is biased towards each input. This effect can be partly negated by using translucent filament. Or it can be exploited for decorative purposes. I have printed a 3 sided pyramid with each face a different colour by using a single tool with a mixing ration of 0.34:0.33:0.33 and orientating the pyramid on the build plate such that each face is directly opposite a filament input.    


The same pot, taken from 3 angles, showing the different sides
This due to partial mixing in the Diamond hotend.

Video


This is a video of my custom CoreXY printing the large Julia Vase by virtox shown in the picture above:




Friday, 15 July 2016

DuetWifi Thermal Testing

The DuetWifi is our new advanced 3d printing electronics board based on the Duet 0.8.5 but completely redesigned with David Crocker (DC42 on the reprap forums). We are currently running a pre-order which is due to end 17 Jul 2016 with the first boards delivered in the first week of August. We have also had a batch of pre-production beta boards made which are with beta testers right now. We put one of the boards through thermal testing by Andy Hingston (who was part of the Duet 0.6 design team). This blog post will deal with the thermal testing, I have future posts planned to detail the hardware design of the DuetWifi.

The main concern for heat generation on the board are the stepper driver chips. The TMC2660s are rated to 2.8A RMS, however we have limited them in firmware to 2A for now. What our testing has shown is that the TMCs drivers, coupled with the board design mean these drivers will run cool in most "normal" desktop size 3d printers (~1A motor current) and have the capacity to scale for significantly larger printers comfortably (~2A motor current).

In order to do a comprehensive test we decided to test the TMCs with 1A, 1.5A and 2A (RMS) of stepper motor current in three conditions:

  1. With the motors held in a "half step": in this condition there is 100% of the current flowing through half of the stepper driver with 0% through the other half.
  2. With the motors held in a "full step": in this condition there is 1/Sqrt(2) of the current ~70.7% of the maximum current flowing through both halves of the driver.
  3. In a normal microstepping mode with a step frequency of 8000 steps/min at 16 microsteps, interpolated by the drivers to 256 microsteps.
In all cases we allowed the temperature to stabilise for 20 mins from an ambient temperature of ~25C

The results: in summary the drivers and heatsinking design on the board have performed really well. At 2A RMS in the "half step" condition (the worst case) we saw the temperature rise to 87.7C (a 62.7C rise from ambient). In the actual use case of the normal stepping at 2A it was a rise to 71C (a 46C rise from ambient). All these tests were performed powering X,Y and Z drivers on the board at the same time so that the Y driver had hot drivers on either side of it. We expected it to get the hottest but actually Z was generally the hottest by about a degree indicating the importance of the PCB to dissipate the heat.

The thermal camera output is below; click on the pictures for larger images.

1A Half Step hold
DuetWifi Thermal Test 1A Half Step Hold - 48.7C

1.5A Half Step hold
DuetWifi Thermal Test 1.5A Half Step Hold - 62.1C

2A Half Step hold
DuetWifi Thermal Test 2A Half Step Hold - 87.7C - Front View
This view of the back of the board shows just how effective the heatsinking on the back layer is.
DuetWifi Thermal Test 2A Half Step Hold - 71.0C - Back View


1A Full Step hold
DuetWifi Thermal Test 1A Full Step Hold - 51.0C

1.5A Full Step hold
DuetWifi Thermal Test 1.5A Full Step Hold - 62.1C

2A Full Step hold
DuetWifi Thermal Test 2A Full Step Hold - 79.8C




1A Normal Stepping
DuetWifi Thermal Test 1A Normal Stepping - 41.8C

1.5A Normal Stepping

DuetWifi Thermal Test 1.5A Normal Stepping - 55.5C

2A Normal Stepping

DuetWifi Thermal Test 2A Normal Stepping - 71.0C

The other area of interest as far as power dissipation on the bard was the heated bed MOSFET and associated power traces. We wanted to carry at least 15A so I increased the width of the trace and doubled it up (both front and back). With 15A on constantly we saw a stable temperature of 88.5C at the hottest point.

DuetWifi Thermal Test 15A Bed MOSFET - 85.3C on Front power (-) trace, 81.9C on MOSFET

DuetWifi Thermal Test 15A Bed MOSFET - 88.5C on Back power (+) trace

Tuesday, 8 March 2016

Updating RepRapFirmware and PanelDue firmware using Mac OS X as a host

(Guest post by Michael Hackney, SublimeLayers.blogspot.com and www.EclecticAngler.com)

Recently, I worked out the process for updating Duet and PanelDue using a Macintosh computer as a host. Once you have the right tools and information, it's quite simple. I've tested this on Mac OS X Yosemite and El Capitan.

Firmware updates for both the Duet and PanelDue are performed via USB. Before we can update that firmware though, we need to install the right tool. This tool is called BOSSA and is an Open Source flash programmer for the Atmel SAM microcontroller used on both the Duet and PanelDue. Unfortunately, there are many different versions of BOSSA, including both command line (BOSSAC) and GUI versions, but only a few of them will actually work! Not to worry, I'll make sure you get a workable version.

1) Get BOSSAC
You can get the BOSSAC command line utility with the Arduino IDE 1.6.1 release. This release is no longer supported but since you can install multiple versions of Arduino IDE on OS X, it isn't an issue to install it. Another option is to find a copy of the BOSSAC utility and use that. I've extracted BOSSAC from the Arduino 1.6.1 IDE and made it available on my Google drive: BOSSAC for Mac OS X.

2) Get the new firmware
Once you have the BOSSAC utility, you need to download the firmware you are planning to install. These are found on David Crocker's GitHub here:

RepRapFirmware-dc42
PanelDue firmware

I like to keep the BOSSAC utility and the firmware versions all in one place in a single folder for convenience.

3) Find the Duet's or PanelDue's port number
This is the most finicky step in the process but this should make it a little easier. The tricky part is that the device we need is not available until you press the Erase and Reset buttons on the Duet or PanelDue. But, there already may be devices with similar names so it isn't obvious which one to use. So, I look in the device directory (/dev) first, then Erase-Reset the board and then look in the device directory again to see what's new!

  • Launch the Terminal application and type "cd /dev" and press [return] (without the quotes). /dev is the directory where Mac OS X keeps all of its device files.
  • There are lots of devices in the directory but we are only interested in a particular type. You can see everything by issuing the "ls" command. But to narrow it down to the USB device we need, run "ls | grep tty.usbmodem". 
  • Now hook up the USB cable to your Duet or PanelDue and press the Erase button and then the Reset button. 
  • Run "ls | grep tty.usbmodem" again and watch the output for the new device that should be found. It will look something like tty.usbmodem14444421 but most likely with a different number sequence.
4) Run BOSSAC
Now we're ready to flash the new firmware. I'll show two ways of doing this depending on if you are using the Arduino IDE BOSSAC or the "naked" BOSSAC. In both cases you run BOSSAC from a Terminal window, so launch Terminal if needed. Then, "cd" into the folder where you keep your firmware .bin files to make it easier.

4a) Running BOSSAC from the Arduino IDE
Type the following command into the Terminal window but replace the YOUR_PORT_# with the port number you found in step 3 and the firmware version you are uploading. Note that this assumes several things: 1) that you installed the Arduino 1.6.1 IDE in your Applications folder and that you have "cd" into the folder that contains the firmware. Make sure you type it exactly and don't forget the "-R" at the end:
/Applications/Arduino.app/Contents/Resources/Java/hardware/tools/bossac --port=tty.YOUR_PORT_# -U true -e -w -v -b RepRapFirmware-1.09o-dc42.bin -R

4b) Running BOSSAC directly
This example assumes that you have placed the bossac utility in the same folder with your firmware .bin file and you have "cd" into the folder in a Terminal window. Make sure you type it exactly and don't forget the "-R" at the end:

./bossac --port=tty.YOUR_PORT_# -U true -e -w -v -b RepRapFirmware-1.09o-dc42.bin -R

Here is an example of what you should from bossac as it runs:
./bossac --port=tty.usbmodem1444431 -U true -e -w -v -b RepRapFirmware-CHTest-3.bin -RErase flashWrite 309308 bytes to flash[==============================] 100% (1209/1209 pages)Verify 309308 bytes of flash[==============================] 100% (1209/1209 pages)Verify successfulSet boot flash trueCPU reset.
When bossac finishes, it resets the board and you are ready to go.



Friday, 26 February 2016

How to compile RepRapFirmware-dc42 for Duet on Mac OS X

(Guest post by Michael Hackney, SublimeLayers.blogspot.com and www.EclecticAngler.com)

As RepRapFirmware gains momentum, more users will want to contribute to its development. There are some good resources for setting up a development environment for Windows computers but very few resources for developing on Mac OS X. I tried for several months to setup my environment and wasn't able to, so I pushed forward and started with a clean slate and documented every step along the way.  Now that it's done, I can install the development environment from scratch in about 15 minutes.

As I discovered, one of the more significant challenges I confronted was the interdependence of specific versions of the various tools and even the operating system. I worked through each of these with the goal of using the most up-to-date version for each component possible, starting with the operating system. Please pay particular attention to these versions as you work through the setup process - they are highlighted in bold. I highly recommend starting with the specific versions I used and once you have your environment running, update components one at a time if necessary. And if you do that successfully, please leave a comment here so others can benefit.

The reference date for this process is 2/14/2016.

Start with your Macintosh updated to Mac OS X: El Capitan 10.11.3 I have not attempted this on earlier versions of OS X so if you are successful, please leave a comment. I'll also leave comments when new versions of OS X come out.

1) Get the tools and setup the basic environment

The first step is to download the development tools. This development environment is based on the Open Source Eclipse IDE. However, a special plug-in to integrate the Arduino tools is required. Putting together this environment was a big challenge but now there is a pre-built Arduino Eclipse  IDE that eliminates the grunge work. A big thanks goes out to Jantje for this work!
Create a folder to use for the root of everything. Please note, once you start this process you can not change the path later. Eclipse is very finicky about installation path so pick something you can live with. Also, DO NOT include spaces in the pathname. NONE!  I created a folder named "Development" on my desktop and will use that for this document. My path looks like:

/Users/mhackney/Desktop/Development

Now copy the Eclipse tar file and Arduino file into Development and unpackage them (on OS X you can simply double-click the tar file to untar it). You can delete the tar file once you've unpackaged it.

Next, open the Arduino.app package (by control-clicking it's icon) and navigate to /Contents/Resources/Java
  • Copy the /libraries and /hardware folders into your Development folder.
At this point, your Development folder should look like:
  • Create a folder named workspace inside the eclipseArduino folder.
2) Configuring Eclipse

Now you can launch he Eclipse application - called eclipseArduinoIDE in the eclipseArduino folder. When Eclipse asks you for the workspace, click [Browse...] and navigate to your Development/eclipseArduino/workspace folder and click the [Open] button. Check the "Use this as default" box and click [OK].

Click the EclipseArduinoIDE menu and choose "Preferences..." then select the Arduino tab in the list on the left. 
  • Set the "Arduino IDE path" to your Arduino.app
  • Set the "Private Library path" to the library folder you copied to your Development folder
  • Set the "Private Hardware path" to the hardware folder you copied to your Development folder
  • Click Apply then [OK] (choose [OK] for the dialogs that tell you Arduino is newer than the plugin)
Here's what the dialog should look like (with your Development path substituted of course) when you are done:


Next, click the Arduino menu and select New Sketch. Set the project name to RepRapFirmware and then make sure sam/boards.txt is selected. Select Arduino Due (Native USB Port) for board. You can set the COM port now also but if you don't know it, it can be set later.

Quit Eclipse.

3) Setup the RepRapFirmware

Download the latest version of dc42 dev branch of RepRapFirmware: https://github.com/dc42/RepRapFirmware (Click the [Download ZIP] button at the upper right). At this writing version 1.09r-dc4 is the latest). Copy all of the files to the RepRapFirmware folder in your workspace folder.

Copy the patched libraries out of RepRapFirmware/ArduinoCorePatches into the Arduiuno.app package. The path is Arduino.app/Contents/Resources/Java/hardware/arduino/sam. Use the "Merge" option and "Apply to All" when the copy dialog asks what to do. Remove the ArduinoCorePatches folder from the RepRapFirmware folder (you can delete it).

Launch EclipseArduinoIDE and setup the project like this:
  • Remove the RepRapFirmware.ino file from the RepRapFirmware Project list on the left - this will delete it from the filesystem too.
  • Select the RepRapFirmware project in the Project Explorer and control-click and select Refresh. All of the source files should appear in the list.
  • Select the RepRapFirmware project in the Project Explorer and control-click and select Index->Rebuild. 
Select the RepRapFirmware project in the Project Explorer and control-click and select Properties... at the bottom of the menu.
    • Find the C/C++ General/Paths and Symbols page. Now you need to add each of the library folders in the workspace/RepRapFirmware/Libraries folder to the GNU C list. Do this by clicking the [Add...] button. Then check the Add to all languages box and click the [File system...] button to navigate to the workspace/RepRapFirmware/Libraries/EMAC (the first folder library to add). Do this for each of the folders in the Libraries folder. It's a little tedious but gets the job done. 
    • You also have to explicitly add SD_HSMC/utility the same way.
    • You also have to add hardware/arduino/sam/system/libsam/include (this is the hardware folder you copied to your Development folder)
    • Then click [Apply] and click [Yes] to rebuild the indexes.
    When you are finished, your list should look like this:
    • Next click the C/C++ Build/Environment tab on the left list. 
      • Set JANTE.EXTRA.C.COMPILE to -std=gnu99 
      • Set JANTJE.EXTRA.CPP.COMPILE to -std=gnu++11
      • Find the A.BUILD.USB FLAGS variable and remove the manufacturer and product part - it looks like this: 
        • '-DUSB_MANUFACTURER=${A.BUILD.USB_MANUFACTURER}' '-DUSB_PRODUCT=${A.BUILD.USB_PRODUCT}'
      • Now find all occurances of the compiler flag "-Os" and change them to "-O2". This is in:
        • A.COMPILER.C.ELF.FLAGS
        • A.COMPILER.C.FLAGS
        • A.COMPILER.CPP.FLAGS
      • Remove the '-w' option in A.COMPILER.C.FLAGS and A.COMPILER.CPP.FLAGS
      • Click the [Apply] button and click [OK] to exit the dialog
    That's It!

    It might seem a little tedious but you'll be rewarded with a RepRapFirmware development environment when you are done. I've successfully installed on four different Mac computers.

    If you have any questions, comments or additions please post a comment.












    Sunday, 25 October 2015

    Mini Kossel: Think3dPrint3d Release 3



    Think3dPrint3d Mini Kossel Release 3

    We have been selling our version of the Mini Kossel delta 3d printer for 15 months now. As is the nature of RepRap projects it has evolved along the way. We have marked these tweaks and upgrades and improvements as different versions of our kit and we are now ready to release our 3rd version - the Think3dPrint3d Mini Kossel Release 3. Though it builds on our other upgrades it is by far the most significant revision yet.

    More detail is set out below but in summary we are switching to 32 Bit Duet Electronics, 20x20 extrusions, IR probing for true autocalibration, as well as some other more minor improvements to the usability or ease of assembly of the printer. Of these the single biggest change is using the Duet electronics with David Crocker's improved RepRap Firmware which allows for segmentation free delta printing and easy autocalibration.


    Since David implemented delta support in the RepRap Firmware we have had many enquiries about buying the kits with the Duet (and some customers chose to help out as unofficial beta testers). It has taken until now for us to bring everything together into a kit form, including thdetailed documentation, to ensure builders will get the same great experience assembling this version as the previous ones.



    Improvements in detail


    Electronics


    The Duet is a high powered 32 bit ARM-Cortex-M3-based 3D printing electronics solution which runs the powerful RepRap Firmware; more on this and the web interface later. With our kits in mind we designed a new 5-channel version of the Duet board with all the connectors, switches and power LEDs along one side. This allows for the electronics to be neatly mounted in the base of the printer with the USB, Ethernet, SD card, switches and power LEDs still fully accessible:


    Duet 0.85 mounted in the Mini Kossel base showing accessibility

    The new Duet V0.8.5 also has 2 extruder channels and so allows an easy upgrade path to dual extruders without an extension board, like the RAMPS in previous versions of the Mini Kossel, but unlike previous 4-channel Duets.


    RepRap Firmware and Web Interface


    David Crocker's RepRap Firmware takes advantage of the ARM chip's 32-bit processing power to provide true segmentation-free delta movement for improved smoothness and accuracy. Unlike most 8-bit firmware like Marlin, RepRap Firmware is precompiled and there is not normally any reason to modify or recompile it. The firmware is easy to configure with all the settings controlled through Gcodes in simple text configuration files. David has documented the setup of the configuration files in some detail on the RepRap wiki, for Cartesian printers, Delta printers and CoreXY printers.

    The Ethernet support allows direct connection to a network or ethernet port on a laptop, or connection via Wifi. The web interface by Christian Hammacher is simple yet powerful and can be run on any device that is on the same network as the printer.



    RepRapFirmware Web Interface running on Duet 0.8.5

    I have taken to using my phone to control my printers:


    RepRap Firmware Web interface on an Android Phone

    20x20mm extrusions


    These provide increased frame stiffness and allow the use of T-slot nuts which can simply be dropped into the extrusion channels when required, making assembly much easier.

    Mini Kossel part way through assembly showing 20x20 extrusions


    Frame assembly is greatly simplified with T-slot nuts

    Differential IR Probe


    David Crocker also developed a really great mini IR probe which, when combined with the functions within RepRap firmware allows for quick and accurate printer setup and calibration.


    Hot end assembly showing DC42's differential IR probe mounted next to the E3D V6 heater block.

    Below is a video showing the probe in action:





    Other Improvements


    To further simplify the printer wiring we designed an effector wiring breakout PCB
    AppA-R13-hotend-PCB.JPG
    Effector breakout PCB
    Breakout PCB connected to hotend, IR probe, fans and wiring loom

    The extruder and E3D V6 hot-end are preassembled and tested. 

    AppA-R07-extruder.JPG
    Assembled and tested extruder
    AppA-R14-V6.JPG
    Assembled E3D V6

    While the majority of our customers have had no issues since we switched from the JHead to the V6 in Release 2, a few have struggled with the V6 assembly. As this kit is designed for hassle free assembly we want to eliminate all the potential issues. The V6 is assembled, heated to 290C and the nozzle tightened in accordance with E3D's recommendations.

    We have included a top mounted spool holder for some time now, along with other tweaks and improvements suggested by our customers. For a full specification of the kit see our website.

    Open Source Hardware.


    As with everything we do the changes to the printed parts are available on our Github.

    More to come!


    We are also finalising the design and kit contents, and working on the documentation for a much larger Kossel, based to a large extent on David Crocker's supersized Kossel. It will optionally have a E3D Cyclops/Chimera dual extrusion hotend, 24V power and a massive 300mm diameter by ~480mm high print area. If you are interested in getting your hands on a Beta Kit then feel free to email us! Update 17 November 2015 - all 10 beta test slots have now been taken.