Difference between revisions of "3D PRINTING WITH ROBOTS"

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[[Category:Software]]
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[[Category:Machines]]
  
 
==Material Preparation==
 
==Material Preparation==
  
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*Locate the Rhinoceros 5 or Rhinoceros 6 shortcut on your desktop and double-click to launch the application.
 
  
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Alternatively, you can also click on the Windows Start button and select All Programs. Go to the program group containing Rhinoceros 5. (The name of this program group will usually be called Rhinoceros 5 or 6 unless you specified otherwise during setup). If the installation was successful, upon launching of Rhinoceros 5 you should observe a menu called RhinoCAM 2018 in the main menu bar of Rhino. If you do not see this menu entry then please check the On-Line Help document of the product (found in the installation folder) for help with troubleshooting the installation.
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Testing material viscosity and printability before 3D printing is important to ensure good printing outcomes. Here's a breakdown of the recommended process:
  
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*Before we begin, let's talk a bit about the RhinoCAM display. When you run RhinoCAM for the very first time, your screen may look at this.
 
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These windows on the left belong to plug-in modules that are currently loaded. For now, let's close all of them.
 
  
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*Launch the MILL Module
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'''Manual Extrusion Test with a Closed Tube Mortar Gun:'''
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Now, let's begin by launching the RhinoCAM 2018 MILL module.
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1. From the Rhino main menu bar, you will see the RhinoCAM 2018 menu item.
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2. Drop-down the menu and pick MILL to load the MILL module.
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- Use a closed tube mortar gun to manually extrude the material.  
  
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3. Docked on the left you will see the Machining Browser and the Machining Objects
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[[File:APLICADOR-MORTERO-ALTA-POTENCIA-TUBO-CERRADO-600-ML-ALYCO-198818PRINCIPAL.jpg| 700 × 402 pixels]]<br><br>
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Browser. When you first run RhinoCAM 2018, these two browsers may be docked side
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by side. However, you can move them anywhere on the screen that feels comfortable
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for you.
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4. For example, let's move the Machining Objects Browser so that it displays under the
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- This allows you to assess how the material flows and how it behaves during extrusion.
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Machining Browser on the left. Simply left-click and hold the title bar of the browser
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and drag it around on your screen.
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[[File:RhinoCam interface.JPG|800px]]
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- The closed tube design helps in maintaining consistent pressure and control over the extrusion process.
  
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==Extruder Assembly==
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'''Mixing the Material:'''
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To set up the stock( the whole material to be milled) follow these instructions:
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Machine
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[[File:Mixing Material.png| 700 × 402 pixels]]<br><br>
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1. Define the Machine and Post-processor to use.
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2. Define the Machining Setup including Stock Geometry, Material and Work Zero.
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- Ensure thorough mixing of the material to achieve homogeneity.
  
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3. Create and Select a Tool to use for machining.
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- Inadequate mixing can result in inconsistencies in material properties, affecting print quality.
  
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4. Create the Machining Operations including the Feeds and Speeds, the Clearance
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- Avoid adding excessive water content, as it can cause shrinkage issues.
  
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Plane and other Cutting Parameters.
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- Conversely, too little water content can lead to dry material, making it difficult to print.
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5. Generate the toolpath.
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6. Simulate the toolpath.
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==Motor screw extruder==
  
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7. Post Process the toolpath.
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[[File:Extruder parts 2.jpg| 350 × 201 pixels]]<br><br>
  
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8. Generate Shop Documentation.
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The Motor screw extruder was originally developed by Eduardo Chamorro Martin in collaboration with 3DPA IAAC. This innovative tool, which is open source, has since been further enhanced and modified by IAAC staff members for various applications.
  
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==Select the Post Processor==
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For detailed information and updates on the Motor screw extruder, please visit the GitHub repository at the following link: https://github.com/EDUARDOCHAMORRO/FabricatableTools
  
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[[File:Rhinocam 21.jpg|800px]]
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==Printing Steps==
  
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Next, we'll define the Post Processor.
 
  
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1. From the Program tab select, Post to display the dialogue.
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'''Step 1: Tool setup'''
  
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2. For the Current Post Processor, select Haas from the list of available posts.
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- Ensure that all components of the extruder are properly assembled.
  
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3. Then set the Posted File Extension to .nc.
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- Mount the End Effector with the Robot Flange securely. Use the appropriate screw size and ensure that the extended parts of the screws do not protrude on the rear side of the flange to prevent scratching or damaging the robot arm.
  
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4. Pick OK and notice that the Post type now appears under Machining Job in the Machining Browser.
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[[File:Connector resize a b.jpg| 700 × 402 pixels]]<br><br>
  
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==Create Stock Geometry==
 
  
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[[File:Rhinocam stock.JPG|800px]]
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- Before loading the material into the cartridge, inspect it to ensure there are no air bubbles trapped inside. Air bubbles can disrupt the printing process and cause damage to the print quality.
  
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In this step, we'll define the raw stock from which to cut the part.
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- Apply vaseline to the piston and threads in the metal cap of the cartridge. This helps to ensure smooth movement and prevent friction during the printing process. Make sure the cap is tightly secured to avoid any leaks or inconsistencies in printing material flow.
  
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1. From the Program, tab select Stock and then select Box Stock from the menu to display the dialogue.
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- Release Pressure Using Pressure Regulator.  
  
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2. Under Dimensions, set the Length L to 10.0, Width W to 6.0 and Height H to 0.125. Note that the stock dimensions you enter are measured from the corner of the bounding box selected in this dialogue.
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- Connect the air pressure pipe and the motor cable to the designated connector.
  
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3. Pick OK and notice that the Stock type now appears under Machining Job in the Machining Browser.
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[[File:C connector resize.jpg| 700 × 402 pixels]]<br><br>
  
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4. If the stock does not display on the screen, select the Stock Visibility icon located at the base of the Machining Browser.
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'''Step 2:TCP Calibration'''
  
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==Create Tools==
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- Calibrate the tool properly.
  
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[[File:Rhinocam 20.jpg|800px]]
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- For more details about calibration check the following document
  
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[[File:Rhinocam 22.jpg|800px]]
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https://drive.google.com/file/d/196kO1AxNpu0TbMAIdhFcR8AHWfLMZXfV/view
  
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To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.
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- Place the TCP value in the gh files
  
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1. This will display the Create/Select Tool dialog.  Select Flat Mill from the Tool Type menu at the top of the dialog.
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[[File:Tcp data1-01.png| 700 × 402 pixels]]<br><br>
  
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2. Set tool Name to FlatMill-0.5 and Tool Diameter to 0.5.  Under the Properties tab set Material to HSS and Tool Number to 1.
 
  
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3. Switch to Feeds and Speeds tab and click Load from File.
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'''Step 3:Extrusion test'''
  
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4. From the dialog that displays, set Stock Material to Wood and Tool Material to HSS.
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- Check Digital Outputs Utilize the flex pendant. Use programmable keys on the flex pendant to navigate through the settings and verify that all digital outputs are functioning correctly.
  
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5. Now pick OK and the computed cut feedrate and spindle speed are transferred to the Feeds and Speeds tab of the Create/Select Tool dialog.
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- Activate the motor and preassure, Gradually adjust the pressure regulator to raise the pressure. Monitor the extrusion process for consistency and quality.
  
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6. Pick Save as New Tool to save the tool. The tool is now created and listed under Tools in Session on the left side of the dialog.
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[[File:Extrusion test.jpg| 700 × 402 pixels]]<br><br>
  
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7. Pick OK to close the dialog.
 
  
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==Cut Material Simulation==
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'''Step 4:Base calibration'''
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The new toolpath can now be Simulated to display the in-process stock model.
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1. Switch to the Simulate tab at the top of the Machining Browser.  
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- Use masking or double-sided tape to prevent the base from moving.
  
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2. Select Preferences from the Simulate tab.
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- Jog the robot to three different positions. Add Coordinates to Grasshopper File for accurate geometry placement.
  
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3. From the Preferences dialog set the Simulation Model to Polygonal and the Simulation Accuracy to Fine and then pick OK.
 
  
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4. Then from the Simulate tab, uncheck Simulate by Moves and adjust the slider to the left to slow down the simulation speed.
 
  
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5. Now, under Setup 1 in the Machining Job tree, select the 2½ Axis Profiling operation we just created and then pick Play to start the simulation.
 
  
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6. You can stop the simulation at anytime by selecting the Pause button from the Simulate tab.  Subsequent to pausing the simulation, you can either choose to continue the simulation by selecting the Play button again or exit the simulation by selecting the Stop button.
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[[File:Bas calbr 23.jpg| 700 × 402 pixels]]<br><br>
  
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7. To view the cut model with textures applied, select the Toggle Material Texture Visibility icon located at the base of the Machining Browser.
 
  
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==Post G-Code==
 
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Now with the toolpaths complete we're ready to post-process to an output text file containing G-codes that can then be sent to the machine tool to actually machine the part.
 
  
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1. Select Setup 1 from the Machining Job, right-click and select Post.  This will postprocess all operations created under the Setup.
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'''Step 5:Export and running the file'''
  
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2. The Post & Save As dialog is displayed.  By default, the Part file name and the Setup name are appended for the G-code File name.  Also by default, the posted G-code file is Saved in the folder where the part file is located.
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IMPORTANT:
  
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3. Now pick Post and the G-code file is displayed in Notepad where it can be viewed or edited manually.  
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Before running the main file, conduct a pressure-free dry run, execute the file slowly, verify the correctness of the z value, ensure the nozzle doesn't hit the base, and adjust the z value if needed.
  
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4. Now close Notepad.
 
  
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==Information Report==
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- Check if the robot is in manual mode
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At any time, you can create a Report of your Machining Operations.
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1. Switch to Program tab in the Machining Browser.
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- Acknowledge any errors seen on the flexpendant
  
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2. Select Setup 1.
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- Export your file in .PRG format and copy it in a USB
  
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3. Right-click and select Information to display and Print the report.
 
  
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This dialog provides an estimate of the machining time required for the operations in the Setup.
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[[File:Exportfile.png| 700 × 402 pixels]]<br><br>
  
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Note (Professional & Premium configurations only): In the future, if your Machining Job contains multiple Setups, you can perform the same right-click sequence on the Machining Job to determine the estimated machining time for all Setups.
 
  
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4. Now pick OK to close the Information dialog.
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- Plug in the USB in the port on the flexpendant
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- Go to Main Menu >Production Window >yes >change it to old format (.PRG)
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- Select the file and open
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[[File:Running a file from usb.jpg| 700 × 402 pixels]]<br><br>
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- Check the speed before running the file.
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- Press the Guard stop and press the play button to initiate the file
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==Termination of work and cleaning==
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- After printing, ensure thorough cleaning of all parts using appropriate cleaning tools.
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- Return cleaned parts to their designated places on the shelves.
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- Avoid using the sink for cleaning; utilize the large cleaning space designed specifically for clay and concrete materials.

Latest revision as of 17:15, 31 January 2024


Material Preparation

Testing material viscosity and printability before 3D printing is important to ensure good printing outcomes. Here's a breakdown of the recommended process:


Manual Extrusion Test with a Closed Tube Mortar Gun:

- Use a closed tube mortar gun to manually extrude the material.

700 × 402 pixels

- This allows you to assess how the material flows and how it behaves during extrusion.

- The closed tube design helps in maintaining consistent pressure and control over the extrusion process.

Mixing the Material:

700 × 402 pixels

- Ensure thorough mixing of the material to achieve homogeneity.

- Inadequate mixing can result in inconsistencies in material properties, affecting print quality.

- Avoid adding excessive water content, as it can cause shrinkage issues.

- Conversely, too little water content can lead to dry material, making it difficult to print.

Motor screw extruder

350 × 201 pixels

The Motor screw extruder was originally developed by Eduardo Chamorro Martin in collaboration with 3DPA IAAC. This innovative tool, which is open source, has since been further enhanced and modified by IAAC staff members for various applications.

For detailed information and updates on the Motor screw extruder, please visit the GitHub repository at the following link: https://github.com/EDUARDOCHAMORRO/FabricatableTools

Printing Steps

Step 1: Tool setup

- Ensure that all components of the extruder are properly assembled.

- Mount the End Effector with the Robot Flange securely. Use the appropriate screw size and ensure that the extended parts of the screws do not protrude on the rear side of the flange to prevent scratching or damaging the robot arm.

700 × 402 pixels


- Before loading the material into the cartridge, inspect it to ensure there are no air bubbles trapped inside. Air bubbles can disrupt the printing process and cause damage to the print quality.

- Apply vaseline to the piston and threads in the metal cap of the cartridge. This helps to ensure smooth movement and prevent friction during the printing process. Make sure the cap is tightly secured to avoid any leaks or inconsistencies in printing material flow.

- Release Pressure Using Pressure Regulator.

- Connect the air pressure pipe and the motor cable to the designated connector.

700 × 402 pixels

Step 2:TCP Calibration

- Calibrate the tool properly.

- For more details about calibration check the following document

https://drive.google.com/file/d/196kO1AxNpu0TbMAIdhFcR8AHWfLMZXfV/view

- Place the TCP value in the gh files

700 × 402 pixels


Step 3:Extrusion test

- Check Digital Outputs Utilize the flex pendant. Use programmable keys on the flex pendant to navigate through the settings and verify that all digital outputs are functioning correctly.

- Activate the motor and preassure, Gradually adjust the pressure regulator to raise the pressure. Monitor the extrusion process for consistency and quality.

700 × 402 pixels


Step 4:Base calibration

- Use masking or double-sided tape to prevent the base from moving.

- Jog the robot to three different positions. Add Coordinates to Grasshopper File for accurate geometry placement.



700 × 402 pixels


Step 5:Export and running the file

IMPORTANT:

Before running the main file, conduct a pressure-free dry run, execute the file slowly, verify the correctness of the z value, ensure the nozzle doesn't hit the base, and adjust the z value if needed.


- Check if the robot is in manual mode

- Acknowledge any errors seen on the flexpendant

- Export your file in .PRG format and copy it in a USB


700 × 402 pixels


- Plug in the USB in the port on the flexpendant

- Go to Main Menu >Production Window >yes >change it to old format (.PRG)

- Select the file and open

700 × 402 pixels

- Check the speed before running the file.

- Press the Guard stop and press the play button to initiate the file

Termination of work and cleaning

- After printing, ensure thorough cleaning of all parts using appropriate cleaning tools.

- Return cleaned parts to their designated places on the shelves.

- Avoid using the sink for cleaning; utilize the large cleaning space designed specifically for clay and concrete materials.

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