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This commit is contained in:
Sander Soots
2022-09-13 15:57:39 +03:00
parent 40408742f6
commit f1744e72e2
71 changed files with 510062 additions and 473 deletions
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# Gantry Backing Plates
## The theory
Due to different thermal coefficients of linear expansion between steel (rails) and aluminum (extrusions), the Voron V2 gantry forms a sort of giant bimetal temperature sensor element. This causes a warping of the gantry as it heats up with increasing chamber temperature.
## The evidence
While exploring [frame expansion behavior](https://github.com/tanaes/whopping_Voron_mods/tree/main/docs/frame_expansion), a number of us were noticing empirical values several times what we'd predict simply due to linear expansion of the Z extrusions alone. Although plugging those empirical values in to the compensation code has given me great first layers, the difference from expectation was still bothering me. Maybe, I thought, there was some sort of warping happening? Checking out a table of thermal expansion coefficients, I saw that indeed aluminum expands quite a bit more than steel with temperature.
### Bottom X rail increases frame thermal compensation value
After some discussion on Discord, it appeared that people running the BOM double X rail, with an MGN9 rail on the front and bottom of the X extrusion, by and large seemed to be needing higher compensation values than those who only had a single X rail on the front face of the extrusion.
So I tried loosening the screws on the bottom X rail of my V2.4 350, and re-ran the thermal expansion measurment. Wouldn't you know it, my observed compensation factor went from around 2.8 to about 1.5:
<img src="./images/gantry_factor_loose.png" width="400">
### Bed mesh changes as predicted with frame temperature
To confirm, I decided to go ahead an loosen *all* the rails on both X and Y, heat soak the machine for a couple hours, and then tighten them down; this should ensure that the gantry is as flat as possible when at temperature, but will bow downwards when it is cold as the aluminum contracts more than the steel rail beneath.
And that's indeed what I saw. After hot-tightening the rails, I took a bed mesh while everything was still hot. I then allowed the printer to cool for a couple hours, reheated the bed, and took another mesh while the bed was hot but the frame was still cold.
What I saw was just what we'd predict, with the "hot frame" measurement (left) being quite flat, but the "cold frame" measurement appearing as if the center of the bed were closer to the probe:
<img src="./images/bed_mesh_comparison.png" width=600>
### Shitty modeling is consistent with observation
Finally, I put together a *very simplistic* FEA model in Fusion360. It did the thing with the bendy bendy:
<img src="./images/no_backer.png" width=500>
***Caveat: I am a biologist, not an engineer!*** I only barely know what I'm doing with this shit. But with the rail material set to 440C stainless and the extrusion to 6061 aluminum, with them bonded at the interface, a temperature delta of 40° C led to this 250mm-sized X gantry member deflecting 0.17 mm upwards in the center! That's definitely not trivial, and it's certainly consistent with our empirical observations.
## The (a) solution (maybe??)
Why have *bi*metal when you can have *tri*metal?!
At one extreme, bolting another MGN9 rail on top of the extrusion seems certain to cancel out the bending moment imparted by the one on the bottom.
As a cheaper alternative, I've designed some laser-cut steel extrusion backing plates that weigh less and are lower-profile than rails, but which should at least do a reasonable job at counteracting the thermal defection.
<img src="./images/fusion_y_backer.png" width=600>
These are sized to fit along the top of the Y extrusion and on the top or back of the X extrusion, with a few mm of clearance to printed endpieces:
<img src="./images/fusion_y_chainmount.png" width=600>
They also have pilot holes for the cable chain end link to attach. They are sized to be drilled out with a 2.5 mm bit and then M3 tapped. (Laser cutting hardens the steel at the cut, so the cut holes are undersized for drilling out to be a bit gentler on your taps.)
<img src="./images/fusion_x_chainmount.png" width=600>
To attach them most optimally, you'll also need to countersink the holes so they can be installed with 6mm flat head M3 screws.
### Simulation results
Plugging these into the FEA model shows some serious improvements with a 1.9 mm steel backer:
<img src="./images/steel_1.9mm.png" width=500>
A 1.5 mm titanium backer does even better:
<img src="./images/ti_1.5mm.png" width=500>
### Sourcing
A set of 3 backers in 1.9 mm steel can be bought at [SendCutSend](https://www.sendcutsend.com) for somewhere in the neighborhood of $10 (presuming you've met their minimum order of $29).
If you're feeling spendy, even the Ti backers still cost about the same as cheapo linear rails, with a set of three costing around $60.
## The results
I put in an order for 8 sets of backers in various sizes, all of which have been sent out to people on the Voron Discord for testing. Most of these were in mild steel, but there are also a few pieces in titanium.
Results from testing are below.
### Case study 1: whoppingpochard, steel backers X and Y
After countersinking and tapping my mild steel backers, I tried hastily cold-bluing them with some gun blue. The results were decidedly mixed, and I *also* very conveniently misplaced my 3-in-1, so sadly they were a little splotchy the next morning. They installed perfectly on the machine, though, with apparently just enough clearance without modifying cable chains:
<img src="./images/backers_installed.jpeg" width=600>
To test, I performed the following operation:
1. preheated the bed
2. took a bed mesh while bed was still hot
3. took a bed mesh after 2 hour heat soak (frame at ~35° C)
4. installed backers on each axis
5. repeated steps 1-3
This is the result:
<img src="./images/test1_comparison.png" width=600>
(Please ignore the odd tilt of the bed, as I think I did QGL at a non-equilibrium point.)
The hot bed appears pretty planar from the perspective of the toolhead while the frame is still cold. *Without* backers, after the frame has heatsoaked, the bed appears cupped -- presumably due to the extrusion bending upward towards the center.
But *with* backers installed, the bed still appears planar after the heatsoak. This appears to indicate the backers are actually working!
I also developed a script to test gantry bowing in a more controlled fashion. Essentially, the script does a bed mesh while the frame is cold and then another once the frame heats up, and compares the two. As long as the bed is the same temperature for each mesh, we assume that any non-linear deviation measured is a result of flexing frame members.
Here are the results from my printer, with and without backers installed (I ran this test after swapping out the steel X backer for a titanium one):
<img src="./images/results/whopping_results.png" width=800>
The mesh heatmap is not a measure of the bed surface itself, but rather the *difference* between the hot-frame mesh and the cold-frame mesh. It shows that, on my printer, I get more than 0.25 mm of cumulative change over the span of my bed -- more than a whole first layer thickness!
The line plot is a rough approximation of how we are inferring the gantry frame members are flexing, based on the pre- and post-heat measurements. Although not perfect, it gives us an intuitive illustration of the effect.
On the right side, you can see that installing the backers improved my measurements substantially! The titanium backer on X may indeed be doing better than the *thicker* steel backers on Y.
### Case study 2: garretwp, V2.4 300 mm
In principle, the MGN12 X-axis mod should help ameliorate the bowing problem in X as the single rail is on the front of the X extrusion, thus should not induce any bowing in that extrusion along Z.
That is what garretwp finds with his V2.4 300mm, which is running MGN12 on X.
<img src="./images/results/garretwp_results.png" width=800>
Before installing backers, he measures substantial deflection along Y, but little if any on X. After installing Y backers, the Y deflection is substantially reduced and X is unchanged.
### Case study 3: mgn9 rail as extrusion backer
bythorsthunder and BnE both are running V2.4 350mm machines with the MGN12 X-axis mod.
bythorsthunder had his original mgn9 X-axis rails laying around, and installed them on top of the Y axis extrusions to offset bowing induced by the bottom rails.
BnE installed steel backers on Y.
<img src="./images/results/v2.4_results.png" width=800>
In both cases, we see very straight X axes and little deflection along Y. Although there's some as-yet unexplained overall tilt apparent in bythorsthunder's run, there is absolutely no apparent curve along Y -- indicating that the mgn9s on top of the extrusion *perfectly* offset the rails on the bottom. Although using rails as extrusion backers requires a bit of reconfiguring (especially if running cable chains), they look like a mechanically perfect solution, especially for Y where the added mass is less of a concern.
### Case study 4: V1.8s
The rail arrangement on V1s differs from on V2s, as the Y rails are on top rather than bottom of the extrusion.
In cassiespook's v1.8 (left), we can see the resulting deflection results in a sort of saddle shape, with X bowing upwards and Y downwards.
Yeri is running a single MGN12 on X, and although there is also some unexplained overall tilt apparent in the delta cold/hot mesh, we do see that X seems to be unbowed in Z, as we saw with the MGN12 V2s.
<img src="./images/results/v1.8_results.png" width=800>
---
### Back: [Voron V2.4R2 kit by Lecktor](../Readme.md)
# Sources:
[whoppingpochard extrusion backers Github](https://github.com/VoronDesign/VoronUsers/tree/master/printer_mods/whoppingpochard/extrusion_backers )

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BuildPlates/README.md
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# Voron V1.8/V2.4/Trident Build Plates (250, 300, 350) # Voron V2.4R2 Build Plates (250, 300, 350)
---
### Back: [Voron V2.4R2 kit by Lecktor](../Readme.md)

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EuclidProbe/README.md
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# EUCLID PROBE
The highly accurate, magneticaly coupled Z-Probe that is not affected by bed temp, bed material, magnetism or surface treatment.
The probe can be configured to be used as Z-endstop, be manually or automatically deployed via gcode macros, and can take advantage of the firmware's probe pickup detection scheme to ensure pickup/release. It uses screw attached magnets for both mechanical coupling and for electrical contact. The Z-Probe circuit is completed when the probe is attached.
The unique dock design securely captures the probe, providing secure and reliable docking and undocking.
[Rest of documentation](https://www.euclidprobe.com)
---
### Back: [Voron V2.4R2 kit by Lecktor](../Readme.md)

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Manuals/Readme.md
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## INSTRUCTIONS ## Manual for V2.4R2 kit by Lecktor
First up, assembly. We have produced modified Manual that should make assembly easy. Please read the manual through the first time before starting your assembly as it will make understanding the relations between objects much more easier. All heat inserts are done so those steps are for you to just verify that all of them are inserted. Should there be any missing, you have tooltip and inserts to add finishing touches. First up, assembly. We have produced modified Manual that should make assembly easy. Please read the manual through the first time before starting your assembly as it will make understanding the relations between objects much more easier. All heat inserts are done so those steps are for you to just verify that all of them are inserted. Should there be any missing, you have tooltip and inserts to add finishing touches.
@@ -14,3 +14,6 @@ You should keep always your devices behind VPN for additional security. That bei
* [Tuning the printer](./Tuning/Readme.md) * [Tuning the printer](./Tuning/Readme.md)
If you want to see how assembly of a Voron would look like, step-by-step, there is a great fella on YouTube named [Scott Corn](https://www.youtube.com/watch?v=aHWiCs52pK4&list=PLSdS8RXoNhoRzDMZr9bK9-mfZjJzyWP8E) who has made a series from assembly of Voron V2.4. Your kit is V2.4R2 with some extra goodies so gatry and toolhead will be different for you. If you want to see how assembly of a Voron would look like, step-by-step, there is a great fella on YouTube named [Scott Corn](https://www.youtube.com/watch?v=aHWiCs52pK4&list=PLSdS8RXoNhoRzDMZr9bK9-mfZjJzyWP8E) who has made a series from assembly of Voron V2.4. Your kit is V2.4R2 with some extra goodies so gatry and toolhead will be different for you.
---
### Back: [Voron V2.4R2 kit by Lecktor](../Readme.md)

234
Manuals/Slicer/Doc_250_V22_AB.ini
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@@ -1,234 +0,0 @@
# generated by PrusaSlicer 2.1.0-rc+win64 on 2020-01-08 at 05:33:09
avoid_crossing_perimeters = 0
bed_custom_model =
bed_custom_texture =
bed_shape = 0x0,250x0,250x250,0x250
bed_temperature = 105
before_layer_gcode =
between_objects_gcode =
bottom_fill_pattern = rectilinear
bottom_solid_layers = 5
bridge_acceleration = 3000
bridge_angle = 0
bridge_fan_speed = 15
bridge_flow_ratio = 0.8
bridge_speed = 60
brim_width = 0
clip_multipart_objects = 0
colorprint_heights =
complete_objects = 0
cooling = 1
cooling_tube_length = 5
cooling_tube_retraction = 91.5
default_acceleration = 3000
default_filament_profile =
default_print_profile =
deretract_speed = 30
disable_fan_first_layers = 5
dont_support_bridges = 1
duplicate_distance = 6
elefant_foot_compensation = 0
end_filament_gcode = "; Filament-specific end gcode \n;END gcode for filament\n"
end_gcode = print_end ;end script from macro
ensure_vertical_shell_thickness = 1
external_perimeter_extrusion_width = 0.38
external_perimeter_speed = 40
external_perimeters_first = 0
extra_loading_move = -2
extra_perimeters = 1
extruder_clearance_height = 20
extruder_clearance_radius = 20
extruder_colour = ""
extruder_offset = 0x0
extrusion_axis = E
extrusion_multiplier = 0.9
extrusion_width = 0.4
fan_always_on = 1
fan_below_layer_time = 45
filament_colour = #FFFF00
filament_cooling_final_speed = 3.4
filament_cooling_initial_speed = 2.2
filament_cooling_moves = 4
filament_cost = 22
filament_density = 1.05
filament_deretract_speed = nil
filament_diameter = 1.75
filament_load_time = 0
filament_loading_speed = 28
filament_loading_speed_start = 3
filament_max_volumetric_speed = 11
filament_minimal_purge_on_wipe_tower = 5
filament_notes = ""
filament_ramming_parameters = "120 100 6.6 6.8 7.2 7.6 7.9 8.2 8.7 9.4 9.9 10.0| 0.05 6.6 0.45 6.8 0.95 7.8 1.45 8.3 1.95 9.7 2.45 10 2.95 7.6 3.45 7.6 3.95 7.6 4.45 7.6 4.95 7.6"
filament_retract_before_travel = nil
filament_retract_before_wipe = nil
filament_retract_layer_change = nil
filament_retract_length = nil
filament_retract_lift = nil
filament_retract_lift_above = nil
filament_retract_lift_below = nil
filament_retract_restart_extra = nil
filament_retract_speed = nil
filament_settings_id = "KVP ABS"
filament_soluble = 0
filament_toolchange_delay = 0
filament_type = ABS
filament_unload_time = 0
filament_unloading_speed = 90
filament_unloading_speed_start = 100
filament_wipe = nil
fill_angle = 45
fill_density = 40%
fill_pattern = grid
first_layer_acceleration = 2000
first_layer_bed_temperature = 110
first_layer_extrusion_width = 0.4
first_layer_height = 0.24
first_layer_speed = 25
first_layer_temperature = 240
gap_fill_speed = 40
gcode_comments = 0
gcode_flavor = reprap
gcode_label_objects = 0
high_current_on_filament_swap = 0
host_type = octoprint
infill_acceleration = 4000
infill_every_layers = 1
infill_extruder = 1
infill_extrusion_width = 0.45
infill_first = 0
infill_only_where_needed = 0
infill_overlap = 25%
infill_speed = 120
interface_shells = 0
layer_gcode =
layer_height = 0.2
machine_max_acceleration_e = 10000,5000
machine_max_acceleration_extruding = 1500,1250
machine_max_acceleration_retracting = 1500,1250
machine_max_acceleration_x = 9000,1000
machine_max_acceleration_y = 9000,1000
machine_max_acceleration_z = 500,200
machine_max_feedrate_e = 120,120
machine_max_feedrate_x = 500,200
machine_max_feedrate_y = 500,200
machine_max_feedrate_z = 12,12
machine_max_jerk_e = 2.5,2.5
machine_max_jerk_x = 10,10
machine_max_jerk_y = 10,10
machine_max_jerk_z = 0.2,0.4
machine_min_extruding_rate = 0,0
machine_min_travel_rate = 0,0
max_fan_speed = 30
max_layer_height = 0.3
max_print_height = 180
max_print_speed = 300
max_volumetric_speed = 0
min_fan_speed = 15
min_layer_height = 0.07
min_print_speed = 10
min_skirt_length = 20
notes =
nozzle_diameter = 0.4
only_retract_when_crossing_perimeters = 1
ooze_prevention = 0
output_filename_format = KVP [input_filename_base]-[total_weight]g-[print_time].gcode
overhangs = 1
parking_pos_retraction = 92
perimeter_acceleration = 2000
perimeter_extruder = 1
perimeter_extrusion_width = 0.38
perimeter_speed = 80
perimeters = 4
post_process =
print_host =
print_settings_id = KVP ABS PIF
printer_model =
printer_notes =
printer_settings_id = 250mm3 0.4mm ABS AB
printer_technology = FFF
printer_variant =
printer_vendor =
printhost_apikey =
printhost_cafile =
raft_layers = 0
remaining_times = 0
resolution = 0
retract_before_travel = 3
retract_before_wipe = 0%
retract_layer_change = 0
retract_length = 0.75
retract_length_toolchange = 10
retract_lift = 0.4
retract_lift_above = 0.3
retract_lift_below = 150
retract_restart_extra = 0
retract_restart_extra_toolchange = 0
retract_speed = 50
seam_position = aligned
serial_port =
serial_speed = 250000
silent_mode = 1
single_extruder_multi_material = 0
single_extruder_multi_material_priming = 1
skirt_distance = 3
skirt_height = 1
skirts = 3
slice_closing_radius = 0.049
slowdown_below_layer_time = 15
small_perimeter_speed = 40
solid_infill_below_area = 0
solid_infill_every_layers = 0
solid_infill_extruder = 1
solid_infill_extrusion_width = 0.45
solid_infill_speed = 120
spiral_vase = 0
standby_temperature_delta = -5
start_filament_gcode = ";Filament gcode"
start_gcode = print_start EXTRUDER=[first_layer_temperature] BED=[first_layer_bed_temperature]
support_material = 0
support_material_angle = 0
support_material_auto = 1
support_material_buildplate_only = 1
support_material_contact_distance = 0.2
support_material_enforce_layers = 2
support_material_extruder = 1
support_material_extrusion_width = 0
support_material_interface_contact_loops = 0
support_material_interface_extruder = 1
support_material_interface_layers = 3
support_material_interface_spacing = 0
support_material_interface_speed = 100%
support_material_pattern = rectilinear
support_material_spacing = 2.5
support_material_speed = 40
support_material_synchronize_layers = 0
support_material_threshold = 60
support_material_with_sheath = 1
support_material_xy_spacing = 50%
temperature = 235
thin_walls = 0
threads = 16
toolchange_gcode =
top_fill_pattern = rectilinear
top_infill_extrusion_width = 0.44
top_solid_infill_speed = 40
top_solid_layers = 5
travel_speed = 300
use_firmware_retraction = 0
use_relative_e_distances = 1
use_volumetric_e = 0
variable_layer_height = 0
wipe = 0
wipe_into_infill = 0
wipe_into_objects = 0
wipe_tower = 0
wipe_tower_bridging = 10
wipe_tower_rotation_angle = 0
wipe_tower_width = 60
wipe_tower_x = 180
wipe_tower_y = 140
wiping_volumes_extruders = 70,70
wiping_volumes_matrix = 0
xy_size_compensation = 0
z_offset = 0

234
Manuals/Slicer/Doc_320_V22_M31_KVP.ini
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@@ -1,234 +0,0 @@
# generated by PrusaSlicer 2.1.0-rc+win64 on 2020-01-08 at 05:31:59
avoid_crossing_perimeters = 0
bed_custom_model =
bed_custom_texture =
bed_shape = 0x0,320x0,320x320,0x320
bed_temperature = 105
before_layer_gcode =
between_objects_gcode =
bottom_fill_pattern = rectilinear
bottom_solid_layers = 5
bridge_acceleration = 3000
bridge_angle = 0
bridge_fan_speed = 15
bridge_flow_ratio = 0.8
bridge_speed = 60
brim_width = 0
clip_multipart_objects = 0
colorprint_heights =
complete_objects = 0
cooling = 1
cooling_tube_length = 5
cooling_tube_retraction = 91.5
default_acceleration = 3000
default_filament_profile =
default_print_profile =
deretract_speed = 25
disable_fan_first_layers = 5
dont_support_bridges = 1
duplicate_distance = 6
elefant_foot_compensation = 0
end_filament_gcode = "; Filament-specific end gcode \n;END gcode for filament\n"
end_gcode = print_end
ensure_vertical_shell_thickness = 1
external_perimeter_extrusion_width = 0.38
external_perimeter_speed = 40
external_perimeters_first = 0
extra_loading_move = -2
extra_perimeters = 1
extruder_clearance_height = 20
extruder_clearance_radius = 20
extruder_colour = ""
extruder_offset = 0x0
extrusion_axis = E
extrusion_multiplier = 0.9
extrusion_width = 0.4
fan_always_on = 1
fan_below_layer_time = 45
filament_colour = #FFFF00
filament_cooling_final_speed = 3.4
filament_cooling_initial_speed = 2.2
filament_cooling_moves = 4
filament_cost = 22
filament_density = 1.05
filament_deretract_speed = nil
filament_diameter = 1.75
filament_load_time = 0
filament_loading_speed = 28
filament_loading_speed_start = 3
filament_max_volumetric_speed = 11
filament_minimal_purge_on_wipe_tower = 5
filament_notes = ""
filament_ramming_parameters = "120 100 6.6 6.8 7.2 7.6 7.9 8.2 8.7 9.4 9.9 10.0| 0.05 6.6 0.45 6.8 0.95 7.8 1.45 8.3 1.95 9.7 2.45 10 2.95 7.6 3.45 7.6 3.95 7.6 4.45 7.6 4.95 7.6"
filament_retract_before_travel = nil
filament_retract_before_wipe = nil
filament_retract_layer_change = nil
filament_retract_length = nil
filament_retract_lift = nil
filament_retract_lift_above = nil
filament_retract_lift_below = nil
filament_retract_restart_extra = nil
filament_retract_speed = nil
filament_settings_id = "KVP ABS"
filament_soluble = 0
filament_toolchange_delay = 0
filament_type = ABS
filament_unload_time = 0
filament_unloading_speed = 90
filament_unloading_speed_start = 100
filament_wipe = nil
fill_angle = 45
fill_density = 40%
fill_pattern = grid
first_layer_acceleration = 2000
first_layer_bed_temperature = 110
first_layer_extrusion_width = 0.4
first_layer_height = 0.24
first_layer_speed = 25
first_layer_temperature = 240
gap_fill_speed = 40
gcode_comments = 0
gcode_flavor = reprap
gcode_label_objects = 0
high_current_on_filament_swap = 0
host_type = octoprint
infill_acceleration = 4000
infill_every_layers = 1
infill_extruder = 1
infill_extrusion_width = 0.45
infill_first = 0
infill_only_where_needed = 0
infill_overlap = 25%
infill_speed = 120
interface_shells = 0
layer_gcode = ; pause as layer code\n; {if layer_z ==3.04}M226 ; pause at height for filament swap{endif}\n; {if layer_z ==3.64}M226 ; pause at height for filament swap{endif}
layer_height = 0.2
machine_max_acceleration_e = 10000,5000
machine_max_acceleration_extruding = 1500,1250
machine_max_acceleration_retracting = 1500,1250
machine_max_acceleration_x = 9000,1000
machine_max_acceleration_y = 9000,1000
machine_max_acceleration_z = 500,200
machine_max_feedrate_e = 120,120
machine_max_feedrate_x = 500,200
machine_max_feedrate_y = 500,200
machine_max_feedrate_z = 12,12
machine_max_jerk_e = 2.5,2.5
machine_max_jerk_x = 10,10
machine_max_jerk_y = 10,10
machine_max_jerk_z = 0.2,0.4
machine_min_extruding_rate = 0,0
machine_min_travel_rate = 0,0
max_fan_speed = 30
max_layer_height = 0.3
max_print_height = 280
max_print_speed = 300
max_volumetric_speed = 0
min_fan_speed = 15
min_layer_height = 0.07
min_print_speed = 10
min_skirt_length = 20
notes =
nozzle_diameter = 0.4
only_retract_when_crossing_perimeters = 1
ooze_prevention = 0
output_filename_format = KVP [input_filename_base]-[total_weight]g-[print_time].gcode
overhangs = 1
parking_pos_retraction = 92
perimeter_acceleration = 2000
perimeter_extruder = 1
perimeter_extrusion_width = 0.38
perimeter_speed = 80
perimeters = 4
post_process =
print_host =
print_settings_id = KVP ABS PIF
printer_model =
printer_notes =
printer_settings_id = V320 V2.1 - 0.4mm Nozzle - ABS
printer_technology = FFF
printer_variant =
printer_vendor =
printhost_apikey =
printhost_cafile =
raft_layers = 0
remaining_times = 0
resolution = 0
retract_before_travel = 3
retract_before_wipe = 0%
retract_layer_change = 0
retract_length = 5.8
retract_length_toolchange = 10
retract_lift = 0.4
retract_lift_above = 0.3
retract_lift_below = 0
retract_restart_extra = 0
retract_restart_extra_toolchange = 0
retract_speed = 35
seam_position = aligned
serial_port =
serial_speed = 250000
silent_mode = 1
single_extruder_multi_material = 0
single_extruder_multi_material_priming = 1
skirt_distance = 3
skirt_height = 1
skirts = 3
slice_closing_radius = 0.049
slowdown_below_layer_time = 15
small_perimeter_speed = 40
solid_infill_below_area = 0
solid_infill_every_layers = 0
solid_infill_extruder = 1
solid_infill_extrusion_width = 0.45
solid_infill_speed = 120
spiral_vase = 0
standby_temperature_delta = -5
start_filament_gcode = ";Filament gcode"
start_gcode = print_start EXTRUDER=[first_layer_temperature] BED=[first_layer_bed_temperature]
support_material = 0
support_material_angle = 0
support_material_auto = 1
support_material_buildplate_only = 1
support_material_contact_distance = 0.2
support_material_enforce_layers = 2
support_material_extruder = 1
support_material_extrusion_width = 0
support_material_interface_contact_loops = 0
support_material_interface_extruder = 1
support_material_interface_layers = 3
support_material_interface_spacing = 0
support_material_interface_speed = 100%
support_material_pattern = rectilinear
support_material_spacing = 2.5
support_material_speed = 40
support_material_synchronize_layers = 0
support_material_threshold = 60
support_material_with_sheath = 1
support_material_xy_spacing = 50%
temperature = 235
thin_walls = 0
threads = 16
toolchange_gcode =
top_fill_pattern = rectilinear
top_infill_extrusion_width = 0.44
top_solid_infill_speed = 40
top_solid_layers = 5
travel_speed = 300
use_firmware_retraction = 0
use_relative_e_distances = 1
use_volumetric_e = 0
variable_layer_height = 1
wipe = 0
wipe_into_infill = 0
wipe_into_objects = 0
wipe_tower = 0
wipe_tower_bridging = 10
wipe_tower_rotation_angle = 0
wipe_tower_width = 60
wipe_tower_x = 180
wipe_tower_y = 140
wiping_volumes_extruders = 70,70
wiping_volumes_matrix = 0
xy_size_compensation = 0
z_offset = 0

7
Manuals/Slicer/Readme.md
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@@ -3,7 +3,12 @@
1. You need to adjust slicer profile per material you are using 1. You need to adjust slicer profile per material you are using
2. If you are not using 350mm bed, adjust bed size. 2. If you are not using 350mm bed, adjust bed size.
3. If you are using different nozzle, then adjust it's size. 3. If you are using different nozzle, then adjust it's size.
4. We recommend using [SuperSlicer](https://github.com/supermerill/SuperSlicer) for Voron Printers. 4. We recommend using [SuperSlicer](https://github.com/supermerill/SuperSlicer) for Voron Printers but you can also use [PrusaSlicer](https://github.com/prusa3d/PrusaSlicer).
## Voron 2.4 Bed STL for PrusaSlicer and SuperSlicer
Download the appropriate STL for your bed size
Import under Printer Settings > General > Bed Shape (Set ...) > Model (Load...)
## Where to set the model and textures: ## Where to set the model and textures:
![Examples](SS_Settings.png) ![Examples](SS_Settings.png)

232
NeverMore/README.md
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@@ -0,0 +1,232 @@
# Nevermore Activated Carbon Filters - Micro Edition
<div align="center">Nevermore Micro V5 Duo (dual fan)</div>
![Nevermore Activated Carbon Filter Micro V5 Duo](images/DUO_COMBINED_render.png "Nevermore Activated Carbon Filter Micro V5 Duo")
Originally intended as a carbon fume filter for Voron V2, it has found its way into a multitude of other machines. Let yours be the next! Bad smells or fumes, or complaints thereof, should not keep you from being a maker!
- [Nevermore Activated Carbon Filters - Micro Edition](#nevermore-activated-carbon-filters---micro-edition)
- [About The Nevermore Micro](#about-the-nevermore-micro)
- [Why The Nevermore?](#why-the-nevermore)
- [Nevermore Background](#nevermore-background)
- [Nevermore V5 Duo](#nevermore-v5-duo)
- [FAQs](#faqs)
- [What fans should I use?](#what-fans-should-i-use)
- [How do I make a suggestion/report a bug/find out more?](#how-do-i-make-a-suggestionreport-a-bugfind-out-more)
- [Getting Started](#getting-started)
- [SOURCING THE PROPER ACID-FREE CARBON](#sourcing-the-proper-acid-free-carbon)
- [NEVERMORE 3D PRINTER CARBON](#nevermore-3d-printer-carbon)
- [BOM (V5)](#bom-v5)
- [Assembly](#assembly)
- [Instructions for V5](#instructions-for-v5)
- [Instructions for V4](#instructions-for-v4)
- [Final Thoughts on Usage](#final-thoughts-on-usage)
- [Back: Voron V2.4R2 kit by Lecktor](#back-voron-v24r2-kit-by-lecktor)
- [Sources:](#sources)
# About The Nevermore Micro
[VOCs (Volatile Organic Compounds)](https://en.wikipedia.org/wiki/Volatile_organic_compound) are common in daily life but VOCs generated from 3D printing are known to cause severe health issues and even cause cancer in some cases.
![Emitted VOCs](images/emitted-voc.jpg "Emitted VOCs")
A study from 2013 of [ultrafine particle emissions from desktop 3D printers (2013)](https://www.sciencedirect.com/science/article/pii/S1352231013005086) is a good start to understand the importance of your filament choices and the printer's environment.
![Characterization of volatile organic compound emissions from consumer level material extrusion 3D printers (2019)](images/emitted-voc2.jpg "Characterization of volatile organic compound emissions from consumer level material extrusion 3D printers (2019)")
_(credit: [Characterization of volatile organic compound emissions from consumer level material extrusion 3D printers (2019)](https://www.sciencedirect.com/science/article/pii/S0360132319304196))_
![Characterization of particulate and gaseous pollutants emitted during operation of a desktop 3D printer (2019)](images/emitted-voc3.jpg "Characterization of particulate and gaseous pollutants emitted during operation of a desktop 3D printer (2019)")
_(credit: [Characterization of particulate and gaseous pollutants emitted during operation of a desktop 3D printer (2019)](https://www.sciencedirect.com/science/article/pii/S0160412018323663))_
## Why The Nevermore?
At the end of the day, a fresh single-pass filtered exhaust (at brand new) has perhaps 70% VOC removal efficiency while still exhausting 30% of the nasty. A worn-in 50% efficiency recirculation filter achieving four passes would still remove 94% of the bad stuff. Or 99% at six passes!
The number of passes you get all depends on how well you can seal your build chamber.
Some will have a hard time achieving a good chamber seal, which creates the biggest drawback of recirculation filters - _they're air flow neutral_. Meaning, as nothing pulls air into the chamber, air can diffuse freely to the outside through any remaining gaps. And that air could be _zero-per-cent_ cleaned...
If you plan on using only a Nevermore - be sure to seal your chamber as good as possible to prevent diffusing.
## Nevermore Background
There are many options for 3d printing air filters. Here’s a short list, and why I eventually settled on creating Nevermore:
**1. Home air purifiers**
**PRO:** Plug and play! High air flow (mostly). Will filter most particles a 3d printer produces.
**CON:** ABS headaches are not from particles, but Volatile Organic Compounds (VOCs), that are two orders of magnitude smaller than any particles a HEPA or ULPA could trap - they’re essentially gasses.
While home purifiers typically also contains carbon filtration and/or photocatlytic UV filtration stages, they will still not be suitable for 3d printing. Why? Efficient carbon adsorption in sufficient amount and stages is an absolute airflow killer, so most purifiers contain only a thin layer of carbon mesh/pellets that will be fully adsorbed within days or weeks at full power. And even if the filter is not used, contact with air saturates the carbon in 1-2 months. Yet they’re advertised as lasting for 6 months – that's only true for the HEPA component, not the VOC adsorbant carbon we're after.
And replacement filters typically run 20-60 USD a pop. Quite a lot for changing every few weeks when the carbon component depletes.
UV photocatalyst activity can last though; however, breakdown is slow and inefficient with voc halflives of several hours. The TiO2 layer reacting to the UV will also easily get irreversibly blocked by silicates (of which there are a lot in peoples homes, in everything from sink and bathroom sealants to plaster walls). And breakdown will many times be incomplete. Styrene passing a PCO filter might get turned to even more dangerous benzene, for instance.
**2. Carbon/HEPA filter combinations like the Zortrax M Series HEPA Filters**
Same as above. The HEPA component will keep working, but the carbon is just a few pebbles per hex. It could provide partial VOC clearance when fresh, but will quickly deplete with air flow. Then you need to replace it for 36 USD after a week of printing.
**3. Wet scrubber**
Awesome for both particles and VOCs, but its an industrial solution with any smaller home versions plagued by loud noise, water leakage and mechanical issues. It's not a solution for the masses.
**So, how about Nevermore?**
Well, the carbon in those filters mentioned above, costing a lot for little duration is actually dirt cheap. Whereas you get 20 grams for 36 USD with a zortax filter, **you can get 5000 grams for 36 USD in bulk**.
And with an enclosed chamber, you don't need the air flow of a room-size air purifier. Even a 350mm V2 Voron only holds about 5cf, meaning even a partial flow from a 5015 fan of 0.5-2cfm is enough to filter the fumes efficiently at the source.
So what are we waiting for? We got lots of cheap carbon. We can replace is easily. We don't need high airflow to clean a small chamber. We deal with poor efficiency of one-pass carbon filters by multiplying the amount and recirculate the air.
Enter, _The Nevermore_.
## Nevermore V5 Duo
Following the V4, the V5 Duo was released that changes the direction of air flow, better suited for when the Nevermore Micro would be placed flat on the bottom or top of the printer. Though there are other "outlet" options, like for the V1.8/Trident style that blows outwards and not up.
The V5 Duo also adds a 2nd additional 5015.
![Nevermore Micro V5 Duo](images/nevermore-micro-duo.jpg "Nevermore Micro V5 Duo")
![Nevermore Micro V5 Duo](images/nevermore-micro-duo-opened.jpg "Nevermore Micro V5 Duo")
_(Nevermore V5 Duo. used with permission from Tightwad(JT)#6055)_
This repository hosts both versions, as they the same in design and function.
# FAQs
## What fans should I use?
Aim for any 5015 blower with a rating above 200Pa / 20mmH2O / 1 inH2O.
Since the fan (probably) cant be reused for other projects and will function in a high temp environment affecting its lifetime, go for budget. The Sunon Maglev MF50151VX (12V) / MF50152VX (24V) (high speed version, 6000 rpm) is good but unfortunately almost impossible to find as most are fakes. The GDStime 6000rpm Dual Ball bearing is another good option, but quality may vary. The Delta BFB0524HH is a gucci option, as is the special micro versions made for the papst rlf-35 which is an equally awesome and expensive fan. Any fan that works well for stealthburner should be a good option for nevermore micro as well.
See the BOM below for more details.
## How do I make a suggestion/report a bug/find out more?
- [The Nevermore Micro](https://github.com/nevermore3d/Nevermore_Micro)
- [Report a Bug](https://github.com/nevermore3d/Nevermore_Micro/issues)
- [Request a Feature](https://github.com/nevermore3d/Nevermore_Micro/issues)
- [Explore all Nevermore Activated Carbon Filters](https://github.com/nevermore3d)
# Getting Started
You're ready to build a Nevermore Micro? Cool!
> **_NOTE:_** MADE FOR ABS/PC/PETG - USE A DECENTLY HEAT RESISTANT FILAMENT !!
> **_NOTE:_**: Since you are committing to fan dissection, be aware a 5015 used for a NM Micro will most likely never find a different purpose!
## SOURCING THE PROPER ACID-FREE CARBON
**IMPORTANT!** Since first release the varying quality carbon out there has become increasingly evident. Users has both gotten bad carbon as well as outright dangerous stuff (in one case oxidizing most metal surfaces in a new voron in minutes. Be sure to vet your carbon supplier! You do not want your printer to look like this.
![Acid residue on end-stop switch oxidizing](images/endstop-switch-acid-residue.jpg "Acid residue on end-stop switch oxidizing")
_(z end-stop switch after using acid residue carbon for 30 minutes, oxidizing)_
![Acid residue on rails and screws oxidizing](images/voron2-oxidation1.png "Acid residue on rails and screws oxidizing")
_(oxidation on rails and screws after using acid residue carbon. used with permission from Zeptron#8880)_
![Acid residue on filament tension spring oxidizing](images/voron2-oxidation2.png "Acid residue on filament tension spring oxidizing")
_(oxidation on filament tension spring after using acid residue carbon. used with permission from Zeptron#8880)_
![Acid residue on bolts and washers oxidizing](images/voron2-oxidation3.png "Acid residue on bolts and washers oxidizing")
_(oxidation on bolts and washers after using acid residue carbon. used with permission from Zeptron#8880)_
Optimal carbon for 3D printer VOC adsorption is sourced from **virgin coconut**, not wood/bitumen/charcoal/bamboo/lignin/etc. The porosity for each and every source will vary greatly.
For example, for aquarium or moonshine use you want large macroporosity to filter larger impurities, like oils. For that reason, water/liquid-use carbon has a large macropore area, defined as >100nm. 3D Printer VOCs are generally less than 0.5 nm, meaning that **for optimal capture rate and efficiency we want carbon with a high microporosity ratio, defined as <1nm**. A higher iodine count >1000 usually indicates at least some micro/mesoporosity, and a higher hardness (>95%) will create less dust in air filtration. CTC number doesn't translate well to our VOCs; however, toluene adsorption - which sometimes is available - is a good metric.
**Avoid acid washed carbon at all costs**. Residues have oxidized printers! Go for steam activated, non acid-washed. A blend of neutral carbon and alkaline KOH carbon might be the best blend in the future, but impossible to currently source from trustworthy manufacturers.
Finding carbon that fills all criteria is hard. Look around, ask suppliers about the carbon, hear what others recommend.
## NEVERMORE 3D PRINTER CARBON
**Nevermore offers its own premium carbon of unmatched specifications through selected voron resellers.** Its the best activated carbon for 3D printer use we have found after speaking to most major, vetted suppliers, offering benzene adsorbtion of up to 48 wt%, surface area of 1250 and CTC value of 80. It doesn't come cheap compared to bulk carbon from amazon, but its safe, has unbeatable performance, and every purchase supports the nevermore project by at least a dollar, see [Lecktor listing](https://lecktor.com/en/nevermore/870-nevermore-carbon.html)
## BOM (V5)
- 2x 5015 blowers (rating above 200Pa / 20mmH2O / 1 inH2O)
- Sunon Maglev MF5015VX (high speed version, 6000 rpm. NOTE: There are A LOT of fake sunons out there, even from usually reputable sources. Blantant examples include 24V versions. Also, Sunon does not officially reecommend PWM:ing this fan, so while its still perfectly doable it can have unintended consequences later on) (There is no 24V version for this fan only comes in 12 V)
- GDStime 6000rpm Dual Ball bearing on Aliexpress (This is 12V rated fans)
- Delta BFB0524HH (This is 24V rated fans)
- Avoid mechatronics fans for this purpose.
- 5x M3x0.5mm Heatset inserts (standard voron issue)
- 2 for seating plenum to base
- 2 for seating plenum lid to plenum
- 8x 6x3mm cylindrical magnets
- 1x 2 pin JST header
- 4x M3x16 BHCS
- for heat inserts that go into the four fan tabs
- 1x M3x18 BHCS
- ONLY for delta and v1.8 variants
- 1x M3x6 BHCS
- 1x M3x4 BHCS
- for the extra hole in the plenum@lid for symmetry (it doesn’t attach to anything and is totally optional)
Acid-free Activated Carbon
- 4mm Active Carbon Air Filter Pellets
Optional for the cartridge closure
- 1x M3x0.5mm Heatset inserts
- 1x M3x6 BHCS
Optional for Vorons or any printer with 2020 extrusions
- 2x M3x12 SHCS
- 2x M3 2020 T-Nuts
Optional for Vorons or any printer using 24PSU
- 24 to 12 buck converter
## Assembly
Check out assembly images (**take note at how the fans are cut!**) here: [Nevermore V5 Plenum Assembly Album](https://ibb.co/album/0BN405?sort=name_asc&page=1&params_hidden%5Blist%5D=images&params_hidden%5Bfrom%5D=album&params_hidden%5Balbumid%5D=0BN405)
### Instructions for V5
_Coming soon... Similar to V4 though._
### Instructions for V4
Start by cutting up the 5015 so just the center remains. Take off the top half, cut the bottom piece circular along the fan blades. We aim for removing the focused air stream and instead achieve an even pressure across all of the filter medium.
The Nevermore Micro has three main parts: **Base**, **Plenum**, and **Cartridge** (plus lids for the plenum/cartridge).
- **Base** is mounted in the 130mm space between the bottom extrusions found on many vorons (designed for v2 originally). It’s seated with one m3 on each side, that screws into to a receiving 2020 M3 T-nut.
- **Plenum** holds the cut up 5015 fan, and is seated with two m3 screws into the base (base has two recieving m3 4mm heat inserts) on each side.
- **Cartridge** holds the filter medium of your choice (made for 4mm air filter active carbon pellets, but feel free to filter with what you think works best!). It snaps onto the Plenum piece for easy and quick removal.
For wiring, you are free to connect however works with your printer. If you do not have any direct controls on your MCU (controller board), then directly wiring may be your only option (with an inline switch).
However, if your MCU does have an additional fan output, then it is recommended to connect to it. If you are using Klipper on a Raspberry Pi, you have the option of using PWM fans and connecting the control wire to one of your PWM outputs on the RPi 40-pin header.
## Final Thoughts on Usage
**PID tune AGAIN if a Nevermore Micro is installed right beneath a heated bed, or draws/exhausts air over the bed thermistor. This is important, as worst case it could cause the bed to overheat, and/or make the heater adhesive burn (this will smell worse than any ABS printing!), and/or possibly even damage the bed heater.**
The Nevermore Micro's activated carbon will not filter Ultra-Fine Particulates (UFP). This is what the HEPA filter does in the Nevermore Mini (not released yet) and [Nevermore Max](https://github.com/nevermore3d/Nevermore_Max) variants. Those also have built-in negative-pressure fans.
However, you can achieve the same results with the Nevermore Micro by using a HEPA filter of your own and creating slightly negative air-pressure within your build chamber, exhausting air outwards at a slow pace. Since you are filtering with the Nevermore, the vast majority of VOCs will be filters by the active carbon filtration, leaving the HEPA filter to capture the remaining UFPs. This also greatly extends the live of your HEPA filter as the Nevermore Micro will be accumulating the larger particulates.
To create a negative pressure within your build chamber, simply install a fan to slowly draw air out of your build chamber and our through a HEPA filter. Voron machines already have such a design with their rear exhaust housing for HEPA filters.
The negative pressure will also eliminate diffusion, especially if your build chamber is not completely sealed.
---
### Back: [Voron V2.4R2 kit by Lecktor](../Readme.md)
# Sources:
[Nevermore Github](https://github.com/nevermore3d/Nevermore_Micro)

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# Nevermore Micro - V5 Duo
A directory of files and folders is listed below.
TODO...

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Four parts; Plenum+Lid, and Cartridge+Lid.
Choose between regular and XL cartridge. XL is just 10mm longer, which can make a big difference in air flow.
Choose XL for max carbon content and filter duration, and if you dont mind the fan (200Pa+) has to run faster/noisier. You probably have to use pellets instead of granular carbon too.
Choose regular if you have granular carbon and/or a wekaer fan, and/or wish to have a more silent experience. Regular also allows for somewhat higher airflow, which could make a small difference compared to XL in chamber heat up times.

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# Voron-V2.4 # Voron-V2.4R2 Kit by Lecktor
Lecktor.com sells full solution kit. To get a better understanding, please
take a look at our [manuals](./Manuals/Readme.md). For whats included in kit and why, take a look at mods like [NeverMore](./NeverMore/README.md), [EuclidProbe](./EuclidProbe/README.md), [Backers](./Backers/README.md) and other folders for more information.
#Full BOM of kit
## Frame kit ## Frame kit
- LDO Motors frame kit (black) - 1pcs - LDO Motors frame kit (black) - 1pcs