Project Dashboard Mini v1.04 Mini 1.04 Calibration Workflow

1 Check Screws Are Tight

Tools Needed:

Torque Drivers

Validate all screws on the machine are properly secured.

  • Start with large screws and then check small screws/setscrews.

  • Check that all frame screws are tight/properly torqued to 5 in*lbs.

  • Check that all plastic parts are fastened securely/properly torqued:

Y Assembly:

  • Y ends – 5 in*lbs

  • Double Bearing Holders- 5 in*lbs

  • Belt Mount- 5 in*lbs

  • Wiper Pad Holder- 5 in*lbs

Z axis:

  • Right and Left Z lowers - 5 in*lbs

  • Right and Left Z uppers- 5 in*lbs

X carriage/Toolhead:

  • Extruder body- 8 in*lbs

  • Extruder Mount- 5 in*lbs

  • Upper bearing holder- 5 in*lbs

  • Fan Mounts- 3 in*lbs

  • Belt Mount- 5 in*lbs

Frame:

  • Spool arm hinge bracket to frame- 5 in*lbs

  • Spool arm support- 8 in *lbs

  • Spool Arm- 8 in*lbs

  • Handle- 5 in*lbs

Check that all motors and hardware are mounted securely/properly torqued:

  • Motors-5 in*lbs

  • Endstops-2 in*lbs

  • X and Y Belt Clamps-5 in*lbs

  • Bed washers- 5 in*lbs

  • Z nuts- 8 in*lbs

  • Fans- 3 in*lbs

Check that all set screws are tight/properly torqued:

  • Couplers- 5 in*lbs

  • Motor Pulleys- 5 in*lbs

  • X end setscrews- 2 in*lbs

  • Z smooth rod setscrews- 2 in*lbs

  • Y end motor adjustment screws- 5 in*lbs max

2 Verify Motion of Axes

Tools Needed:

Sonic Belt Tensioner

With the machine off, start by checking that the Y axis moves smoothly and check for play in bearings

  • Check the belt tension with a sonic belt tensioner. The belt tension should be between 23-27 Newtons.
  • Slide the Y axis through its full range of motion and check for binding or play. The bearings should fit snugly on the smooth rods and not wiggle. Try wiggling the bed plate, it should not have any play.

Check the X axis

  • First verify that the ends of the smooth rods are flush with the X end motor side. If you need to adjust make sure that you loosen the X belt before taking the X end's setscrews loose. Once adjusted, make sure your setscrews are tight/torqued before tensioning the belt again.
  • Check the belt tension with a sonic belt tensioner. The belt tension should be between 23-27 Newtons. Slide the X axis through its full range of motion. Again the X carriage should slide smoothly without binding or have any play in the bearings. The bearings should fit snugly on the smooth rods.

3 Install 24V Heat Bed

Materials Needed:

1x- 24v Mini Print Bed Assembly

4x- M3X12mm Stainless Steel Flat Head Cap Screws (HD-BT0136)

4x- Mini Bed Leveling Washers (PP-MP0082)

4x- 8mm Spacers for M3 Screws (HD-MS0360)

Tools Needed:

2mm Hex Driver

Place the four 8mm spacers into the holes in the Ninjaflex bed corners (see picture).

Place the heat bed on the bed corners oriented with the wires coming out the left side of the heat bed (see picture).

Plug in the bed thermistor and heater cable connectors.

Fasten the heat bed down with four M3x12mm Stainless Steel Flat Head Cap Screws (HD-BT0136) and four Bed Leveling Washers (PP-MP0082). Torque to 5 in*lbs. washers must sit level against the bed.

Insert the connectors in the appropriate slots on the Mini Bed Clip(PP-GP0249). Ensure the thermistor (white and yellow wires) is routed under the bud clip as shown.

Bed spacers installed in Ninjaflex bed corners
Bed in position
Connectors plugged in
Fasten Bed Leveling Washers
Connectors in Mini Bed Clip

4 Flash Firmware

Turn on the printer with the USB plugged into the printer and the CPU.

Open the latest edition of Lulzbot Cura.

On the top left, click on the “Machine” drop down menu and select Lulzbot Mini.

Again click on the “Machine” drop down menu and with Lulzbot Mini selected, click on “Install Default Firmware.” A pop up menu will appear stating the .hex file that will be installed.

Click start and the software will automatically install the firmware.

Use the mini firmware check to ensure the correct firmware was flashed.

5 Toolhead

Materials Needed:

3 meters- PolyLite PLA LulzBot Green Filament (RM-PL0118) 3mm

Tools Needed: None

Feed some 3mm filament into the toolhead. It should feed about 100mm before stopping. If it doesn't feed approx 100mm then there is likely a misalignment issue or something obstructing the filament feed path.

With the filament in the toolhead, close the extruder idler block and latch. Check the extruder latch tension. When properly tensioned the washer under the thumbscrews should be flush with the extruder latch.

Check the large and small herringbone gears for play/backlash. The large gear and the small gear need to be mated together in a way that there is easy rotation but won't have any free movement known as “slap” between the gear teeth. Hold the small gear firmly with your finger and thumb, and try to move the large gear back and forth to see if there is any small movement between the teeth of the gears. Rotate the large gear ¼ turn and repeat this process multiple times to ensure alignment. If there is movement the small gear and large gear need to be moved closer to each other. To do this you need loosen the M3 screws ¼ turn counter-clockwise and push the motor closer to the body. Repeat until you have desired the results, tighten screws once the fit is correct.

Latch too loose
Properly tensioned extruder latch

6 Check Endstop Functionality

With the machine still on and connected to Cura or Pronterface,

First auto home the printer to verify the Xmin, Ymax, and Zmax endstops are functional.

Move the z axis up and down through the full range of motion. The z axis should move smoothly and not have any binding.

Turn the motors off (M84 in Cura/Pronterface terminal) and slide the X axis as far to the right as far as it can go.

Slide the Y axis toward the back of the printer as far as it can go.

Enter the command M119 in the Cura/Pronterface terminal to check the endstop status. It should say Zmax, Ymin and Xmax are triggered. This verifies that these endstops are indeed functional.

7 Set Z offset and check wipe function.

Materials Needed:

3m- PolyLite PLA LulzBot Green Filament Sample (RM-PL0118)

Tools Needed:

Micrometer

With the CPU still connected to Octoprint via ethernet connection, open the octoprint dialog box

Enter the command “M851 Z-0.80.” This sets the Z offset to -0.8mm to ensure we don't crash the bed on the first attempt.

Now enter the command “M500” to save this setting.

Load the calibration octopus print and attempt to print:

  • If the initial bead is too tall to stick to the print bed, adjust the z offset a bit using the M851 and M500 commands (make it more negative, try increments of 0.1mm) and try again.

Watch the skirt print and stop the print once the skirt has finished. Measure the skirt height with a micrometer. The skirt should give a 0.30mm-0.45mm bead height.

  • If its off, adjust the Z offset until the initial bead height is within this range.

Verify the extruder fans are mounted correctly and have proper flow (fan rotation direction and air flow) direction. There is a sticker on the center of each fan, if the sticker is facing outward, the fan is mounted backwards.

NOTE: When starting the octopus test print watch the printer perform its wipe function to be sure it is wiping the nozzle on the wiper pad and not dragging the nozzle through the wiper pad mount.

8 Burn In

With the printer still connected to Octoprint, run the “Burn In” G-code.

  • This will run the printer through its full range of motion multiple times to ensure all parts are “broken in.” For instance some tight bearings will loosen up a bit after burn in.

Run this G-code for about 20 minutes.

9 Octopus print

Run the “calibration octopus” G-code.

  • Let the print fully finish and inspect for issues.

  • Check for “flatlining” which occurs when printing a circle or round edge, part of the circle will be a straight edge instead of a smooth arc. This is usually caused by bushings binding on the smooth rods and not sliding smoothly.

  • Check for Z wobble

  • Check for any feature that is inconsistent from "normal" prints

  • If the print doesn't have any issues, the printer is ready for packaging.

Fully Calibrated Mini Ready for Packaging
Done! Take me home