Project Dashboard LulzBot Mini 2 Packaging Workflow

1 Prepare Mini 2 Toolkit

Several of these AS-PK0029 & AS-PK0030 may be prepared for later use
AS-PK0029 consists of:
1x- [AS-PK0010] 90 mm wiper pad set 5 pack
1x- [AS-PK0027] Clam knife with label
1x- [TL-CS0117] Elmer's Glue Sticks
1x- [TL-HD0048] Elmer's X-Acto No. 1 Precision Knife - Aluminum
1x- [TL-HD0050] Stanley 6" Long Nose Pliers
1x- [TL-HD0468] 7 pc Long Arm Ball Hex Key Wrench Set (Metric) - Red
2x- [TL-CS0255] Scotch Brite Maroon Pad, 2"X 3"
1x- [TL-MS0343] Bright Travels Hanging Utility Kit - TAZ Tool Bag with LulzBot Green Logo
1x- [AS-PK0030] Tool Sub kit:

  • 1x- [TL-HD0008] Stainless Steel Pocket Rule Semiflexible, Metric Grads, in a protective sleeve
  • 1x- [TL-HD0049] 6" Deluxe Bent Stainless Steel Tweezers with Serrated Teeth and Safety Cap
  • 1x- [TL-HD0046] PRO DENTAL PICK (PROBE) (DP-19) M S V - with a safety cap
    Insert the Ruler [TL-HD0008] and the Tweezers [TL-HD0049] into the sleeve accompanying the Ruler [TL-HD0008]. This creates AS-PK0030 Tool Sub Kit.

Open the Tool Kit Bag [TL-MS0343] and use the hook inside to hang the bag on a rack to be filled.

Place the Elmer's Glue Sticks [TL-CS0117] into the top mesh pocket.

Place the Scotch Brite Pads [TL-CS0255] into the large bottom pocket of the Toolkit Bag [TL-MS0343]

Place the Wiper Pad Set [AS-PK0010] into the mesh pocket at the top as pictured; close the zipper.

Place the X-Acto Knife [TL-HD0048] into the large bottom pocket of the Toolkit Bag [TL-MS0343]

Place the Clam Knife [AS-PK0027] into the large bottom pocket of the Toolkit Bag [TL-MS0343] with the "Sharp!" label facing towards you.

Place Tool Sub Kit AS-PK0030 , (containing: tweezers, dental pick, metric ruler), into the mesh pouch in front of the clam knife.

Place the Allen Wrench Set [TL-HD0468] into the front mesh pocket with the logo facing towards you.

Place the Pliers [TL-HD0050] into the front mesh pocket and close the zipper.

Close the outer zipper of the toolkit bag.

Dental Pick, Ruler, and Tweezers w/ Sleeve
Ruler & Dental pick in sleeve w/ Tweezers
Tool Kit bag ready to be filled
Insert Glue Stick into Top Mesh Pocket
Place Scotch-brite Pads in Top Mesh Pocket
Insert 5-Pack of Wiper Pads into Top Mesh Pocket
X-Acto Knife placed in large bottom pocket
Place clam knife in large bottom pocket with label facing out
Place AS-PK0030 Tool Sub Kit into lower front mesh pocket
Place Allen Wrench Set in lower front mesh pocket
Place pliers in lower front mesh pocket
Close the zipper on the lower front mesh pocket
Unhook the bag from the rack and close the outer zipper, a completed toolkit should look like this:

2 Prepare Mini 2 Document Bag

Several of these may be prepared for later use
Gather the following materials:
1x- [SH-PG0083] 9x12” Recloseable Bag
1x- [DC-MS0066] Mini 2 Quick Start Guide
1x- [DC-LB0095] LulzBot Logo Sticker, 3 - Inch
1x- [AS-PK0032] Polylite Sample Filament Kit, Mini 2 1x- [DC-LB0111] Filament Samples Bag Label - Mini 1x- [SH-PG0030] 8X10 2MIL RECLOSABLE BAG 1M/CT

Place LulzBot sticker (with backing still attached) inside the Quick Start Guide [DC-MS0066] between cover and first page

Open the 9x12” Bag [SH-PH0083] and place the Quick Start Guide [DC-MS0066] and 3m filament sample into the bag

Materials Required
Place sticker inside booklet between front cover and first page
Sticker placed in seam between front cover and first page
Check The Sticker "Created with" Has been applied
Gather Materials
Place The Sticker Center on Bag
Place PLA Sample Filament Cut at 3 Meter Lengths
Place the quick start guide into the 9x12" Bag

3 Prepare Mini 2 Shipping Box

Gather Materials Needed:
1x- [SH-BX0496] Mini 2 Shipping Box
1725mm- [SH-PG0131] White Reinforced Tape with LulzBot Logo (or 68")

Begin with the box upside down;

Fold the box bottom small end flaps into the box, then fold the long flaps over the end flaps;

Tape the bottom of the box with white reinforced tape- 28” long.

Apply a 20” strip across the bottom of the box at the box ends so the tape is centered on the box,

Fold down the two lengths of tape that overhang the face and rear of the box;

Fold down and adhere remaining flap of tape to the box. Repeat at the opposite end of the box

Starting with the box upside down, fold in the small bottom end flaps
Line up the tape on one of the long flaps
Fold both long flaps in and begin smoothing tape starting from the center
Press the ends of the reinforced tape down around the side of the box
Apply a 20" strip to the end of the box, centered as shown
Fold down the two lengths of tape that overhang the face and rear of the box
Fold inwards on the box ends to make an angled seam
Fold down and adhere remaining flap of tape to the box
Repeat at the other end of the box

4 Prepare for Packaging

Retrieve the following from the boxing queue:
1x- [AS-PR0093] Lulzbot Mini 2 Printer, Calibrated
1x- [EL-CA0063] USB Cable
1x- [EL-CA0030] North American Power Cable
1x- [DC-MS0071] Completed Quality Assurance Record
1x- [EL-MS0385] Preloaded/Tested SD Card
1x- Octopus test print
Other materials required:
1x- [SH-PG0084] 6x10" 6mil reclosable bag
1x- [SH-PG0031] 2x3" reclosable static shielding bag

Place the Power Cable [EL-CA0030] into the 6x10" Bag [SH-PG0084] along with the USB Cable [EL-CA0063]

Insert the SD Card [EL-MS0385] into the Static Shielding Bag [SH-PG0031] and place in the 6x10' Bag [SH-PG0084] with the Power/USB Cables.

Carefully place the totally awesome Octopus test print into the 6x10' Bag [SH-PG0084] with the Power/USB Cables and the SD Card (in static bag).

The bag when organized as pictured helps ensure that the octopus test print remains undamaged during the shipping process. Note the position of the octopus. Once all items are in the bag and properly oriented, close the bag.

For UE/ UK shipments:
Additional power cables EL-CA0031 (England/UK) and EL-CA0032 (EU) are added to the shipment

Place the England/ UK power cable (EL-CA0031) and the EU power cable (EL-CA0032) each into a 6”x 10” resealable bag (SH-PG0084) then seal the bag.

For Australian shipments
Additional power cables EL-CA0056 (Australian) and EL-CA0031 (England/UK) are added to the shipment

Place the Australian power cable (EL-CA0056) and the EL-CA0031 (England/UK) cable each into a 6”x 10” resealable bag (SH-PG0084) then seal the bag.

Materials retrieved from the boxing queue
Other materials required
Place the Power & USB cables inside the bag
Place SD card in static shielding bag, seal the bag
Place the SD Card bag inside the 6x10" bag with the cables, as pictured
Place the awesome octopus test print into the bag with the cables & SD card bag, in the middle of the USB cable, as pictured below. Seal the bag

5 Prepare Documentation

Gather the following materials:
1x- [AS-Pk0028] Mini Document Bag (pre-prepared)
1x- [DC-MS0070] Packing List, Mini 2
1x- [DC-MS0069] EC Declaration of Conformity, Mini 2
1x- [DC-MS0031] Safety & Warnings Sheet
1x- [DC-MS0071] Completed Quality Assurance Record

Complete the Packing list [DC-MS0070]

Copy the machine's serial number off of the Quality Assurance Record [DC-MS0071] and verify that both serial numbers match the serial number on the back of the machine
Fill out your name and today's date
Complete the checklist, ensuring that each item is present and complete
Verify printed documents are clean and free of any stains or damage.

Stack the documents in the following order:

1) Warning sheet, Mini [DC-MS0031]

2) EC Declaration of Conformity, Mini v1.0 [DC-MS0069]

3) Completed Quality Assurance Record [DC-MS0071]

4) Packing List, Mini 1.0 [DC-MS0070]

Flip the Packing List over, so that once the documents are in the bag, the Packing List will show on the back side of the bag.

If necessary, remove other items from the bag to ease insertion of the documents as it is important that they do not become creased or folded.

Place the other items back in the bag on the side facing the Warning Sheet, ensuring that the Quick Start Guide is on top, as pictured.

Documents gathered
After completing the packing list, order the documents as pictured
Flip the packing list over and stack the documents in that order
Slide the documents together into the document bag
Make sure "Safety & Warnings" is facing up, with the Quick Start Guide on top "Start Here" facing up, and the filament sample in between; as pictured. Seal the bag

6 Prepare Mini Printer for Packaging

Examine the machine:

  • Ensure customer facing surfaces are free of unacceptable cosmetic defects.

  • Ensure the Z-Axis has been placed in proper shipping position.

  • Ensure that the heat bed is free of unacceptable defects.

  • Verify the serial number sticker on the rear of the machine is present and matches both the Quality Assurance Record and the Packing List.

Gather the following materials:
1x- [SH-PG0173] Mini 2 Print Head Stabilizer
1x- [DC-LB0063] Modification Warning Insert
100mm- [SH-PG0069] 1/2' Blue strapping tape

Using two short lengths (~1”) of small blue strapping tape [SH-PG0069], affix the Modification Warning Insert [DC-LB0063] to the printer's heat bed, as pictured.

Break apart the Mini 2 Print Head Stabilizer [SH-PG0173] and keep only the pieces in the picture.

Insert the front foam piece, ensuring the print head is supported.

Lift the top of the front foam piece over the filament protruding from the top of the tool head, and poke the filament into the foam so that it rests flat on top as pictured.

Insert the rear foam piece as pictured. The two halves should meet in the center of the machine.

Place the Cap Foam over the machine's X-Carriage Cap, encompassing both front and rear halves of the packaging foam.

Place the foam ring around the printers spool arm support as pictured.

Modification warning properly affixed to bed plate
Break apart the Mini 2 Print Head Stabilizer, keeping only the pieces shown
Front foam piece in place
Lift over filament
Poke the filament into the foam so that the foam rests flat
Insert the rear foam piece
Rear foam piece inserted, note how both front and back foam pieces meet in the middle
Place the cap foam over the extruder and both front and back halves as pictured
Cap foam piece in place properly
Foam ring in place around spool arm support

7 Place unit into shipping container

Gather Materials Needed:
1x- [AS-PR0093] Mini 2 Printer, calibrated – prepared in previous steps
1x- [AS-PK0028] Mini 2 Document Bag – Completed
1x- [AS-PK0029] Mini 2 Toolkit - Completed
1x- [SH-BX0496] Mini 2 Shipping Box – See above for preparation 1x- [SH-PG0176] Mini 2 Foam, Top
1x- [SH-PG0177] Mini 2 Foam, Bottom 1x- [SH-PG0019] Mini 2 Barcode Label
1725mm- [SH-PG0131] White Reinforced Tape with LulzBot Logo (or 68")
1x- [DC-LB0111] Filament Samples Bag Label – Mini 2
1x- [SH-PG0030] 8x10" RECLOSABLE BAG
200mm- [SH-PG0072] 2” wide blue poly tape cut to approximately 100mm long

Orient the Shipping Box [SH-BX0496] on the stand upright, with the green outline for the serial number facing you.
Locate the correct Serial Number/Barcode Label [SH-PG0019] for the machine to be packaged, verify the serial number matches the number on the rear of the machine.

Apply the Serial Number/Barcode Label [SH-PG0019] within the green outline. This should be on the same side of the box as the control box for the printer.

Locate the Mini 2 Foam Bottom [SH-PG0177] refer to picture for identification.
Place the Mini 2 Foam Bottom [SH-PG0177] in the box, ensuring the flat side is facing up and the left side is facing towards you (and the side of the box with the green outline), refer to picture for orientation.

Grab hold of the machine by using your fingers underneath each end of the Y-Axis, as pictured. The control box side of the machine should be facing you.

Lower the machine into the box, ensure the printer is fully seated in the Mini 2 Foam Bottom [SH-PG0177]

Ensure both front and rear foam pieces seat into the Mini 2 Foam Bottom [SH-PG0177] properly

Box on stand with green outline facing you
Apply barcode label
Barcode label applied
Bottom foam identification
Bottom foam in box
Grab hold of machine with control box facing you
Lower the printer into the box, ensuring it is fully seated in the bottom foam
Mini 2 printer securely in bottom foam

8 Install Top Foam & Accessories

Locate the Mini 2 Foam Top [SH-PG0176] and orient as pictured.
Place the Mini 2 Foam Top [SH-PG0176] on top of the printer and ensure that is fully seated.

Ensure both front and rear foam pieces seat into the Mini 2 Foam Top [SH-PG0176] properly, and the cap foam is seated as shown.

Place the Mini 2 Toolkit [AS-PK0029] into the cell on the Top Foam as pictured.

Place the bag with the cables, SD Card, and Octopus test print in the cell to the right of the Toolkit, as pictured.

Place the Mini 2 Document Bag [AS-PK0028] over the Mini 2 Toolkit Bag [AS-PK0029], with Start Guide "START HERE" facing up

Place available Filament Sample packs into the 8x10" Resealable bag [SH-PG0030], label the bag with the sample filament bag label [DC-LB0111], seal the bag.
Place bagged sample filament into the box in the corner opposite the documents bag with the filament label facing up, secure the sample filament bag in and place in the location shown with 2x- 2” wide blue poly tape [SH-PG0072] cut to approximately 100mm long each.

Place [DC-LB0121] Save your Mini Packaging Sticker on the inside top flap of the box as pictured.

For EU/UK/AU shipments
Place each additional power cable into a 6x10" Bag [SH-PG0084], fold and place into the long section along the end of the box opposite the Toolkit Bag, as pictured.

Install and secure the filament sample bag per normal procedure

Install the printer document package per normal procedure.

Close and tape the box, utilizing the same procedure used to tape the bottom of the box. Ensure that tape is placed evenly and all edges pressed as flat as possible.

Mini 2 foam top, orient as pictured
Foam Top in place on printer, fully seated.
Front and back foam pieces properly mated with top foam, cap foam properly seated also
Mini 2 Toolkit Bag properly placed
Bag with cables, SD card, and octopus properly placed.
Document bag properly placed
Save your packaging sticker should be applied at the location shown
FOR EU/AU/UK SHIPMENTS: Place the extra cables in bags in the long slot opposite the toolkit bag as shown
Close and tape the box

9 Log Machine & Place on Pallet

Log the date, time, and your name, in the log entry containing the serial number that matches the Packaged Mini Printer. See your supervisor if you have questions regarding this step.

Once calibrated and packaged, the Lulzbot Mini 3D printer will then be stacked on heat treated pallets for shipping. Following this guide for pallet stacking will help ensure the printer arrives at its destination undamaged and will assist Shipping & Receiving staff in serial number tracking.

Retrieve a heat treated pallet from Shipping & Receiving. Heat treated pallets are identified by a stamp on the side that reads “HT” at the bottom. Refer to picture for example.

Lulzbot Mini printers are stacked 4 machines per layer, no more than 3 layers in height, for a total of 12 machines per pallet.

The machine’s serial number is located on a sticker on one side of the box. That side of the box should face the front or back of pallet, whichever is closest to the machine’s position on the pallet. Serial numbers are recorded both in the Boxing Log and on the “Serial Numbers By Pallet” sheet, which will be affixed to the completed pallet before being moved to Shipping & Receiving.

  1. Place an empty heat treated pallet on the floor, with the pallet openings facing the Shipping and Receiving hallway.

  2. Place the first packaged Mini printer on the pallet in position 1. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  3. Place the second packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  4. Place the third packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

5.Place the fourth packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the first layer, proceed to second layer.

1.Place the fifth packaged Mini printer on the pallet in position 5. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  1. Place the sixth packaged Mini printer on the pallet in position 6. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  2. Place the seventh packaged Mini printer on the pallet in position 7. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  3. Place the eighth packaged Mini printer on the pallet in position 5. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the second layer, proceed to the third and final layer.

1.Place the ninth packaged Mini printer on the pallet in position 9. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  1. Place the tenth packaged Mini printer on the pallet in position 10. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  2. Place the eleventh packaged Mini printer on the pallet in position 11. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

  3. Place the twelfth packaged Mini printer on the pallet in position 12. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the third and final layer.

Before transferring the completed pallet to Shipping & Receiving, ensure that all Serial Numbers have been recorded on the serial numbers by pallet sheet.

Use a small piece of transparent tape to affix the “Serial Numbers by Pallet” sheet to the front of the pallet.

The pallet is now ready to be moved to Shipping & Receiving. Make sure to communicate with Shipping & Receiving Clerks for appropriate placement.

Stamp indicating heat treated pallet
Complete pallet front
Completed pallet back
Empty Pallet on floor
Printer in Position 1 Rear
Printer in Position 1 Front
Printer in Position 2
Printer in Position 3
Printer in Position 4
Printer in Position 5
Printer in Position 6
Printer in Position 7
Printer in Position 8
Printer in Position 9
Printer in Position 10
Printer in Position 11
Printer in Position 12
Serial numbers by pallet, on pallet
Done! Take me home