I’ve always been an avid flight sim fan. Over the last few years I haven’t really spent any time flying on the sim. I recently installed a few different flight sims and have spent some time flying again. Here is a video of my current setup
This is an overview of the Behemoth 3d printer that I designed and built. It has a 330x360x400mm build envelope. I also show a sample of a number of objects that I have printed on it. This video turned out a little longer than I intended.
I picked up a Rostock Max 3d printer a few weeks back. I wanted one to gain experience with a bowden hot end setup and a delta arm configuration. The build was pretty straight forward for me as I have built many 3d printers and even designed my own. I found the stock power supply did not provide enough power for me to heat the bed and maintain a constant temp on the hot end. I replaced it with a quality Corsair 600W supply that has a single 12V rail. Other than this and the fans I added the rest of the RMax is stock. If I had to pick one thing about the build that I did not like it would be the fitting of the arms to the aluminum u-joints. This required a lot of sanding, scraping and countless refits to get them to move with minimal friction.
My first prints turned out a lot worse than I was hoping for. However I was expecting more tuning than usual as I had read that Bowdens and delta’s required it to make decent prints. I was starting with PLA instead of ABS so it was even harder to tune the bowden setup. I needed to add a fan to cool the peek part of the hotend to stop the PLA from oozing up and causing a jam. I spent a lot of time on PLA prints and tuning but could just not get a result I was happy with. I decided to switch to ABS as it was supposed to be easier with the Rmax and its Bowden setup. Well I spent an equally frustrating amount of time trying to tweak the settings and not getting acceptable results. I was basing my tuning on the nozzle size of 0.5mm. In order to be sure I confirmed with John at SeeMeCNC that mine was indeed shipped with a 0.5mm nozzle.
Well it turns out my 0.5mm nozzle was not actually a 0.5mm nozzle. It was most likely a 0.7mm or larger. I figured out the nozzle wasn’t 0.5mm by extruding slowly into open air and waiting for it too cool then measuring the diameter. I was between 0.9 and 1mm in diameter. Normally a 0.5mm nozzle would measure about 0.6mm or so.
0.7mm nozzle on the left and 0.??? on the right
The mush was caused because I was using 0.5mm nozzle settings for extrusion and infill width in KISS. If you try and print infill with a width less than the nozzle diameter it won’t work. It makes sense why if you think about it. How can you possibly extrude infill at a diameter less than the nozzle diameter keeping in mind that infill typically bridges itself in open air. Mine would just fall apart as the flow calculation was wrong.
Once I dialed in the correct extrusion width into KISS the results were amazing. Infill was perfectly connected and layered. No more mushy mess!
I’d really like to be printing with a 0.5mm nozzle but I’ll have to wait until SeeMeCNC sends a replacement. For now I put on the 0.35mm nozzle. In this video you can see me printing the golvend tornado. I sliced it with KISS slicer at 0.25mm layer height. Printing at 20mm/s with feedrate at 150% and temp set to 230.
More pics using PLA
I sliced this with Skeinforge 50 at 0.35mm layers and printed with silver pla at 175C on the Behemoth. I set cool to 10 second layer minimum and used the two fans as picture on high. I am very happy with the way this turned out.
I found this on thingiverse the other day. I wanted to see how it would print on the Behemoth. The only way it can be made is on a 3d printer. It can’t be assembled or dissambled (at least without breaking it). It printed great and it was very easy to break the gears free and start rotating it. I ran it in a drill a little bit and it loosened up very nicely. I’m not sure how long they will last but I intend to use them in the smaller 1 pound spools.
You can see the results here
I picked up a piece of 41cm x 35cm x 3mm float glass at the local glass shop. It weighs in at a hefty 1029grams. I’m printing a 300x300mm square picture frame just as a test of the large surface area. The glass does sag a bit in the center but that can be easily remedied with some supports underneath. So far it doesn’t seem to effect the print.
I think I’ll work on a system to make these print beds easier to interchange. I’d like to be able to put the smaller bed back on there when I need heat on the bed.
This is the second PLA rocket I am building. The first one flew well and is ready for another flight. See it here. The bottom section of this rocket is 300mm tall. I will print a 300mm tube and a 70mm nose cone for a total height of 670mm.
The layer alignment on this section is the best I have ever seen on any of the printers I have built. I was worried about issues surfacing as I printed at higher and higher elevations. So far I have not had any. This one was printed at 0.35mm layer height and took about 2 hours to print.
I measured the Z height again and I can print 390mm high.
This spiral lightbulb is always a challenge to print. It requires good retraction. As the print gets taller the spirals get pushed around by the print head. This makes the layer alignment difficult and as a result the surface finish suffers. That said this is the best one I have printed to date on any of my printers. The Behemoth is my 4th 3d printer.
I printed this one at 0.2mm layer height sliced with slic3r. Fill was 0.15 with solid infill threshold area set to 0. I also enabled cooling with min layer time of 15 seconds and min print speed of 10mm/s. I printed using silver 1.75mm PLA from Ultimachine at 198C. I used my floor fan on low to cool as it printed.
Printed Yoda on the Behemoth @ 0.2mm layer height with 15% infill. Look at the overhang on those ears!
I have the Behemoth printing! I printed out the slic3r version of the tornado posted by Sound on thingiverse. I thought this would be a good test for the printer. This isn’t your typical first print. No calibration cubes here. Just right to business. It turned out very well. Layer alignment was excellent. I was a little worried that I might have issues with large objects This is the biggest object I have ever printed. I’m relieved now and can spend time cleaning up the wiring and install the end stops for x and y.
- 210mm tall
- 0.31mm layer height
- 195 C
- Active cooling from a floor fan on low
- 2 perimeters
- 3 solid layers on bottom, 0 layers on top
- 0% infill density
- build envelope (350mm+ on X, 350mm+ on Y, and 400mm+ on Z)
- 0.35mm steep head nozzle with makergear hot end.