Operating Manual
Contents
1. 4 6 6 Gerate a eae eee eee ee 12 HDE Cleaning AUN 12 Step 7 Filament Collection a a 13 11 Which Materials 13 Te 14 2 D3DV1 00 D3D ae 2 Disclaimer This manual is intended for your safety and protection This information could contain technical inaccuracies typographical errors and out of date information This document may be updated or changed without notice at any time Use of the information is therefore at your own risk In no event shall 030 Innovations Limited be liable for special indirect incidental or consequential damages resulting from or related to the use of this document D3D Innovations Limited makes no representations or warranties either expressed or implied with respect to the contents hereof and specifically disclaims the implied warranties of merchantability or fitness for a particular purpose 3 Warning This is a mains electrical appliance and must be earthed If you have any questions or are not qualified to work on the equipment hire a licenced electrician Isolate from mains supply before removing cover This device is a work in development and should be treated as such Itis recommended that the device be inspected for use by a licensed electrician in the country of use prior to connecting to the mains supply D3DV1 00 D3D a2. to operate without the enclosure in place and hopper lid on e Do not operate the machine for more than 4 hours before allowing 2 hours to cool down e f motor fails to turn when powered on then turn off immediately wait for 5 minutes and try again e Consult the manufacturer data sheet for safe material usage for all materials additives and colourants e Consult materials manufacturers for suitability of material use with FilaFab e Do not push anything through the vent slots or block them e Extruded filament is extremely hot do not touch until it has cooled down e Keep loose clothing hair and jewellery away from machine in particular the hopper and hot nozzle D3DV1 00 D3De Innovations Fi F D 5 Notices e No part of this manual may be reproduced copied transmitted transcribed stored in a retrieval system or translated into any language in any form by any means without D3D Innovations Limited prior written permission e D3D Innovations Limited reserve the right to change the specifications of the hardware described in this manual at any time and without prior notice e Innovations Limited will not be held liable for any damages resulting from the use of this product e While every effort has been made to ensure that the information in this manual is accurate and complete we accept no liability for errors or omissions We would however appreciate it were you to bring any errors or omissions to the atten
3. D3D Operating Manual IMPORTANT READ INSTRUCTION MANUAL BEFORE CONNECTING OR OPERATING READ ALL SAFETY INFORMATION RETAIN FOR FUTURE REFERENCE www filafab co uk Copyright 2014 by D3D Innovations Limited D3DV1 00 DS0 1 Table of Contents fs 2 MONG GIANNIS Fetes itso cea ease ms uama sup 3 3 WaAmMiNG sisata aaah naa 3 4 Saleb PRECAUMONS n uma 4 Os NOIES ua Zn naa asua aaa seus 6 6 Lifting and Transport Instructions 6 SOV N sonia 7 Li F sed Filament Fabrication uu uu u uu uu u u pasas 7 azu uuu er rer u a 7 PAS OVelyNISWu musu asnus 8 Gi IODC ae 9 92 MENE u ua 9 10 10 DIED AIC NOZZE ua 11 Step 2 CONNECTING 11 DIED S LOAGING ODD CN ura s han as 11 Step 4 Temperature Controller sessirnir raa a aa 11 m 4
4. e machine 4 Reasons the motor may struggle include insufficient heat not allowing the machine enough time to heat up blockage or incompatible material Step 6 Cleaning Run When running the machine for the first time and when changing plastics it may be necessary to do acleaning run This will clear any particles leftover from the manufacturing process and clear out any previous materials 1 To do this remove the nozzle and run the machine until the extruded material is contaminant free If this does not sufficiently clean the extrusion tube then try removing the nozzle adapter adjust the temperature to slightly lower than the normal melt point and run the machine again This method should push enough material through to effectively clean the auger and the extrusion tube 12 D3DV1 00 DS0 Fila Step 7 Filament Collection 1 To ensure a consistent tolerance ensure that the filament is collected in a consistent way Collecting the filament at different distances from the nozzle will impact the size of the filament TIP Collect filament on a flat surface approximately 2 feet below the nozzle Allow the filament to fall with gravity and it will fall into circles itself TIP The greater the fall distance from the nozzle to the surface the narrower the filament will be this is because the weight of the extruded filament will pull down on the soft filament causing it to elongate TIP It may be necessary to
5. e KEEP LOOSE CLOTHING HAIR AND JEWELLERY CLEAR OF THE MACHINE e OVER TEMPERATURE WILL CAUSE MATERIAL DAMAGE AND POSSIBLE CHARRING e THE SAFE OPERATION BY MEANS OF SETTING THE CORRECT TEMPERATURE OF THE MACHINE IS DOWN TO THE USER e F OVER TEMPERATURE OCCURS ENSURE THAT THE TEMPERATURE IS REDUCED IMMEDIATELY AND THAT ADEQUATE VENTILATION AND SAFETY MEASURES ARE INPLACE TO ACCOUNT FOR ANY FUMES RELEASED FROM THE MATERIAL IT IS RECOMMENDED THAT HEATPROOF GLOVES ARE WORN EYE PROTECTION AND A FUME EXTRACTION SYSTEM BE PUT IN PLACE e ENSURE MACHINE IS ON A STURDY AND LEVEL SURFACE AND THAT NO ARTEFACTS ARE IN CLOSE PROXIMITY OR TOUCHING THE ENCLOSURE SURFACE OR NOZZLE 10 D3DV1 00 DS0 Fila Step 1 Attach Nozzle 1 2 3 4 Ensure the motor power switch is in the off position Ensure the mains power switch is in the off position Tighten the nozzle adapter with a large spanner Screw in the required nozzle and fasten with an 8mm spanner do not overtighten Step 2 Connecting Power 2 3 Ensure the motor power switch is in the off position Ensure the mains power switch is in the off position Connect an IEC C13 power cable to the IEC C14 power inlet Step 3 Loading Hopper 1 2 Ensure the motor power switch is in the off position Ensure the mains power switch is in the off position Remove the hopper lid by unscrewing 2 screws Carefully pour material in to hopper Do not overfi
6. guide the filament using a rod and or cool it using water or a fan Caution The filament remains very hot after extrusion 11 Which Materials can extrude FilaFab is designed to extrude thermoplastics only Do not attempt to extrude a thermosetting plastic since charring will occur Unlike thermoplastics thermosetting plastics cannot be reformed once they have been fabricated FilaFab has been tested for use with Acrylonitrile Butadiene Styrene ABS and Polylactic Acid PLA only Many varieties of plastics are available and the user should therefore consult the manufacturers to ascertain the best temperature settings If other materials are used t is the user s responsibility to ensure that the optimal temperature settings are used and that the material is safe for use 13 D3DV1 00 DS0 12 Notes No reproduction in any form of this manual in whole or in part except for brief quotation in critical articles or reviews may be made without written authorisation from D3D Innovations Limited D3D Innovations Limited 2014 D3D Innovations Limited 14 D3DV1 00
7. ll or allow to spill around the edges Replace lid and secure with screws Do not place your fingers or any body part into the hopper Step 4 Temperature Controller 16 2 Ensure the motor power switch is off Switch on the mains power supply switch to turn on the system Allow a few seconds for the Temperature Controller to initialise Please follow the separate instruction leaflet for the Temperature Controller before turning on Configure the Temperature Controller s parameters as per the separate instruction leaflet Notice that by default the temperature is displayed in degrees Celsius and is set to 170 C This will need to be changed according to the pellets being used 11 D3DV1 00 DS0 7 the temperature set point has been reached it may necessary to wait a further 5 20 minutes to allow the heat to spread throughout the material and fully soften melt the material 8 It is recommended that the temperature setting be lowered before setting up the parameters in order to avoid excessive heating Step 5 Extruding 1 Ensure that the temperature has reached the appropriate set point as above 2 Turn on the motor by moving the motor switch to the on position 3 The motor should be immediately turned off if it sounds like it is stalling Under normal running the pitch of the motor should remain fairly constant Running the motor while the material has not melted through may cause damage to th
8. mp Innovations Fi CJ FS 4 Safety Precautions READ ALL INSTRUCTIONS BEFORE USING THE MACHINE KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE e WARNING This appliance must be earthed e Before plugging in check that the voltage on the rating label is the same as the main supply e To protect against electric shock do not immerse any part of this product in water or other liquid e Unplug from outlet when not in use and before cleaning e Allow to cool before putting on or taking off parts e Do operate this appliance with a damaged cord or plug e Do not allow the cable to touch hot surfaces or hang over the edge of a table or counter top e When in use a fire may occur if the appliance is covered or touching flammable material e Do not use near combustible materials e When turned on do not leave machine unattended THIS IS AN ATTENDED APPLIANCE e This appliance is not intended for use by children or persons with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety e Children and any person with reduced physical sensory or mental capabilities or lack of experience and knowledge should be supervised at all times when using or dealing with this machine e Only use in well ventilated areas e Do not use under cupboards or other low hanging objects incl
9. ng an ancillary granule tube 9 Motor and Drive The motor and chain drive system has been designed to provide consistent power to the auger If however the extrusion tube becomes blocked by foreign objects or by insufficient melt temperature or over temperature charring then the drive system will begin to stall This can be recognised by a change in the sound the motor makes i e a sudden lower tone or by Stalling altogether The motor power supply has been deigned to cut out if an over current condition exists i e the motor is stalled However this should be treated as a last resort only since repeated stalling of the motor may results in damage to the machine The motor should be turned on only when the polymer has reached a sufficient molten state The motor should be turned off again immediately if it sounds like it is struggling to rotate normally D3DV1 00 D3D amp 1 Fi CO f D 10 Operating Instructions e DURING TRANSPORT THE NOZZLES ARE STORED IN THE HOPPER REMOVE BEFORE OPERATING e CAUTION VERY HOT NOZZLE e ALLOW FILAMENT TO COOL BEFORE TOUCHING e HOT SURFACES DO NOT TOUCH e ENSURE TEMPERATURE SET POINT IS CORRECT FOR MATERIAL TYPE e ALLOW TO COOL DOWN FOR 2 HOURS AFTER EVERY 4 HOURS RUNNING e KEEP FLAMMABLE MATERIAL AWAY FROM MACHINE e USE ONLY WELL VENTILATED AREA e PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN AT ALL TIMES INCLUDING HEAT PROOF GLOVES AND EYE PROTECTION
10. produce either 1 75mm or 3mm diameter filament Typically a master batch is produced which can contain colourants and additives in addition to plastic pellets This master batch is then loaded into the machine for extrusion into filament 7 2 Features e Rapid extrusion rate e Built in hopper with lid e Changeable nozzle e Integrated temperature controller e Extrusion motor power switch e Powerful 2 stage chain drive e Standard fused power inlet e Built in enclosure power interlock switch e Powder coated steel enclosure e Rubber feet D3DV1 00 D3D Fila 7 3 Parts Overview 01 02 08 07 04 99 eet 05 E ma 06 Part Number Hopper Lid Powder Coated Enclosure Motor Switch Temperature Controller IEC Power Inlet and Switch 06 Rubber Feet 07 O Nozzle Shaft Adapter 8 D3DV1 00 D3D Innovations Fi 8 Hopper The hopper is made from aluminium and is thermally connected with the extrusion This is to allow the granules in the hopper to be pre heated before being drawn into the SCrew Please note that the side walls of the hopper can present a burn hazard since they will become very hot depending on the temperature settings some polymers for example PLA may stick to the heated hopper sidewalls or to the screw at the entry to the extrusion tube If this occurs then the polymer can be scrapped from the hopper sidewalls or directed straight into the auger by usi
11. tion of D3D Innovations Limited e This symbol indicates that this device is to be collected separately m e The following apply only to users in European countries e This device is designated for separate collection at an appropriate collection point Do not dispose of as household waste e For more information contact the retailer or local authorities in charge of waste management di Lifting and Transport Instructions e machine weighs up 16kg e Isolate and unplug the power cable when lifting or moving e Be careful when lifting or moving Lift from underneath e Be aware that the machine is heavier towards the rear e When moving remove the nozzle to avoid damage D3DV1 00 Fila Innovations lord 7 Overview Thank you for purchasing a 030 Innovations Limited s FilaFab desktop thermoplastic extrusion system Please make sure you read all of the safety precautions and keep this manual for future reference This device is under development and should be treated as a conceptual testing machine 7 1 Fused Filament Fabrication FFF In a FFF 3D printer a filament usually 1 75mm or 3mm in diameter is heated an extrusion chamber before being pushed through a fine nozzle the melted filament is then used to create 3D objects FilaFab is designed to produce filament for FFF printers By melting down virgin pellets and recycled plastics before extruding it through a nozzle designed to
12. uding curtains e Do not use outdoors e Do not use without fuse fitted e Replacement fuses should be ASTA approved to BS 1362 e Do not operate appliance after the appliance malfunctions or has been damaged in any manner e THE NOZZLE WILL GET EXTREMELY HOT DURING OPERATION e Do not touch the nozzle during operation and allow to completely down before changing e Replace hopper lid before operating appliance D3DV1 00 DS0 Fila Safety precautions continued e Do not put anything except for plastic pellets into the hopper e DO NOT REACH INTO HOPPER WITH FINGERS OR BODY PARTS SINCE A CRUSH HAZARD IS PRESENT e Consult the manufacturer for optimum extrusion temperature for each material used Do not allow materials to burn or give off fumes e Ensure the temperature controller is setup correctly before adding materials to the hopper tis the users responsibility to ensure safe operation for all types of material being extruded e Place level and flat stable surface before operating e Lift the machine only do not attempt to push on legs since damage may result e Do not block vents e Isolate mains supply before removing cover e Allow time for the material to melt before turning on motor drive e Extruded material must be allowed to cool before handling since it poses a burn risk e Do not allow extruded material to come close to or touch combustible or flammable materials e Do not attempt
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