Poli Log

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Project planning

Specific goals

  • Upgrade extruder (learn to make great extruders)
  • Recycle #1 plastic to filament
  • Develop additional tool heads for different kinds of printing (solvent dispersion)- screw driven syringe

Current projects

  • Volcano nozzle upgrade - get extruder prints from library, get missing BOM parts (bowden) , assemble
  • 3D printing class - send follow-up email, establish relationships with library print services, curriculum, website
  • D3D wiring upgrade - get bigger backboard, add prongs to power supply connections, reinforce the Arduino power connections

Upcoming projects

  • Heat bed upgrade - look into dual power wire
  • D3D PVC build

Someday projects

  • D3D workshop
  • Plastic recycling shredder and extruder - experiment with recycled PET and virgin PETG coextrusion


Trying to get the D3D optimized to print. Looking to present open source 3D printing at ForkFest and Midwest Peace and Liberty Fest, so need to get spiel together. D3D is not using the z-offset from Cura. Need to figure out if it is due to g-code at start (G28 command?) or marlin overriding something.


Looking to redesign magnetic mount plate for D3D with aero titan extruder, do not want to reorient the y axis. Looking to combine File:Prusa i3 mk2 extruder adapted interface.fcstd and File:E3dtitanbracket.fcstd. Tried an assembly but the dimensions weren't right. Will redesign from scratch but need to find the dimensions of the parts. Need to use drawing view in FreeCAD? Definitely need to practice more with FreeCAD. Confused about the difference between a part and a body. Can't map a sketch to a face with an error "need to add a body, use transfer function". Want to keep five magnet spaces, and have extender on each corner, but maybe should use magnets in all 9 positions. Maybe make mounting plate thicker to reduce magnets' effect on extruder electronics.


Purchased all metal titan aero knockoff from ebay, along with inductive sensor and fan. Need to find what size screw to secure inductive sensor to nozzle assembly. Titan aero will require assembly. Need to redesign mounting plate and purchase magnets. Need to figure out how to add plugs to hot end wires.


Examining the D3D v19.02 extruder and the parts. Nozzle assembly attaches to the heat sink of titan aero, the assembly holds the z sensor and a blower fan for the hotend. Would prefer not to turn z axis cable and will alter magnetic mounting plate to hold aero by the mounting bracket.


Sent follow-up email for interest in D3D and 3D printing.


At the MSU expo for the day. Started up the D3D and OSE linux but had scaling issues with models be 10x (very strange). Had to reset the settings, but lost the start-gcode. Using default start g-code worked with the addition of command G29 (autolevel bed) and G92 E161.2 (steps of extruder per cm). Wasn't getting great printers (issues with not sticking to the bed, z-axis) but good enough to demonstrate. Kids and some adults were pretty into the concept. Should have grabbed a second screen to display computer on the walkway side of the table. Talked to 100+ people and gathered contacts of ~20 people/families interested in a D3D build workshop locally. Many kids had 3D printed at school, a few kids have made their own models with TinkerCAD, a few very inspiring. One had just gotten a 3D printer for home. Definitely an educational niche, with some parent investment. Suggested parents help children get FreeCAD or TinkerCAD and use 3D print services at a local library.


Printing volcano nozzle with 0.1 mm layers, z-offset of .12 seems very good. Tried using a snippet of filament, while print went overnight and the filament ran out. Good print quality but incomplete. Need to tape down servo wires. The extruder attachment plate does not have magnets on the fan corner and this may allow the extruder to wobble, need to stabilize corner with an insert.


Attached cable guide to extruder and collected wires in bundles. Zip tied wire bundles and placed attached to guides, wires seem too short to fit completely in guide, maybe the guide can be shortened by removing links. Did some practice prints, issues with extruder retracting filament before printing. Googling found the code G92 E0, should be included in G-code start to reset extruder position after the first print. Got it confused with M92 E161.2 (extruder steps), wasted some time. Everything is working pretty well now. Attached filament spool with more zip ties. Filament likely has crossing strands, making torsion during print.


Not successful at tweaking z-offset through marlin lcd interface and had to use the Cura settings. Printer is up and running. Printed the body for a volcano extruder with .15 mm layers (will add pic soon). Print went pretty well, some strings and globs but hollow cylinder was produced. Extrusion sometimes doesn't seem to happen with some first layers, and manual pressure is needed. Slight warping on extended arm but likely can be improved with more outlines. Further tests and printing of the extruder parts are next.


Replaced mosfet board, and soldered on prong connector to the end of the wires. This seems like it could be a good step to increase robustness, ease of assembly, and introduce the connections to new builders (would have to connect two wires to a few connectors). Heat bed works well. Did some small printing, but need to tweak z axis offset.

Have been using Cura to control printer but need to start using marlin interface directly. https://www.youtube.com/watch?v=Q5M7DvdMcew


Smoking D3D. Mosfet has heat damage at the DC out terminal, melted plastic and ash. Wires at DC terminals are covered in melted burned plastic. Ordered new mosfet, filament holder, and heated bed (prewired). Replacing the bared stranded wire for the connection with screwed on connectors. If conducting builds with first time builders outcomes would likely be more successful if using quality prewired components. Plan to print volcano extruder when D3D is running.

Gluing the heat bed to the z-axis is inconvenient when troubleshooting a heated bed, which seems to be a temperamental component, need to think about mechanical mounting. Looking at aluminum t-slot bars on ebay as a frame for the next build.


Getting decent prints with D3D. Honing the z-axis takes a while but there may be a more efficient technique. Got down to .12 mm layers, pretty good details. Need a spool for the filament. Was able to tighten in hotend thermistor after a print, the tightening screw was

Small wisps of smoke are coming from the control panel towards middle/end of prints when fan in power unit comes on. Seems to be coming from DC in terminal of hotend board, likely when the hotbed is being heated. There may be solder on the end of the wire that is the source. Going to cut end off end of wire and reattach.


Still working on getting D3D running consistently. Had a very good print at 0.15 mm layer height. Then started tetting thermal runaway error on the heated bed during printing. Once the issues are worked out, will secure wires in wire guides. Planning to bring D3D to some liberty festivals this summer, so I need to get the D3D secured for transport.


Ran D3D. had to pull out filament, stringy end from last failed print. With fresh PLA end, was able to print roctopus with decent fingers. Slowed print to 20mm/sec. Maybe need to tighten axis belts. Pretty happy to have a printer!


Cleaned out axis, little black screw and axis piece fragments built up, removing the material allowed the motor to rotate freely. Reassembled and printed a cube. After honing z-axis had problems with extruder, maybe overheating.


Worked on D3D. Calibrating z-axis. Honed in the height probe distance and used z-offset to get the perfect distance. Had some pretty good prints with PLA, slowed down speed to .30 mm/s. One of the axis locked up after a print. Have to disassemble motor from axis and see what is not rotating freely.


Received OSE poster for expo. Looks pretty good.


Had an online meeting to gather people interested in open source genetic engineering/open science. Organizing future mastermind group.


Planning materials for expo. Want to have a few figures to teach concepts related to D3D. Need to introduce the math concepts involved in making a model and how to turn that into an object by CNC.



Getting together BOM for D3D volcano extruder


Will have an expo table at the 2019 MSU science festival (April 6th), so need to get materials together and D3D working well. Have a Rostock 3D printer in the lab that I can borrow and use to print parts for D3D. Optimizing Rostock for ABS printing for new extruder parts. Installed PET heatbed to get bottom layers to stick, also applying ABS/acetone solution to bed before rinting for better sticking.

D3D heatbed has been a little finicky for retaped with kapton and seems okay. Thermistor is falling out of hotend and I cannot tighen or loosen the black screw on the hotend. Used a little superglue to secure it but it is not ideal.

Working on longterm vision for OS work and life.

Need: Working 3D printers with corresponding computers.

Signage to draw eyes and give impression of demonstration

Handouts or QR codes linked to OSE resources


D3D printed manual

Signage/graphics of GVCS

(Eric Here, OSE Participation in Makerfaires may be a good place to put some stuff. Then also pamphlets on pretty much everything sounds like it would be good (brocures from a mass print service). Using an Open Source Power Supply (Solar Controller etc) may spark some additional intrest if you can manage that (not too neccissary though). One completely crazy (yet possibly possibly doable) would be to drive a lifetrack/lifetracck mini up to the event; I don't know the exact adresses, but I did plug this into google maps: https://www.google.com/maps/dir/Michigan+State+University,+220+Trowbridge+Rd,+East+Lansing,+MI+48824/Kansas+City,+Missouri/@42.4046285,-123.0686184,4z/data=!4m14!4m13!1m5!1m1!1s0x8822c259da888d63:0x6e9898ab05aa3b3f!2m2!1d-84.4821719!2d42.701848!1m5!1m1!1s0x87c0f75eafe99997:0x558525e66aaa51a2!2m2!1d-94.5785667!2d39.0997265!3e0 It seems like ~ a 10 hour drive.

I may make a construction set for publicity event kits soon and maybe even some graphics for posters etc (altough I probably will just dig for old ones to keep the style the same).

All in all it is great that you are getting us out there for some publicity, I will try to help, and good luck!)


https://www.lansingmakersnetwork.org/ https://lib.msu.edu/makecentral/3DPrinting/


Messing around with FreeCAD-PCB. Putting together guide for OSE.


Mounted flash drive with GParted and split off a partition from the oversized main partition (this was likely a waste of time), probably should have shrunk drive just using windows disk manager. Installed OSE linux on empty space (use do something else option for installation), ext4 format, mount /, primary, start. Stable OSE linux successful, to boot between systems switch Bios to UEFI or legacy. Downloaded FreeCAD-PCB workbench, extracted. Had trouble moving the file in the mod folder /usr/lib/freecad/MOD, wanted to use gksu nautilus, had to reset root (sudo passwd root). Opened Nautilus, moved PCB into MOD. Booted up FreeCAD but needed a model. Located templates for kicad http://kicad-pcb.org/libraries/download/ . Opened PCB of Arduino Mini, voila.


Researching KiCAD to FreeCAD. Seems to be FreeCAD-PCB workbench available and it looks pretty nice. Working with workbenches will require a stable OSE linux.


Having too much fun outlining OS synbio. Trying to make contact with other OS synbio backers, so we can get stock what is already OS. Thinking about yeast and yeast vectors. Strategizing to OS current bio projects. Getting ready to dive into CNC circuit mill, emailed Shane to get wiring info and any other info he might have.


Organizing thoughts on OS synthetic biology


Getting D3D CNC Circuit Mill v18.06 design requirements and modules broken down. Looking for wiring info but can't find it.


Looking through D3D CNC Circuit Mill, collecting CAD files. Want to dual install OSE linux on laptop running windows, only open source partition software found is GParted. Will work through development template of circuit mill.


Collecting thoughts on conversations yesterday, poking around kicad and watching some tutorials, going through D3D CNC Circuit Mill appreciate the design work but the development template is very incomplete. Embedded new development template on CNC Circuit Mill v18.06.

June 12, 2018

  • CNC Circuit mill - 12 weeks
  • Schedule by week:
  1. Set up Development Template for CNC Circuit Mill v18.06 and embed a Burndown
  2. Use 20 item templat
  3. Burndown from OSEdev page - Lex@berezhny.com
  4. Get acceess to $109 Welder + flux core welder
  5. Get access to 5 amp angle grinder or 15 amp abrasive metal cutoff
  6. Take a look at all stuff at the https://www.opensourceecology.org/cnc-circuit-mill-workshop/ page
  7. Addding the arduino controller + wiring into FreeCAD using the KiCAD export - Teach the Team how to import electronics between FreeCAD and KiCAD.
  8. Use the OSE Piping Workbench - and add the wiring into CNC Circuit mill
  9. Wiring diagram from Shane Oberloier
  10. Source materials, do logging, take pictures - upload to drive
  11. Create a Part Library (gallery) as in the Part Library of all the electronics parts and wires
  12. Shoot for Electronics Components in FreeCAD lesson to team on July 10, 2018


Reviewing fluidized bed reactor specifications and making model in freecad.

Developer test self-assessment

Overall the developer cube test likely took 20 hours to complete, spread over a few weeks. Downloading the iso was delayed by browser issues, but after download setup was easy enough, taking maybe 2 hours and buying a flash drive. Making the cube in CAD was the most time consuming part of the exercise taking time to refresh CAD navigation, toolbars, and selecting things. The exercise took several (10-20) tries mainly due to conflicting constraints, this is when I started to review previous tests to see the strategies used. One trick I have been unable to replicate is being able to select or copy an object and move it with the mouse without changing the orientation. The strategy I used was to duplicate tubes made in each orientation and place the tubes using constrains on each axis, building a cube. It took several hours of frustration with plane constraints to find out about the fixed position property, with the ability to fix a single tube and constrain the others to it building the cube was fairly straight-forward. Marcin told me how to find the bolt in the fastener workbench and it took watching a few old tests to find out how to attach the bolt and screw. Building the cube took about 15 hours, but I can now make the cube in less than 20 minutes. After unsuccessfully trying to screen record in windows I booted OSE linux. What a difference! Very smooth operation, with programs that have most professional options. Recording with vokoscreen produced manageable videos, these were easy to lay out in kdenlive. Googling found options to speed up the video but it couldn't be reduced to 30 seconds. Making the videos took maybe 3 hours in total.

I would assess myself a score of 80% mainly due to a lack of following directions. I did not switch to linux until I had already reviewed freecad in windows, working in linux longer may have produced a been video (-10). As a result the video is over the allotted time (-10), perhaps there is another option for speeding up the video that I overlooked.

Overall score: 80


Test 2

Poli's second cube

Test 1

Poli's cube

Booted up OSE linux on acer aspire e5-525, had to change bios from uefi to legacy. Very nice platform! Used vokoscreen to record building the cube. Had to modify toolbars to include duplicate selection and pocket. Collected a few clips to cover all of the steps and laid out in kdenlive, used property->motion->speed 2000% to speed up movie, max setting but video is still 1 min. Downloaded OS music, dropped in audio track, clipped at 1 min. Rendered as MP4 and MPEG for upload to youtube, had issues with MP4 on youtube at first but worked eventually.


Trying to get a recording of the developer test cube, having issues with VLC and CamStudio. Will try to work in OSE linux next.


Working on finishing developer test cube. Attaching bolt (ISO 4014 M27 220 length) and hex nut (ISO 4032). Working to produce recording of desktop by VLC, VCL output is by default to very large avi files https://superuser.com/questions/613368/how-do-i-set-the-format-vlc-media-player-uses-when-recording https://forum.videolan.org/viewtopic.php?t=95081 Still working on creating pocket from initials.


Reorganizing OSE approach to biotechnology pages


Made the cube by constraints using assembly2, looking for bolt part to finish design.


Downloaded ose linux iso, was having trouble with google download link through brave browser but worked with chrome. Formatted and mounted image to usb. Have been practicing freecad, making the cube for the developer test. Downloaded VLC for screen capture.


Have been experimenting with 3D printed parts for D3D using a Rostock printer, ABS plastic, and Repetier to generate g-code. ABS is warping away from the bed, and optimization has included raising the bed temperature, decreasing the printing speed, and printing on a bed lined with painters tape. In order to optimize prints had to generate axis pieces stl files and mirror part.


Started receiving ordered materials. Preparing to print necessary parts in ABS on Rostock printer. Investigating 16' frames considering steel, PVC or acrylic, leaning towards steel.


Have been researching D3D printer and how to solvent cast 3D print set-up documentation site for a replication build. Dispersion of solvent disssolved material require fluid pumping to drive extrusion.


Installed freecad. Focusing research on cellulose based 3D printable materials because this seems to be the most boot-strappable material to manufacture in the OSE context. Printable cellulose requires solvents for dispersion rather than using thermal melting.


After a long hiatus the OSE bioplastic project is back under development. Background research is near completion and current work is to design and build prototypes of a chemical reactor capable of producing PLA (and PE).

Where to pick up again?: 1. Determine the necessary capabilities of a reactor for producing bioplastics. 2. Make reactor core schematics and determine manufacturing techniques. 3. Build a budget for reactor prototype and substrates. 4. Crowdfund necessary funds. 5. Build prototypes at FeF in Summer 2019.