Prusa Core One
Our Prusa Core One 3D printers where generously financed by Sparebankstiftelsen DNB
3D printing with the Prusa Core One printers is fast and relatively easy, based on FDM technology. However, it is easy to make mistakes due to hardware or software setup. The following article gives you the necessary background for getting started with rapid prototyping and 3D printing with Prusa Core One printers.
Risk Assessment
| Hazard | Likelihood(1-5) | Consequence (1-5) | Risk Rating (L x C) | Risk Level |
|---|---|---|---|---|
| Burn injuries | 3 (possible) | 3 (moderate) | 9 | Moderate risk |
| Starting a fire | 1 (rare) | 5 (severe) | 5 | Moderate risk |
| Mechanical injury (pinching, crushing and entanglement) | 3 (possible) | 3 (moderate) | 9 | Moderate risk |
| Airborne fumes and particles | 4 (likely) | 2 (minor) | 8 | Moderate risk |
Required Safety Equipment
None
Hazards
 |  |  |
|---|---|---|
| The bed and nozzle are hot during, and after printing | Moving parts during operation | Build plate may cause minor pinching or crushing injuries during operation |
Guidelines
- Do not use the printer unless you know how to use it.
- Keep hands, hair, and clothing away from the machine during operation.
- Use only 0.4mm nozzle size
- Print only with Polymaker 1.75mm PLAs. For other materials use our Prusa i3 mk3 instead.
- Don't print in materials that produce hazardous fumes such as ASA, ABS and Nylon.
- Do not move the machine during operation.
- Do not leave the printer before the first layer is completed. Most errors arise during this stage.
- Do not tamper with the 3D printer.
- Do not connect to the printer through Wi-Fi or Bluetooth.
- If you want instruction, have trouble with the printer, or we are running low on materials, contact sonen staff at ifi-sonen@ifi.uio.no.
- Always follow the SOP outlined below.
- Follow our General 3d printing guidelines
Standard Operating Procedure
1. Retrieve/create a 3D model
You can fetch files from creator spaces such as Thingiverse or model them yourself using a CAD tool such as Fusion360, SolidWorks, or Blender.
The next step requires the file format of your model to be either .3mf or .stl.
2. Generate toolpaths for the 3D printer
The tool for generating toolpaths for 3D printers is called a slicer. For Prusa printers, we use PrusaSlicer. A guide to PrusaSlicer can be found here.
The standard preset grants highly detailed results and short printing time. You can tweak the print settings as you see fit as long as it's in accordance with our 3D printing guidelines. I.e., total printing time should exceed 1 day (24 hours). Infill should not exceed 20%.
This process is called slicing, which gives you a .gcode file. Save this file onto a micro SD card and insert it into the printer.
3. Prepare the build plate
Remove any debris that may be on the plate. If the bed is starting to get dirty, rinse it with lukewarm water. The water will dissolve the leftover glue on the build plate.
Apply glue on the area of the build plate where your first layer will adhere. This provides a strong bond between the build plate and the first layer. It also makes the print easier to remove from the build plate after it is finished.
4. Double check the filament
Make sure that the type of filament on the spool holder corresponds to the material defined in your slicer and on the 3D printer itself. A mismatch may cause your print to fail.
Make sure that there is enough material remaining. In your slicer, you will get an estimate of how many grams of filament are required for the print. On the side of the filament spool, there is an indicator estimating the amount of remaining filament. Should you run out of material during printing, the printer will pause, and you may add another spool of filament.
5. Consider if your print requires auto-calibration
When starting a print, consider whether you want the printer to auto-calibrate before printing. The entire auto-calibration sequence takes 5 minutes and isn't always necessary for smaller parts.
6. Remove your print from the printer
The build plate is fixed to the printer magnetically, making it easy to remove. To remove your part from the build plate, gently bend the build plate, and your print should pop off.
Do not use a metal scraper tool! The cold plate is easily damaged by sharp metal edges. If necessary, use a plastic scraper instead.
7. Post-processing your part
Arguably the most boring part of 3D printing. Break off supports, peel off brims. Tidy up the print with a knife and/or sandpaper. 3D printed parts are well suited for painting.
8. Tidy up after you
Dispose of supports and other leftover parts of your print in the designated bin. Replace all tools to their proper home. Clean the build plate with lukewarm water if necessary and replace it in the printer.
Filament
Though the Prusa Core One was desinged with printing engineering materials in mind, we only permit user to print PLA filaments from Polymaker. This is to increase uptime and reduce user error from occurring due to mismatches in filament. The Prusa printers only support 1.75mm diameter filament.
Errors
If a print goes wrong, proceed accordingly:
- Check setup in PrusaSlicer and on the printer.
- Rewash the bed level.
- Calibrate the printer.
If this does not help, please notify the engineer here.
Clog
Clogging of the nozzle typically occurs when the workpiece has tilted due to overhang, wrong settings in PrusaSlicer, or wrong filament type. A solution to clogged nozzle is using the Atomic Method.