Open Source Possibilities For Inkjet 3D Printing Advanced Manufacturing Research Institute, Rice University Harrison Tyler 2014

Open
Source Possibilities for Inkjet 3D Printing

Advanced Manufacturing Research Institute, Rice University
Harrison Tyler 2014
Abstract
The use of Inkjet technology for 2D and 3D printing is seen widely in higher-‐end or proprietary
printers, these processes are renowned for their accuracy, for the complex geometries possible, and
for efficient print times. Additionally, multi-‐material printing with minimal cross contamination is
possible through contact-‐free inkjet and polyjet printing. This technology is a potentially huge asset
for the bio and DIY-‐bio communities, open source research and hardware development communities,
and artists; unfortunately the high prices and closed-‐source hardware, software, and materials of
these existing inkjet 3d printing platforms make this technology inaccessible for open-‐source
research applications and stifles non-‐market driven development. The development of an open
source inkjet printing platform and workflow could help to not only make the benefits of inkjet
deposition available to more fields of research, but to also fuel development and bring down the cost
of inkjet technology as has been seen in the proliferation of other open source 3d printing projects.
Introduction
This work completed during the 2014 session of AMRI involves the development and testing of
hardware and materials for an open source inkjet based 3d printing platform. The focus of this
documentation is to discover and characterize material compatibility of printing mediums with
the HPc6602 thermal inkjet cartridge for both 2d and 3d printing operations. This project is
based around the parameters of an existing workflow designed by Steve Kelly during AMRI 2013,
utilizing a Prusa i3 3d printer, N.C.Lewis’s Inksheild, and HPc6602 ink cartridges.
A primary goal of this project is to successfully demonstrate 3d printing using an open source inkjet
printing platform and workflow. This includes materials research, testing, and categorizing of print
mediums, modifications to the hardware, and to the workflow to suit 3D printing of variable
materials. This is to provide foundations for a more affordable and open platform that takes
advantage of the many benefits of inkjet printing.
The main parameters of this project are that 1. It is limited to using the HP C6602 thermal inkjet
cartridge and 2. That it is controlled by openr source hardware and firmware. As an introductory
study into an open source workflow for inkjet fabrication I will focus on the characterization of the
2d printing parameters of the HP c6602, using HP ink as the control print medium, and on
fabrication possibilities for the 3d printing of calcium alginate hydrogels. While this work makes up
the bulk of
the collected information, I also document some initial experiments involving the inkjet printing of
UV curable resins and PEG-‐DA.
The HPc6602 thermal inkjet cartridge has several features that distinguish it from those used on
commercial inkjet and polyjet 3d printers and deposition systems. The 96dpi HP c6602 has only 12
nozzles; this allows its compatibility with the Inksheild and the interface with an ArduinoMega. As
Inkjet technology has improved, much higher resolutions of 300, 600, and 1200dpi are more
common. Typically in commercial inkjet heads utilized for 3d printing by Objet, Nordson EFD, Xaar,
Epson, etc. piezoelectric inkjet technology is favored over thermal inkjets, as thermal inkjet uses
intense heat to fire a small volume of the printing medium which can be less forgiving to the print
medium and also shorten the life of the nozzle. The relatively simple design of the HP C6602 is what
has allowed for a more straightforward reverse engineering, and the subsequent development of an
Arduino compatible workflow, but also the parameters of thermal (as opposed to piezoelectric)
Inkjet technology will determine and limit material compatibility.
Thank you to the following for helping to make this project possible:
Jordan Miller, Millerlab

Johnny and Britt, Ultimachine
Ultimaker
Steve Kelly
Josh Ellis, Makerjuice
Nicholas C. Lewis
Nick Parker
Bagrat Gregorian
Anderson Ta
Open Source Possibilities for Inkjet 3D Printing:
HP C6602 Characterization and Application
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HP C6602a cartridge & HP ink

Images captured on ZEISS Discovery.V8 stereo microscope
Fig. A
Lets look at the cartridge itself:
1.
HP c6602 nozzles @ 1x mag
2.
HP c6602 nozzles @ 3.2x mag
figure a2. provides a clear view of the spread of the 12 nozzles. This is important to note for
reference in image_to_gcode.py that calls for “spread” as a variable. The spread of the
HPc6602 = 3.175mm
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3.
HP c6602 nozzles @ 8x mag
Figure a3. shows the nozzle size. Note: the actual apertures are the small openings within the larger circles. The
approximate aperture of each inkjet nozzle is ≈ 60µm. This measurement becomes important for many factors
including: estimating droplet volume, determining particle size in the making of printing mediums, quantifying
droplet expansion as it hits paper, etc.
The following documentation of inkjet printing at incrementally variable heights references two situations of default
nozzle height, each describing a different home Z height called “Z=0mm”. Looking at the figure below: Nozzle Z=0mm
describes the situation where a height of “0mm” means that the paper placement is ≈0.1mm below the actual inkjet
nozzle assembly. This can function as the absolute zero distance possible for inkjet printing. Carriage Z=0mm
describes the situation where a height of “0mm” means that the paper placement is ≈0.1mm below the carriage
assembly. This functions as the default Z=0 position when using the standard HP carriage which does not allow for
any closer distance when printing on a flat surface. (for full size images see the reference image folder)
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Samples referencing Nozzle Z=0mm Height_test.gcode/Sample 05/8-‐17-‐2014
Samples referencing Carriage Z=0mm Height_test.gcode/Sample 01/8-‐17-‐2014

Height_test.gcode/Sample 02/8-‐17-‐2014
Align2_test.gcode/Sample 01/8-‐17-‐2014
Align2_test.gcode/Sample 02/8-‐17-‐2014
A character is printed via inkjet at increasing Z-‐heights running Steve Kelly’s height_test.gcode; 0mm-‐9mm at 1mm
increments @ “0mm” = Carriage Z=0mm
Goal of testing is to observe droplet shape, droplet overspray, and droplet placement
Height_test.gcode/Sample 01/8-17-2014
1) firing height = 0mm 2.5x 2) firing height = 1mm 2.5x mag 3) firing height = 2mm 2.5x mag
mag
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mag
mag
10) firing height = 9mm 2.5x 11) firing height = 0mm 8x mag 12) firing height = 1mm 8x mag
mag
A grid of droplets is printed via inkjet at increasing Z-‐heights
0mm-‐5mm at 0.5 mm increments @ “0mm” = Carriage Z=0mm
Goal of testing is to observe droplet shape, droplet overspray, droplet placement, and grid alignment
Alignment Test and droplet placement at varying and exaggerated firing heights
*note the offset of the two cartridges, causing the misalignment of the checkered pattern. While this is an
imperfection caused by misalignment of the inkjet carriages, this offset gives insight into how nozzle-‐to-‐paper
distances not only affect overspray but also exaggerates jetting angle
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align2_test.gcode/Sample 01/8-17-2014
1) firing height = 0mm 1x mag 2) firing height = 0mm 8x mag
3) firing height = 0.5mm 1x mag 4) firing height = 0.5mm 8x mag
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A grid of droplets is printed via inkjet at increasing Z-‐heights;
17mm-‐57mm at 20mm increments @ “0mm” = Carriage Z=0mm
Goal of testing is to observe abstracted droplet shape, droplet overspray, droplet placement, and grid alignment as
inkjets fire at high range.
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align2_test.gcode/Sample 02/8-17-2014
Carriage Z=0mm v.s. Nozzle Z=0mm
When looking at a print from the Z = 0mm height from each of the different home position tests, a difference in the
quality of droplet shape, placement, and overspray control can be seen
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Height_test.gcode/Sample
01/8-17-2014
control
1) Carriage Z = 0mm 2.5x mag 1i) Nozzle Z = 0mm 8x mag

Height_test.gcode/Sample
05/8-17-2014
At a true nozzle height of ≈0.1mm

from paper, droplet placement
and circularity are more accurate.
3) Nozzle Z = 0mm 2.5x mag 3i) Nozzle Z = 0mm 8x mag
Working towards a solid layer:
Deviation of point placement:
Carriage Z=0mm, 2.5mag: 1px = 4.1µm
10417px total droplet area
1 pass 2.5x mag

area/2= 8228.5px
10417px-‐8228.5px=2188.5px overlap
2188.5/10417= 0.21009
21% overlap
placement accuracy:
maximum 30.26µm (7.38px) deviation from mean center
2 passes 2.5x mag
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area/5=4992px
10417px-‐4992px=5425px overlap
5425/10417=0.52078
52.1% overlap
placement accuracy:
5 passes 2.5x mag

area/25=px
10417px-‐2610.88px=7806.12px overlap
7806.12/10417=0.74936
74.9% overlap
placement accuracy:
25 passes 2.5x mag

Mean Deviation from mean center = 106.89µm (26.07px)
Fig. C
Dithering and layer offset
Initial attempt to generate 100% layer Second attempt to generate 100% layer
infill, via printing 4 layers with identical infill, via printing 4 layers with drop
drop placement. Solid infill unsuccessful placement offset in each layer to fill in
remaining white space. Solid infill
successful. This sketch will be used to
modify the image_to_gcode script to
simulate dithering.
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I worked with Nick Parker to modify Steve Kelly’s image_to_gcode script to add variables “hp” and “vp” which will
create dithering by adding variable sub-‐pixel passes in the X and Y directions. See the reference folder for the
image_to_gcode_dithermod folder.
diagram of dithering in image_to_gcode
B spacing (--hp = 1, --vp = 1) C spacing (--hp = 2, --vp = 1) D spacing (--hp = 2, --vp = 2)
Inkjet Application 1:
Manufacturing of Calcium Alginate Microspheres via Inkjet Deposition:
Material deposition via inkjet printing has many applications involving the controlled deposition of material. With a
consistent nozzle size and a consistent droplet size (relative to each material) ink jetting material can allow for very
precise control of placement and also for precise control and measurement of volume jetted. The application of inkjet
printing for the manufacturing of alginate microspheres is especially valuable for making a consistent and measurable
subject. The bead size, quantity, and surface area of alginate microspheres can be estimated and measured accurately,
as well as providing a consistent bead diameter of ≈ 80µm.
The protocol for printing via inkjet uses an image to gcode script written by Steve Kelly in which each pixel of a
bitmap image translates to 1 inkjet nozzle firing. This allows for a basic control over the frequency and positioning of
each nozzle firing, this also allows for the total quantity and volume of ejected droplets to be accurately estimated. e.g.
(below)
In a 120px*120px rectangle, 14400 droplets will

be jetted.
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The Above 14400 pixel bitmap is used as the input image for the Image To Gcode script. The output .Gcode file is then
repeated x times within the Gcode text file to yield an estimated 1.7 million Calcium Alginate Microspheres per hour.
Different alginate mixes and concentrations of CaCl solution are tested to find a compatible and reproducible
combination that produces discrete and consistently sized calcium alginate microspheres.
Available Mixtures:
2% Manucol Alginate Jetted consistently with repeatable results, prone to drying in nozzle forming a clog.
4% Manucol Alginate Jetted consistently with repeatable results, prone to drying in nozzle forming a clog.
6% Manucol Alginate Jetted less consistently but with repeatable results, prone to drying in nozzle
forming a clog. Mixture performed similarly to 4% when heated to 60˚C
8% Manucol Alginate Difficulty Jetting, with inconsistent results, prone to drying in nozzle forming a clog.
Mixture performed similarly to 6% when heated to 60˚C
16% Manucol Alginate Mixture was too thick to pour at room temperature, did not attempt to inkjet.
#01 5x mag 2% Manucol in The alginate remained

2% CaCl Solution floating on the surface on
the CaCl, and formed a
purge in place; 2hr continuous Calcium
Alginate film, individual
droplets were
indistinguishable
#02 8x mag 2% Manucol in

2% CaCl Solution
120px grid; 30min
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#03 8x mag 4% Manucol in

2% CaCl Solution
120px grid; 4hr
#04 8x mag 4% Manucol in This is the most successful
0.2% CaCl Solution and repeatable relationship
between alginate and CaCl
120px grid; 1hr concentration. *Need to
separate spheres fully,
either through sonicating
post print, or printing in a
more dispersed grid
Evidence of wear on the cartridge nozzles and contacts
-‐Nozzles are clogged by dried alginate.
(Note the translucent cloudy blockage in the

middle nozzle)
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-‐The contacts, one for each nozzle and one

ground, are made of thin foil surface mounted to
the silicon pad. These can easily scrape off by the
repeated changing and refilling of cartridges.
Each time the cartridge is clamped into its
carriage, wear occurs.
-‐Tris EDTA (used as cleaner to unlink any
Calcium Alginate cured in the nozzle) appeared
to accelerate the deterioration of the contacts or
their mounting adhesive.
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3D printing of Calcium Alginate
This method for the 3d printing of calcium alginate hydrogel differs from existing examples as this method functions
not by full submersion of alginate into a fixed CaCl2 substrate, or by application of CaCl2 into a fixed alginate substrate,
but by the simultaneous deposition of Alginate and CaCl2 solution.
The 3D printing of a solid and dimensionally accurate Calcium alginate form requires the precise joining of individual
droplets. This is different from the making of Calcium Alginate microspheres, a process of depositing isolated and
distinct alginate droplets. 3D printing via inkjet deposition uses two inkjet heads to deposit a 2D layer of Calcium
Alginate Hydrogel, stacking these layers to build 3D form. The generating of solid-‐infill via inkjet deposition requires
finding an effective relationship between the concentrations of the Calcium Solution and Alginate and print speed.
This experiment attempts to find on a usable range of concentrations of Alginate and Calcium solution for the building
of layers with solid infill.
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Initial attempt/Base point

As a beginning point, I follow the concentrations used in the alginate microspheres experiments in which I observed
sheets of Calcium alginate forming on the surface, rather than droplets. I use a 2% solution of Calcium Chloride and
2% mix of Manucol Alginate. The procedure for printing uses Steve Kelly’s image_to_gcode script to output gcode for a
24px square using the “red” and “green” cartridges to represent Calcium solution and Alginate respectively. The
output .gcode file prints a 6mm square with one layer of Calcium solution followed by one layer of Alginate. This
.gcode is sent repeatedly to form each layer of the 3d print.
Fig. D
Initial attempts at 3d printing calcium alginate hydrogel
2% Calcium Chloride
2% Manucol Alginate
federate: 1000mm/min
400 layers
1 2
B spacing
side view top view
(--hp = 1, --vp = 1)
3 4
top view top view
5 6
top view top view
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2% Calcium Chloride
2% Manucol Alginate
700 layers
7 8
side view top view D spacing
(--hp = 1, --vp = 1)
Figures D1-‐6 provide very revealing information about the placement of droplets, layer height, rate of cross linking,
and effect of dithering. The print very clearly demonstrates the un-‐dithered “b spacing” by instead of forming a solid
“cube” individual columns 1 droplet wide were formed. D2-‐3 show top views of the print, individual droplets can be
seen from the top. The print after being washed in DI water, the individual columns began separating to reveal cross
sections and slices. D4 reveals columns (on their side) D5-‐6 shows an individual column that has separated from the
cluster. From this individual column the droplet width and layer can be inferred. A droplet width of 120µm and a layer
height of 5µm are estimated from measurements. D7-‐8 is printed with the same alginate and calcium concentrations
but with a fully dithered “D spacing” while individual droplets can no longer be seen and droplet blending appears to
have occurred, irregularly sized “sheets” have formed. This indicates incomplete bonding of layers and of individual
droplets. This could be because of too high of a Calcium solution causing droplets to fully crosslink before having time
to join with neighboring droplets and subsequent layers.
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Fig. E
Cross-‐linking of Alginate hydrogel
The above diagram illustrates the cross-‐linking of calcium alginate hydrogel at play during the 3d printing of the
hydrogel. The full cross-‐linking of alginate occurs over a duration of time determined by the concentration of calcium.
The more calcium present, the quicker and more fully the alginate will crosslink. With less concentrated mixtures of a
Calcium solution, a “gradient” will appear from more firmly cross-‐linked alginate towards the bottom of the print to
newly deposited and minimally cross-‐linked alginate towards the top. By varying the concentration of calcium
solution, the extent of bonding of deposited droplets and layers to each other can be controlled. The following
experiment is the beginning of finding effective concentrations of calcium for full joining of layers and columns.
2% Calcium Chloride
2% Manucol Alginate
20 layers
B spacing 1.6xmag B spacing 8xmag
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2% Calcium Chloride
2% Manucol Alginate
20 layers
C spacing 1.6xmag C spacing 8xmag

2% Calcium Chloride
2% Manucol Alginate
20 layers
D spacing 1.6xmag D spacing 8xmag
2% CaCl2 and 2% Alginate mixes yield results similar to my initial tests: in results testing spacing B,C,D droplet
adhesion is irregular and weak. A solid form is not created, but a spongy and flakey form.
0.5% Calcium Chloride

2% Manucol Alginate
200 layers
B spacing 1.6xmag B spacing 8xmag

2% Manucol Alginate
200 layers
C spacing 1.6xmag C spacing 8xmag
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2% Manucol Alginate
200 layers

2% Manucol Alginate
200 layers
with a 10% Calcium Chloride

curing bath
0.5% CaCl2 and 2% Alginate mixes yield very different results as droplet adhesion appears very full and layers are
very homogenous. Printing using B spacing still creates distinct and isolated columns, showing that accurate drop
placement and cross-‐linking is taking place. In C and D spacing, individual droplets are indistinguishable, instead a
solid form is observed. The initial print is very transparent, which might describe the extent of cross-‐linking being
very weak. When I wash the print in a bath of 10% CaCl2 , the form becomes opaque, the toolpaths become more
evident, but the object is still very much solid.
This test using D spacing was run at 300% federate which produced a very distorted puddle of partally crosslinked
alginate. This explains that the concentration of Calcium solution and the rate of cross-‐linking is proportional to the
federate. A faster federate would require faster cross-‐linking to support the more rapid stacking of layers.
8x detail indistinguishable 0.2% Calcium Chloride

2% Manucol Alginate
20 layers
B spacing 1.6xmag
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2% Manucol Alginate
200 layers
1. before bath
2. after a 10% Calcium Chloride
curing bath
C spacing 1.6xmag C spacing w/bath 1.6xmag

2% Manucol Alginate
200 layers
1. before bath
2. after a 10% Calcium Chloride
curing bath
D spacing 1.6xmag D spacing w/bath 1.6xmag
0.2% CaCl2 and 2% Alginate mixes yield results similar in appearance to a 0.5% calcium solution. droplet adhesion
appears very full and layers are very homogenous. However cross-‐linking appears too weak as toolpaths are
indistinguishable after a 10% bath, and the square is less geometrically accurate. Printing using B spacing no longer
displays distinct and isolated columns, but homogenous solid layer. This could mean that accuracy of droplet
placement is less than when using a 0.5% or 2% CaCl2 solution.
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0.5% Calcium Chloride 2% Manucol Alginate federate: 1000mm/min

200 layers with a 10% Calcium Chloride curing bath
Measuring the exact height of 200 passes of Calcium + Alginate allows for the layer height to be much more accurately
determined.
Layer height = 4.415µm
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2d and 3d printing of polyethylene glycol diacrylate (PEG-DA) Hydrogel
This is a very preliminary compatibility test of PEG-‐DA with the HP C6602. The images below show the successful 2D
deposition of 3.4kda PEGDA 20% with 0.5% I2959 (photoinitiator). This opens up possibilities for 3d printing of uv
curable PEGDA.
notes: this preliminary testing involved the printing of PEGDA onto a glass slide. I attempted to crosslink the PEGDA
with a high powered UV light source but the PEGDA appeared to become dehydrated before cross linking was
possible. Additionally, the exposure of uv light onto the print can refract ambient uv light and cure PEGDA on the
nozzles of the inkjet, forming a clog. To prevent this I had the inkjet nozzles press into a wiper pad during exposure.
top view of 3.4KDA PEGDA 20% printed onto

glass slide
Side view of 3.4KDA PEGDA 20% printed onto

glass slide
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2d and 3d printing of uv curable resin
Several preliminary compatibility tests are run using a “purge” gcode that fires all nozzles as rapidly as possible. This
is to test the compatibility of different commercially available resins. I tested several pigmented and unfigmented
Madesolid resins, all of which were too viscous to be fired. I saw some successful results with majerjuice substance G
and G+ (unpigmented) which have a low enough viscosity to fire through the HP C6602. I built a heater for the HP
C6602 to heat the resins, lowering their viscosity, this improved firing of sub G+ but did not appear to affect subG. (see
the hardware section for details on heater assembly) While Makerjuice sub G and G+ fired and displayed accurate
droplet placement, the very small volumes of the droplets prevented curing via uv resin. Josh Ellis from makerjuice
made a custom resin with a similar viscosity to sub G and G+ but formulated for “surface curing” which could be
required to cure the small volumes of resin.
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Compatible Hardware, Firmware, Scripts, and Research Materials
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This research was conduced on a printing platform comprised of one Prusa i3 3D printer controlled by a RAMBo
board, two inksheilds, many HP C6602 ink cartridges, two HP Carriage Assemblies (HP Q2347A), and several custom
components outlined in the following pages.
I am beginning from and adding to the general workflow set up by Steve Kelly during AMRI 2014 for the integration of
inksheild with the open source and popular Marlin Firmware for 3d printing, this involves the connection of the
inksheilds to the RAMBo board and several modifications to marlin. See below for instructions on connecting the
Inkshield to RAMBo.
INKSHIELD 1 AUX IN

RAMBo Motor Extension MX1 VCC +5v D RAMBo SERIAL VCC
RAMBo VMOT AUX +12v +12v C RAMBo SERIAL GND
RAMBo VMOT AUX GND GND B RAMBo SERIAL RX0
RAMBo SERIAL TX1 PULSE A RAMBo SERIAL TX0

INKSHIELD 2 AUX IN

RAMBo Motor Extension MX2 VCC +5v D X
X +12v B X
X GND C X
RAMBo SERIAL RX1 PULSE A X

Patch the INKSHIELD 1 ABCD pins and (9-‐12v) pins to the corresponding INKSHEILD 2, see below for visual diagram:
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Marlin Integration:
See my Reference folder to download the version of Marlin used for this research: already configured for Inksheild,
RAMBo, and the Prusa i3.
Marlin firmware sourced from: https://github.com/sjkelly/Marlin
Steve Kelly specifies his modifications to Marlin to add Inkshield compatibility here:
https://github.com/sjkelly/Marlin/commit/c0dcb9d726e0e034a6c4905d767b1eea17674e17#diff-‐
1cb08de130a6ece2d1b5b9c37bcfef48R2136

Additions to the i3 requiring modification to Marlin:
Mechanical end stops are added to the i3 to allow for homing and accurate positioning over print surface. This
required editing Configuration.h by a. enabling and configuring end stop logic and b. the directions of the X and Y axis
are flipped from the configuration used by Steve. (Flipping the axis directions will require modification to the
image_to_gcode script)
a.
b.
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This is documentation of my first attempt running Steve Kelly’s
image_to_gcode.py for converting bitmap slices to gcode for
compatibility with marlin and the hpc6602 inkjet head.
To generate Gcode output from a bitmap input:
I am using a modified version of Steve Kelly’s Image_to_gcode

script “image_to_gcode_dithermod” which adds subpixel passes
(dithering) and also adjusts the gcode to compensate for the
flipped direction of the X and Y axis. This can be executed in
terminal or an editor such as Canopy
%run /Users/AMRI/Desktop/image_to_gcode- 2.
master/image_to_gcode.py -
o/Users/AMRI/Desktop/image_to_gcode-
master/tests/test01.txt
-hp 2 –vp 2
/Users/AMRI/Desktop/image_to_gcode-
master/tests/align2_test.bmp
Green = .py Script source (image_to_gcode.py)

Red = variables: -o output destination, -hp hozontal subpixel
passes, - vp vertical subpixel passes
Blue = input bitmap source (align2_test.bmp)
Expanded instructions follow:
I am running Mac OSX and had some initial trouble installing 3.

opencv and other modules needed for python to run this script.
See page-2 for a brief tutorial using Canopy to manage python
packages needed to run image_to_gcode.py
once the script opens, run the script. If all python packages are
Open image_to_gcode.py in the canopy editor installed properly, image_to_gcode.py should display options:
4.
1.
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Note options: -h ,–o, –s, –n, –a, –f, –r, –g, –b, -k
7.
Troubleshooting python package installation on Mac:
5. I used the Canopy Package Manager to download and install

opencv and termcolor packages:
To generate Gcode output from a bitmap input:
%run /Users/AMRI/Desktop/image_to_gcode-
master/image_to_gcode.py -
o/Users/AMRI/Desktop/image_to_gcode-
master/tests/test01.txt
-hp 2 –vp 2
/Users/AMRI/Desktop/image_to_gcode-
master/tests/align2_test.bmp
Green = .py Script source (image_to_gcode.py)

Red = variables: -o output destination, -hp hozontal subpixel
passes, - vp vertical subpixel passes
Blue = input bitmap source (align2_test.bmp)
See results in the python pane and open new file to view
gcode:
6.
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The standardized process for opening and draining an HP c6602 inkjet cartridge for all experiments
A1-6: The precision and control of cut on the mill is desired as to avoid cutting either the vertical tab in the front or
the clasp in the back which allow the cartridge to clip into its carriage. Other methods of removing the lid via razor,
saw, or dremel tool exist but were less precise or more dangerous for this procedure.
A new HP C6602 Inkjet Cartridge is clamped in the vice on a benchtop mini-‐mill, using a set of parallel bars to ensure
that the cartridge is held in square. Using a ¼” endmill at roughly 2500rpm position the bit to a cut depth
approximately 1.5mm into the lid. Proceed to mill away the lid while leaving the Tab and clasp intact. Adjust cut depth
until the beige sponge is revealed. Some cleanup with a razor may be necessary to clean burr from the cut plastic. See
the figures below for specific cut placement.
A1 A2 A3
A4 A5 A6

A7-11: Use tweezers to remove the sponge from the cartridge, be careful to not squeeze the sponge while removing as
most of the ink is suspended within it. When the sponge is almost free from the cartridge, while wearing gloves, gently
remove the sponge with your hand. Empty all remaining ink into an ink waste container; pour from cartridge and
squeeze thoroughly all remaining ink from sponge. Using warm tap water, flush the main cavity of the cartridge until
the water is clean. Empty, and repeat with DI water, making sure to wash nozzles. Fill cartridge with DI water and
place on a folder paper towel. This will wick all remaining ink from the cartridge, once no more ink flows from nozzle,
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the cartridge is ready to dry and fill. Wash the sponge thoroughly with warm tap water until clean, then do a final and
saturating wash with DI water, squeeze and let dry.
A7 A8 A9

A10 A11

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HP c6602 mounting assembly
(x2) Hp c6602
(x2) HP Carriage Assembly (HP Q2347A)
(x1) 3d printed Carriage adaptor to mount the inkjet system on a prusa i3 or Jimmi/beta carriage.
(x8) M2.5 x 6mm screws
(x2) M3 x 14mm screws

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carriage adaptor schematic

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2 cartridge roller assembly for alginate layer compression

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2 cartridge carriage adaptor and roller assembly schematic

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Hardware as configured for all Alginate printing

Petri dish mount Adaptor clamp for 38mm x 80mm glass slide
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Schematics for Custom printbed adaptor
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UV curable Resin hardware
Figures B1-9 Outline the assembly and use of a custom heater designed for heating the HP C6602 ink cartridge
reservoir to 60˚C to lower the viscosity of uv-‐curable resins. The heater is constructed of 3 aluminum plates lined with
24” of insulated nichrome wire. The nichrome wire is wrapped around the aluminum plates and the two ends of the
wire connect to lengths of 22awg wire to connect to the hotend output mosfet of the RAMBo. Kapton tape is used to
hold the wire in place and to secure a 100k thermoster onto the aluminum. Once assembled, the heater is attached to
the HP C6602 cartridge with kapton tape. The heater and thermoster are connected to the RAMBo ports: Heat 0 and
T0 respectively. The cartridge heater Is calibrated in Marlin firmware via PID Tuning, following the same procedure
for calibrating a typical hotend. All PID MAX values are adjusted to 100, max temp is set at 70˚C to prevent
overheating, damage to ink cartridge, or combustion of resin.
B1 B2 B3
B4 B5 B6
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B7 B8

Primary Hardware used to accomplish this research

C1 Prusa i3 3D printer C3 Zeiss Discovery Microscope
C2 Jimmi /beta 3D printer

C4 Autoclave C5 Sonicator Bath
C6 Omnicure Uv light source

C7 Mini-‐Mill
C8 Microscale C9 Milli-‐Q water filtration system
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C10 fume hood C11 Auto pipette C12 various pipettes

C14 vortex mixer C15 various glassware

C13 various bottles

C16 Centrifuge

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Open Source Possibilities For Inkjet 3D Printing Advanced Manufacturing Research Institute, Rice University Harrison Tyler 2014

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Source Possibilities for Inkjet 3D Printing

Jordan Miller, Millerlab

HP C6602a cartridge & HP ink

Lets look at the cartridge itself:

Samples referencing Nozzle Z=0mm Height_test.gcode/Sample 05/8-­‐17-­‐2014

Samples referencing Carriage Z=0mm Height_test.gcode/Sample 01/8-­‐17-­‐2014

Carriage Z=0mm v.s. Nozzle Z=0mm

1) Carriage Z = 0mm 2.5x mag 1i) Nozzle Z = 0mm 8x mag

At a true nozzle height of ≈0.1mm

3) Nozzle Z = 0mm 2.5x mag 3i) Nozzle Z = 0mm 8x mag

Working towards a solid layer:

Deviation of point placement:

Carriage Z=0mm, 2.5mag: 1px = 4.1µm

10417px total droplet area

1 pass 2.5x mag

24960px total droplet area

5 passes 2.5x mag

25 passes 2.5x mag

Dithering and layer offset

diagram of dithering in image_to_gcode

Inkjet Application 1:

Manufacturing of Calcium Alginate Microspheres via Inkjet Deposition:

In a 120px*120px rectangle, 14400 droplets will

#01 5x mag 2% Manucol in The alginate remained

#02 8x mag 2% Manucol in

120px grid; 30min

#03 8x mag 4% Manucol in

120px grid; 4hr

Evidence of wear on the cartridge nozzles and contacts

-­‐Nozzles are clogged by dried alginate.

(Note the translucent cloudy blockage in the

-­‐The contacts, one for each nozzle and one

Inkjet Application 1:

3D printing of Calcium Alginate

Initial attempt/Base point

Cross-­‐linking of Alginate hydrogel

B spacing 1.6xmag B spacing 8xmag

C spacing 1.6xmag C spacing 8xmag

D spacing 1.6xmag D spacing 8xmag

0.5% Calcium Chloride

B spacing 1.6xmag B spacing 8xmag

C spacing 1.6xmag C spacing 8xmag

0.5% Calcium Chloride

D spacing 1.6xmag D spacing 8xmag

with a 10% Calcium Chloride

D spacing 1.6xmag D spacing 8xmag

8x detail indistinguishable 0.2% Calcium Chloride

0.2% Calcium Chloride

C spacing 1.6xmag C spacing w/bath 1.6xmag

D spacing 1.6xmag D spacing w/bath 1.6xmag

0.5% Calcium Chloride 2% Manucol Alginate federate: 1000mm/min

Inkjet Application 3:

2d and 3d printing of polyethylene glycol diacrylate (PEG-­DA) Hydrogel

top view of 3.4KDA PEGDA 20% printed onto

Side view of 3.4KDA PEGDA 20% printed onto

Inkjet Application 4:

2d and 3d printing of uv curable resin

Samples referencing Nozzle Z=0mm Height_test.gcode/Sample 05/8-‐17-‐2014

Samples referencing Carriage Z=0mm Height_test.gcode/Sample 01/8-‐17-‐2014

-‐Nozzles are clogged by dried alginate.

-‐The contacts, one for each nozzle and one

Cross-‐linking of Alginate hydrogel

2d and 3d printing of polyethylene glycol diacrylate (PEG-DA) Hydrogel