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
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:
Fig. A
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
1
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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)
2
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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
3
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
4) firing
height
=
3mm
2.5x 5) firing
height
=
4mm
2.5x
mag 6) firing
height
=
5mm
2.5x
mag
mag
7) firing
height
=
6mm
2.5x 8) firing
height
=
7mm
2.5x
mag 9) firing
height
=
8mm
2.5x
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
4
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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
5) firing height = 1mm 1x mag 6) firing height = 1mm 8x mag
5
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
7) firing height = 1.5mm 1x mag 8) firing height = 1.5mm 8x mag
9) firing height = 2mm 1x mag 10) firing height = 2mm 8x mag
11) firing height = 2.5mm 1x mag 12) firing height = 2.5mm 8x mag
6
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
13) firing height = 3mm 1x mag 14) firing height = 3mm 8x mag
15) firing height = 3.5mm 1x mag 16) firing height = 3.5mm 8x mag
17) firing height = 4mm 1x mag 18) firing height = 4mm 8x mag
7
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
19) firing height = 4.5mm 1x mag 20) firing height = 4.5mm 8x mag
21) firing height = 5mm 1x mag 22) firing height = 5mm 8x mag
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.
8
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
align2_test.gcode/Sample 02/8-17-2014
1) firing height = 17mm 1x mag 2) firing height = 17mm 8x mag
3) firing height = 37mm 1x mag 4) firing height = 37mm 8x mag
5) firing height = 57mm 1x mag 6) firing height = 57mm 8x mag
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
9
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
Height_test.gcode/Sample
01/8-17-2014
control
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
10
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
placement
accuracy:
maximum
112.87µm
(27.53px)
deviation
from
mean
center
placement
accuracy:
maximum
177.53µm
(43.3px)
deviation
from
mean
center
Fig. C
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.
11
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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.
B spacing (--hp = 1, --vp = 1) C spacing (--hp = 2, --vp = 1) D spacing (--hp = 2, --vp = 2)
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)
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.
13
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
#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
14
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
15
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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.
16
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
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
17
Open
Source
Possibilities
for
Inkjet
3D
Printing:
HP
C6602
Characterization
and
Application
Harrison
tyler
2%
Calcium
Chloride
2%
Manucol
Alginate
federate:
1000mm/min
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.
18
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Fig. E
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
federate:
1000mm/min
20 layers
19
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2%
Calcium
Chloride
2%
Manucol
Alginate
federate:
1000mm/min
20 layers
20 layers
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.
200 layers
200 layers
20
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200 layers
200 layers
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.
20 layers
B spacing 1.6xmag
21
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200 layers
1. before
bath
2. after
a
10%
Calcium
Chloride
curing
bath
200 layers
1. before
bath
2. after
a
10%
Calcium
Chloride
curing
bath
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.
22
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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
23
Open
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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.
24
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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.
25
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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.
Patch the INKSHIELD 1 ABCD pins and (9-‐12v) pins to the corresponding INKSHEILD 2, see below for visual diagram:
26
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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
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.
27
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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.
%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
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.
28
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Note options: -h ,–o, –s, –n, –a, –f, –r, –g, –b, -k
7.
%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
See results in the python pane and open new file to view
gcode:
6.
29
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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,
30
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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
31
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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
32
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carriage
adaptor
schematic
33
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2
cartridge
roller
assembly
for
alginate
layer
compression
34
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2
cartridge
carriage
adaptor
and
roller
assembly
schematic
35
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2
cartridge
carriage
adaptor
and
roller
assembly
schematic
36
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3
cartridge
carriage
adaptor
and
roller
assembly
schematic
37
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Petri
dish
mount
Adaptor
clamp
for
38mm
x
80mm
glass
slide
38
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39
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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
40
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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
41
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C10
fume
hood
C11
Auto
pipette
C12
various
pipettes
C14
vortex
mixer
C15
various
glassware
C13
various
bottles
C16
Centrifuge
42