Replicator 2 - advice

[optima]

Hello.
The company I work for has a Rep. 2 (Firmware Version 7.4) which has done 1001 hours printing.
The prints have become gradually worse, as expected from a machine which has had almost zero care.
I've been tasked with fixing whats necessary or replacing whats required.

Please see attached images.IMG_6434.jpgIMG_6435.jpg

The most recent two prints are shown in the foreground of the second image (20mm cube and test print)
I have gradually worked the Feedstockmultiplier rate down (from 0.93, in 0.05 increments, finally to 0.73) as described in the document below. This was in an effort to solve the underfeeding and gaps.

http://download.makerbot.com/replica...aintenance.pdf

As you can see it will print a 20mm block OK-ish but ask anything more complicated and the result is poor.

Any help greatly appreciated.

[Sebastian Finke]

You give scant information. Material? Slicer? Current feeds and speeds? Current temps?

Also, rafts? Why?

[optima]

Hi Sebastian,
I'm afraid my understand of the makerbot is limited so hope to glean as much information as possible.
Material: PLA

I have added rafts as the first layer was struggling to adhere to the bed.

Thanks in advance.

See below for exported profile.


{
"comment" : [
"This is a custom profile for MakerBot Slicer. Editing it will modify your",
"slice settings. For documentation on MakerBot Slicer parameters, see here:",
"http://www.makerbot.com/support/makerware/documentation/slicer"
],
"version":"2.2.0",

"layerHeightMinimum": 0.12,
"layerHeightMaximum": 0.27,


"layerHeight": 0.20,
"layerWidthMaximum": 0.4,
"layerWidthMinimum": 0.4,
"layerWidthRatio": 1.481481,
"bedZOffset": 0.0,
"startX": -110.4,
"startY": -74.0,
"startZ": 0.2,
"defaultExtruder": 0,


"rapidMoveFeedRateXY": 150,
"rapidMoveFeedRateZ": 23,


"minLayerDuration": 5.0,
"minSpeedMultiplier": 0.3,

"doDynamicSpeed": false,
"dynamicSpeedCurvatureThreshold": 15,
"dynamicSpeedDetectionWindow": 3.0,
"dynamicSpeedSlowdownRatio": 0.3,
"doDynamicSpeedGradually": true,
"dynamicSpeedTransitionWindow": 6.0,
"dynamicSpeedTransitionShape": 0.4,
"doDynamicSpeedOutermostShell" : true,
"doDynamicSpeedInteriorShells" : false,

"doSplitLongMoves": true,
"splitMinimumDistance": 0.4,


"extruderTemp0": 230,
"extruderTemp1": 230,
"platformTemp": 0,


"numberOfShells": 2,
"infillShellSpacingMultiplier": 0.7,
"insetDistanceMultiplier": 1.0,


"roofThickness": 0.8,
"roofLayerCount_disabled": 4,
"roofAnchorMargin": 0.4,
"floorThickness": 0.8,
"floorLayerCount_disabled": 4,


"coarseness": 0.0001,


"sparseInfillPattern": "hexagonal",
"infillDensity": 0.1,
"infillOrientationOffset": 0,
"infillOrientationInterval": 90,
"infillOrientationRange": 90,


"gridSpacingMultiplier": 0.99,
"solidFillOrientationOffset" : -45,
"solidFillOrientationInterval": 90,
"solidFillOrientationRange": 90,


"doBacklashCompensation": false,
"backlashEpsilon": 0.05,
"backlashFeedback": 0.9,
"backlashX": 0.0,
"backlashY": 0.09,


"doBridging": true,
"bridgeAnchorMinimumLength": 0.8,
"bridgeAnchorWidth": 0.8,
"bridgeMaximumLength": 80.0,
"bridgeSpacingMultiplier": 1.0,


"doExternalSpurs": true,
"doInternalSpurs": false,
"maxSpurWidth": 0.5,
"minSpurLength": 0.4,
"minSpurWidth": 0.12,
"spurOverlap": 0.001,


"doRaft": true,
"raftAligned": true,
"raftBaseAngle": 0,
"raftBaseDensity": 0.7,
"raftBaseLayers": 1,
"raftBaseRunGapRatio": 0.8,
"raftBaseRunLength": 15.0,
"raftBaseThickness": 0.3,
"raftBaseWidth": 2.5,
"raftInterfaceAngle": 45,
"raftInterfaceDensity": 0.3,
"raftInterfaceLayers": 1,
"raftInterfaceThickness": 0.27,
"raftInterfaceWidth": 0.4,
"raftModelSpacing": 0.21,
"raftOutset": 4,
"raftSurfaceAngle": 0,
"raftSurfaceLayers": 2,
"raftSurfaceThickness": 0.27,

"anchorWidth": 2.0,
"anchorExtrusionAmount": 5.0,
"anchorExtrusionSpeed": 2.0,


"doSupport": false,
"doSupportUnderBridges": false,
"supportAligned": true,
"supportLeakyConnections": true,
"supportDensity": 0.2,
"supportExtraDistance": 0.5,
"supportAngle": 68.0,
"supportModelSpacing": 0.4,
"supportExcessive": false,


"doFanCommand": true,
"fanLayer": 1,
"weightedFanCommand": -1,


"doPrintProgress": true,


"startGcode": "",
"endGcode": "",


"commentClose": "",
"commentOpen": ";",


"extruderProfiles": [
{
"bridgesExtrusionProfile": "bridges",
"feedDiameter": 1.70,
"feedstockMultiplier": 0.73,
"firstLayerExtrusionProfile": "firstlayer",
"firstLayerRaftExtrusionProfile": "firstlayerraft",
"infillsExtrusionProfile": "infill",
"insetsExtrusionProfile": "insets",
"nozzleDiameter": 0.4,
"outlinesExtrusionProfile": "outlines",
"raftBaseExtrusionProfile": "raftbase",
"restartExtraDistance": 0.0,
"retractDistance": 1.3,
"retractRate": 25
},
{
"bridgesExtrusionProfile": "bridges",
"feedDiameter": 1.70,
"feedstockMultiplier": 0.73,
"firstLayerExtrusionProfile": "firstlayer",
"firstLayerRaftExtrusionProfile": "firstlayerraft",
"infillsExtrusionProfile": "infill",
"insetsExtrusionProfile": "insets",
"nozzleDiameter": 0.4,
"outlinesExtrusionProfile": "outlines",
"raftBaseExtrusionProfile": "raftbase",
"restartExtraDistance": 0.0,
"retractDistance": 1.3,
"retractRate": 25
}
],
"extrusionProfiles": {
"bridges": {
"feedrate": 40,
"temperature_disabled": 230.0
},
"firstlayer": {
"feedrate": 30,
"temperature_disabled": 230.0
},
"firstlayerraft": {
"feedrate": 50,
"temperature_disabled": 230.0
},
"infill": {
"feedrate": 90,
"temperature_disabled": 230.0
},
"insets": {
"feedrate": 90,
"temperature_disabled": 230.0
},
"outlines": {
"feedrate": 40,
"temperature_disabled": 230.0
},
"raftbase": {
"feedrate": 10,
"temperature_disabled": 230.0
}
}
}

[iDig3Dprinting]

230 seems rather hot for pla

[LambdaFF]

for adherence, nothing like paper glue sticks.

[curious aardvark]

yep knock it down to 210, add gluestick and calibrate.
Probably a good idea to clean the rails as well.

[optima]

Thanks all, will give it a go and report back.

Thanks again.

[optima]

Morning all.

This mornings print.
Extruder 210°c and calibrated, rails cleaned.
Unfortunately no glue stick - need to get one.

IMG_6439.JPGIMG_6440.JPG

[iDig3Dprinting]

I am tempted to suggest, when looking at the images you posted first, especially the second one, that it looks like your settings have it overextruding (to compensate for the gaps) with the idea that underextrusion is the issue. This suggest that it may not be down to the feed rate but may in fact be due to some other issue like the extruder slipping, blocked nozzle or some other mechanical feature of the printer?? but obviously we don't know.

https://www.makerbot.com/support/new...s_in_My_Prints