In this report I
will talk about the building process a Prusa i3 MK3S+ 3D printer and
calibrating it for ideal print quality.
The kit is contained in a single box, this includes an instruction manual and
one spool (1 Kg) of PLA filament. Following the instruction manual on how to
build the printer is extremely straight forward, the components need for each
step are labeled in their own bags (x-axis, y-axis, z-axis, extruder...). After
building and wiring everything up selecting the correct print bed is extremely
important, this was learned by multiple failed print attempts. The standard
heat bed is a slightly textured steel sheet. This worked well for small prints
that took very little time, but if the object took longer than an hour or was
tall in the z-axis the piece would come dislodged from the print surface. Using
a glue stick to help keep the print fixed to the bed helped a little bit but
still did not give enough adhesion for the print to finish without missing up.
When the printer is initially turned on you are greeted with a setup process,
this helps with calibrating the z-axis, and home position for the extruder
head. Using the built in "z" calibration the extruder nozzle is
supposed to be automatically set 0.2 mm away from the print surface, this is
the ideal distance for printing. After measuring the "bottom layer
test print" the filament was outputting at a higher layer height
(0.43 mm). This was fixed by using the "live z adjustment feature."
As seen in this image, three attempts were made using the textured steel bed
with a layer height of 0.2 mm but none of them completed.
After the failed attempts the bed surface was changed from the steel sheet to a steel sheet lined with PEI. This bed had a smooth texture. On initial impressions this bed was going to give less adhesion to the filament, but it worked much better. After calibrating the extruder due to the change in print bed height and applying a layer of purple glue using an Elmer’s glue stick, the same print file was tested. This worked on the first try.
The reason this
file was chosen was because it is the standard 3D printer quality test. It has
multiple features which are hard for additive 3D printers: overhangs, gradual
slopes over multiple layers, layer delamination, webbing caused by the printer
moving to different areas to print (starting/stopping filament extrusion), and
infill settings. The Prusa did exceptionally well, it had no issues except for
some small webbing spots that could be cleaned later.