3d Printing Introduction

3D PRINTING
Julia can make solid, three dimensional simple and complicated things- from toys to
bearings, machine parts, replacements for broken parts, casings, models and a variety of other
things. Julia helps turn concepts and ideas into physical prototypes saving time, reducing costs and
shortening product development life cycles. Printing solid 3-dimensional things is an additive
process which involves taking a digital file, slicing it into layers and depositing molten material
layer by layer with the help of a 3-axis manipulator.
SAFETY
Electric Shock Hazard: Never open the access panel when the printer is powered on. Before
removing electronics case cover always power down the printer, completely turn off and unplug
the power supply and allow the power supply to discharge for at least one minute.
Burn Hazard: Never touch the extruder nozzle or heater block without first turning off the hot
end and allowing it to completely cool down. The hot end can take up to twenty minutes to
completely cool. Also, never touch recently extruded plastic. The plastic can stick to your skin and
cause burns. Beware of the heated bed which can reach high temperatures capable of causing
burns.
Fire Hazard: Never place flammable materials or liquids on or near the printer when powered or
in operation.
Pinch Hazard: When the printer is in operation take care never to put your fingers in the moving
parts including the belts, pulleys, or gears. Also, tie back long hair or clothing that can get caught
in the moving parts of the printer.
Static Charge: Make sure to ground yourself before touching the printer, especially the
electronics. Electrostatic charge can damage electronic components. To ground yourself touch a
grounded source.
Age Warning: For users under the age of 18, adult supervision is recommended. Beware of
choking hazards.
Design Thinking and Product Innovation Laboratory

TECHNICAL SPECIFICATIONS
Print Technology : Fused Filament Fabrication
Build Volume : 210x250x260 mm3
Layer Resolution : 317 microns to 127 microns
Dimensional Accuracy : XY:- 50-100 microns, Z:- 20-50 microns
Filament Diameter : 1.75mm
Nozzle Diameter : 0.3mm – 0.8mm
Filament Compatibility : ABS, PLA, NYLON, PHA, WoodFill, Bronzefill,
Carbon Fiber, NinjaFlex, XT-Copolymer
SOFTWARE
Software Bundle : Fracktory
File types : .stl, .obj
Supports : Windows (32 bit XP/ 7+)
PHYSICAL DIMENSIONS
Without Spool : 46.8L x 49.7W x 42H cm3
Shipping box : 58L x 58W x 42H cm3
Weight : 22.5kg
Shipping weight : 32kg
TEMPERATURE
Ambient operating temperature : 22O – 32OC (70O – 90OF)
Storage Temperature : 0O – 32OC (32O – 90OF)
ELECTRICAL
AC input : 220V, ~5 amps, 50Hz
Power Requirements : 265W
Connectivity : USB, SD Card
MECHANICAL
Chassis : Sheet metal
Build Platform : Aluminium
XYZ bearing : Re-circulating ball bearings

COMPONENTS OF 3D PRINTER
1. Filament (ABS/PLA)
2. PET tapes
3. Build Plate
4. SD card reader
5. Print Adhesive
6. Squeegee
7. SD card
8. PTFE tube
9. Nipper
10. Spatula
11. Spool Holder
12. Nozzle Cleaning Apparatus
13. Tweezer
14. Allen keys
15. Power Cable
16. USB Cable
17. User Manual
18. Lubrication Spray
Figure 1: List of Components

SETTING UP OF PRINTER
 Connect the power cable to the port on the back side of the printer as shown in Figure 2.
 Switch on the main supply and press the red switch above the power port as shown in Figure 3.
 The screen on Julia V2 lights up to display “Julia ready” as shown in Figure 4.
Figure 2 Figure 3
Figure 4
 After turning on power supply for Fracktal works Julia V2, the LCD screen should activate.
BUILD PLATE PREPERATION:
 Apply pet tape on the build plate as follows, ensuring that no bubbles are formed. (This process
is similar to applying a screen guard on a touch screen.)
 Peel and remove the transparent sheet from the green coloured PET tape as shown in figure 5.
 Spray some soap water on the build plate before applying PET Tape for easier application.
Figure 5 Figure 6

 Apply the green PET tape on the build plate. Remove air bubbles with the help of squeegee as
shown in figure 6.
 Apply a thin layer of Adhesive on the PET tape as shown in figure 7.
 Now mount the build plate onto the Z-axis carriage. Keeping the handle facing the outer side,
align the 4 holes on the corners of the build plate with the 4 protrusions on the Z-axis carriage as
shown in figure 8.
Figure 7 Figure 8
FILAMENT LOADING
After you have connected the power cable, the LCD will display “Julia is ready”, along with the
other parameters of the printer such as bed temperature, and so on as shown in figure 4. For the
levelling and first print for testing and also to print an object anytime, performing the following
procedure is mandatory.
 Press the Dial, and rotate it to navigate to “PREPARE” as shown in figure 9.
 Under “PREPARE”, navigate to “Nozzle” as shown in figure 10.
 Set the temperature according to the filament used by rotating the navigate button as shown
in figure 11.
 Insert the spool holder in the socket provided on the Left side wall of Julia V2 as shown in
figure 12.
Figure 9 Figure 10
Figure 11 Figure 12

LOADING FILAMENT
 Load the spool provided onto the spool holder and unwinding of the filament must be done
from the bottom of the spool as shown in figure 13.
 Cut and remove a small part of the filament at an angle from the spool to ensure that the
filament end is sharp and even. This is shown in figure 14.
 Push the filament through the bottom of the Filament Sensor as shown in figure 15.
 Push the filament till it comes out of the other side of the PTFE tube. Make sure around 7 to
8cm of filament comes out of the PTFE as shown in figure 16.
 Put the filament through the pneumatic connector, extruder gear and all the way in to the PTFE
tube which is connected to the hot end till some filament extrudes from the nozzle as shown in
figure 17.
 Insert the PTFE tube to the pneumatic connector as shown in figure 18.
Figure 13 Figure 14
Figure 15 Figure 16
Note: In order to remove the PTFE tube, press the blue ring on top of the extruder as shown
in figure 18 and gently pull it out.

Figure 17 Figure 18
LEVELLING THE BED
Julia V2 has gone through the process of levelling at the Fracktal Works factory. However, we
cannot guarantee small changes that it might have suffered in the transportation and unboxing
process.
If the extruder nozzle is too far from the build platform, or if all parts of the build plate are not at
the same distance from the nozzle, then the builds will not attach properly on the plate. If the
extruder nozzle is too close to the build platform, then the filament might get prevented from being
extruded from the nozzle and scratches might occur on the build plate.
Levelling the build plate ensures that the objects you print adhere well to the build plate to give
you a hassle-free smooth experience.
THE PROCESS OF LEVELLING AND TESTING
Note: Make sure there no plastic sticking out of the nozzle. It is recommended to heat and the
nozzle and remove any excess plastic using supplied tweezers before continuing. You will also
need a sheet of A4 printing paper (or equivalent) to complete this step
1. Press Dial and navigate to Prepare=>Levelling Wizard
2. You will be introduced to Bed levelling wizard on display. The machine will perform
homing and moving to first levelling position, wait for the machine to stop moving
completely before pressing the Dial.
3. Place a sheet of A4 printing paper underneath the nozzle and turn the Dial anticlockwise
while sliding the paper under the nozzle until the nozzle touches the paper and you just
begin to feel slight a friction. You may turn the dial clockwise to move the nozzle away
from the bed if required. Press Dial when you are satisfied.
4. Next a screen will intimate that you will need to change Levelling Nuts, which are located
on the underside of the Bed. Press Dial to acknowledge and the Carriage will move to the
first levelling point.
5. With paper under nozzle again, Screw/Unscrew the Left Front Levelling Nut sliding paper
underneath nozzle until you feel a slight friction. Press Dial after you are satisfied.

6. The Carriage will then move to the next levelling point. Repeat the last step again for the
Left Back Levelling Nut and then Press the Dial.
7. The Screen will now intimate to set the final height. Click to acknowledge, and the machine
will perform homing, and will move to the centre.
8. Once the carriage is at the centre, rotate the Dial anticlockwise while sliding the paper
under nozzle until you can start to feel a little friction. Click to acknowledge that you are
done. You are done finished with Bed Levelling.
9. If you move the Machine, if your prints are not getting stuck evenly, perform bed levelling
again.
10. To validate whether the height is calibrated properly you can print out the “calibration
square” model on the SD card, or can be downloaded from our website.
11. Next, select “Print from SD card”.
12. The LCD next displays the list of files stored on the SD Card. Scroll down and select
“calibration square”.
13. The calibration square takes only a few minutes to print. We have shown in images what a
perfect calibration square should look like.
14. If it still having issues then you can change offset manually. If the nozzle is too close to
the bed then reduce the offset. If the nozzle is too far away from the bed then increase the
offset. An increment/decrement of 0.2 should be used.
Figure 19

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3D PRINTING

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

Figure 1: List of Components

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

Design Thinking and Product Innovation Laboratory

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