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My current Railcore II printer

by Empiricus

This is a collection of parts I did during 6 months building and using a custom single and dual extruder Railcore II.
Please share your experiences.

My version is 5cm taller compared to the original proposed (https://railcore.github.io/) as I knew I would be creating print heads that need more space below the y axis. Thanks to Tony Akens and Steve White for coming up with the design that is superb and flexible.
Project R3D did custom side panels for me for a reasonable price.

Objective was to double standard print speeds and have a decent build volume which is currently 30x30x34cm.
These are the speeds I use right now (obviously depending on the model): PETG 60-80mm/sec, PLA 100-120mm/sec, ABS 60-80mm/sec.

I did a print head for the E3D Titan Aero extruder with a vulcano heat block with brass nozzle which I use most of the time and a
dual extrusion print head using the Bondtech BMG-X2 Extruder and E3D Chimera. Find the configs and S3D profiles below.

I use a Omron E2B-M12KN08-WP-C1 2M inductive probe for auto leveling with a 31x31cm Wham Bam flexible build surface. Initially used a 1mm PEI bed, but the Wham Bam surface is superb. The probe works much more reliably with the steel flex plate of the system.

The two 12mm Iverntech x-rails croacked after 5 months and I exchanged them for 15mm Mitsumi pre-tensioned rails. Fortunately, there is enough play in the AL motor mount and the opposite plate to accommodate for the increased height. Had to modify the Al y carriages to be able to mount on the larger rails.

Added a 12V LED strip for light and integrated a Duet3D laser filament sensor in the print head for the Titan Aero.

I replaced the rubber pads below the heated bed with springs from the Titan extruders and screws with locknuts. Gives about 4mm of play to avoid hard print head crashes into the print surface.

I use Super lube synthetic grease for lubrication.

Added a Duet3D IR laser filament sensor. I set it to 2-130% over 3mm now. Otherwise prints stop every few seconds-minutes. For me, PLA or PETG, it doesn't matter the range of movement detected varies dramatically. Anyway, the sensor already saved a few prints when filament entangled, ran out or slipped because I forgot to tension the extruder gear.

View Comment

Config single extruder, inductive probe and filament sensor

by Empiricus

; Configuration file for Empiricus Printer
; Communication and general
M111 S0 ; Debug off
M550 ; Machine name and Netbios name (can be anything you like)
;M551
; Machine password (used for FTP)
; If you have more than one Duet on your network, they must all have different MAC addresses, so change the last digits
M540 P0xBE:0xEF:0xDE:0xAD:0xFE:0xEE ; MAC Address
;
Wifi Networking
M552 S1 ; Enable WiFi
M555 P2 ; Set output to look like Marlin
M575 P1 B57600 S1 ; Comms parameters for PanelDue

G21 ; Work in millimetres
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

; Axis and motor configuration
M667 S1 ; CoreXY mode

M584 X0 Y1 Z5:6:7 E3:4:8:9 ; Map Z to drivers 5, 6, 7. Define unused drivers 3,4,8 and 9 as extruders
M569 P0 S0 ; Drive 0 goes forwards (change to S0 to reverse it) X stepper
M569 P1 S1 ; Drive 1 goes backwards Y Stepper
M569 P2 S0 ; Drive 2 goes forwards Unused
M569 P3 S0 ; Drive 3 goes forwards Extruder
M569 P4 S0 ; Drive 4 goes forwards Extruder (unused)
M569 P5 S0 ; Drive 5 goes backwards Front Left Z
M569 P6 S0 ; Drive 6 goes backwards Rear Left Z
M569 P7 S0 ; Drive 7 goes backwards Right Z

;Leadscrew locations
M671 X-10:-10:333 Y22.5:277.5:150 S7.5 ;Front left, Rear Left, Right S7.5 is the max correction - measure your own offsets, to the bolt for the yoke of each leadscrew

M350 X16 Y16 Z16 E16 I1 ; set 16x microstepping for axes& extruder, with interpolation
M574 X1 Y1 Z0 S1 ; set homing switch configuration (x,y at min, z at max) IF YOU NEED TO REVERSE YOUR HOMING SWITCHES CHANGE S1 to S0
M906 X1000 Y1000 Z1000 E700 I60 ; Set motor currents (mA)
M201 X3000 Y3000 Z20 E1000 ; Accelerations (mm/s^2)
M203 X24000 Y24000 Z900 E3600 ; Maximum speeds (mm/min)
M566 X100 Y100 Z30 E20 ; Maximum jerk speeds mm/minute
M208 X300 Y300 Z340 ; set axis maxima and high homing switch positions (adjust to suit your machine)
M208 X0 Y0 Z-0.5 S1 ; set axis minima and low homing switch positions (adjust to make X=0 and Y=0 the edges of the bed)
M92 X200 Y200 Z1600 E837 ; steps/mm, X/Y may be more around 201.5 for accuracy

; Thermistors
M305 P0 T100000 B4240 R4700 H0 L0 ; Put your own H and/or L values here to set the bed thermistor ADC correction
M305 P1 T100000 B4240 R4700 H0 L0 ; Put your own H and/or L values here to set the first nozzle thermistor ADC correction

M307 H0 A265.1 C864.1 D7.5 S1.00 V24.3 B0 ; Bed Heater
M307 H1 A594.0 C315.0 D4.3 S1.00 V24.3 B0 ;Heater 1 Vulcano copper
;M307 H1 A590.7 C197.0 D4.7 B0 S1.00 V24.3 B0 ;Heater E3D regular
M570 S360 ; Hot end may be a little slow to heat up so allow it 180 seconds
M143 S285

; Fans
M106 P0 H-1 ; disable thermostatic mode for fan 0
M106 P1 H-1 ; disable thermostatic mode for fan 1
M106 P2 H-1
M106 P3 H-1
M106 P4 H-1
M106 P0 S0 ; turn off fans
M106 P1 S0
M106 P2 S0
M106 P3 S0.5; Set fan 3 value for our LED to on.
M106 P4 S1; Set fan 4 value for Cooling to on.
; Tool definitions
M563 P0 D0 H1 ; Define tool 0
G10 P0 S0 R0 ; Set tool 0 operating and standby temperatures
;*** If you have a single-nozzle build, comment the next 2 lines
;M563 P1 D1 H2 ; Define tool 1
;G10 P1 S0 R0 X0 Y17 ; Set tool 1 operating and standby temperatures

;Filament sensor
M591 D0 P5 C3 R20:130 E3.0 S1 ; Duet3D laser sensor for extruder drive 0 is connected to endstop input 3 (E0), tolerance 40 to 120%, 3mm comparison length
M591 D0 ; display filament sensor parameters for extruder drive 0

; Z probe and compensation definition
;*** If you have a switch instead of an IR probe, change P1 to P4 in the following M558 command
;M558 P1 X0 Y0 Z1 ; Z probe is an IR probe and is not used for homing any axes
;G31 X0 Y30 Z2.0 P500 ; Set the zprobe height and threshold (put your own values here)

;BLTouch - leave commented out if using a IR Probe
;M307 H3 A-1 C-1 D-1
;M558 P9 X0 Y0 Z1 H5 F50 T6000 A5 S0.02
;G31 X2 Y42 Z2.65 P25 ; Customize your offsets appropriately.

;Omron
M558 P5 I1 X0 Y0 Z1 ; Z probe is an IR probe and is not used for homing any axes
G31 X0 Y30 Z3.027 P500 ; Set the zprobe height and threshold (put your own values here)

M208 S1 Z-0.2 ; set minimum Z
;
T0 ; select first hot end

View Comment

Config dual extruder

by Empiricus

; Configuration file for My Printer
; Communication and general
M111 S0 ; Debug off
M550 ; Machine name and Netbios name (can be anything you like)
;M551
; Machine password (used for FTP)
; If you have more than one Duet on your network, they must all have different MAC addresses, so change the last digits
M540 P0xBE:0xEF:0xDE:0xAD:0xFE:0xEE ; MAC Address
;
Wifi Networking
M552 S1 ; Enable WiFi
M555 P2 ; Set output to look like Marlin
M575 P1 B57600 S1 ; Comms parameters for PanelDue

G21 ; Work in millimetres
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

; Axis and motor configuration
M667 S1 ; CoreXY mode

M584 X0 Y1 Z5:6:7 E3:4:8:9 ; Map Z to drivers 5, 6, 7. Define unused drivers 3,4,8 and 9 as extruders
M569 P0 S0 ; Drive 0 goes forwards (change to S0 to reverse it) X stepper
M569 P1 S1 ; Drive 1 goes backwards Y Stepper
M569 P2 S0 ; Drive 2 goes forwards Unused
M569 P3 S0 ; Drive 3 goes forwards Extruder
M569 P4 S1 ; Drive 4 goes backwards Extruder
M569 P5 S0 ; Drive 5 goes backwards Front Left Z
M569 P6 S0 ; Drive 6 goes backwards Rear Left Z
M569 P7 S0 ; Drive 7 goes backwards Right Z

;Leadscrew locations
M671 X-10:-10:333 Y22.5:277.5:150 S7.5 ;Front left, Rear Left, Right S7.5 is the max correction - measure your own offsets, to the bolt for the yoke of each leadscrew

M350 X16 Y16 Z16 E16:16 I1 ; set 16x microstepping for axes& extruder, with interpolation
M574 X1 Y1 Z0 S1 ; set homing switch configuration (x,y at min, z at max) IF YOU NEED TO REVERSE YOUR HOMING SWITCHES CHANGE S1 to S0
M906 X1000 Y1000 Z1000 E700:700 I30 ; Set motor currents (mA)
M201 X3000 Y3000 Z20 E300:300 ; Accelerations (mm/s^2)
M203 X24000 Y24000 Z900 E3600:3600 ; Maximum speeds (mm/min)
M566 X100 Y100 Z30 E120:120 ; Maximum jerk speeds mm/minute
M208 X250 Y250 Z290 ; set axis maxima and high homing switch positions (adjust to suit your machine)
M208 X0 Y0 Z-0.5 S1 ; set axis minima and low homing switch positions (adjust to make X=0 and Y=0 the edges of the bed)
M92 X200 Y200 Z1600 E415:415 ; steps/mm, X/Y may be more around 201.5 for accuracy
M84 S30

; Thermistors
M305 P0 T100000 B4240 R4700 H0 L0 ; Put your own H and/or L values here to set the bed thermistor ADC correction
M305 P1 T100000 B4240 R4700 H0 L0 ; Put your own H and/or L values here to set the first nozzle thermistor ADC correction
M305 P2 T100000 B4240 R4700 H0 L0 ; Put your own H and/or L values here to set the second nozzle thermistor ADC correction

M307 H0 A265.1 C864.1 D7.5 S1.00 V24.3 B0 ;Bed Heater
M143 H0 S120 ;Set temperature limit for heater 0 to 120C
M307 H1 A467.3 C196.8 D4.4 S1.00 V24.3 B0 ;Heater 1 model
M143 H1 S285 ;Set temperature limit for heater 1 to 285C
M307 H2 A503.7 C211.5 D4.2 S1.00 V24.3 B0 ;Heater 1 model
M143 H2 S285 ;Set temperature limit for heater 2 to 285C

M570 S360 ; Hot end may be a little slow to heat up so allow it 180 seconds
M143 S285

; Fans
M106 P0 H-1 ; disable thermostatic mode for fan 0
M106 P1 H-1 ; disable thermostatic mode for fan 1
M106 P2 H-1
M106 P3 H-1
M106 P4 H-1
M106 P0 S0 ; turn off fans
M106 P1 S0
M106 P2 S0
M106 P3 S0.5; Set fan 3 value for our LED to on.
M106 P4 S1; Set fan 4 value for Cooling to on.

; Tool definitions
M563 P0 D0 H1 ; Define tool 0
G10 P0 X0 Y0 Z0
G10 P0 S0 R0 ; Set tool 0 operating and standby temperatures
;*** If you have a single-nozzle build, comment the next 2 lines
M563 P1 D1 H2 ; Define tool 1
G10 P1 S0 R0 X0 Y-20 ; Set tool 1 operating and standby temperatures

; Z probe and compensation definition
;*** If you have a switch instead of an IR probe, change P1 to P4 in the following M558 command
;M558 P1 X0 Y0 Z1 ; Z probe is an IR probe and is not used for homing any axes
;G31 X0 Y30 Z0.4 P500 ; Set the zprobe height and threshold (put your own values here)

;BLTouch - leave commented out if using a IR Probe
;M307 H3 A-1 C-1 D-1
;M558 P9 X0 Y0 Z1 H5 F50 T6000 A5 S0.02
;G31 X2 Y42 Z2.65 P25 ; Customize your offsets appropriately.

;Omron
M558 P5 I1 X0 Y0 Z1 ; Z probe is an IR probe and is not used for homing any axes
G31 X0 Y30 Z1.5 P500 ; Set the zprobe height and threshold (put your own values here)

;Grid
;M557 X20:250 Y20:250 S20

M208 S1 Z-0.2 ; set minimum Z
;
T0 ; select first hot end

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