July 12th edit : I have now a Form1 Calibration procedure.
These past few days some very nice Form 1 tests have been publish by TJ and Gregg. These tests have been concentrating on the shape and small features. I’ve not yet seen a test on accuracy / linearity.
The Form1 is supposed to have a 300 microns (0.3mm) diameter laser spot which limits the size of individual features but the galvanometers (galvos) can be oriented very precisely. I think I recall reading that someone in Formlabs was talking about a few micron of positioning accuracy (position of the center of the spot on the bottom of the vat). The galvos are a dynamic system using PID controllers and tuning them to get a perfect positioning takes time (see my post on the ILD test cases).
Recently I had to print a mechanical assembly for someone and even with the 300 microns tolerance, it was difficult to slide the cylinder into the tube. So I decided to investigate a bit more: I was also wondering if the peeling was not introducing some deformation in the piece.
Simple Linearity Test
The test I designed is simple: It’s a series of 20mm cylinders that are horizontal/vertical and with a 45 degrees angle. The piece is placed perpendicular to the platform to measure independently the X and Y galvo. As any mechanical system, the mirrors are not jumping from one location to the next instantly. So even if the calibration is perfect in static condition (after some resting time), the dynamic properties (damping and oscillations) might be off. These configurations are also axis dependent as the mirrors might have a different shape/mass and each axis has his own amplifier. In the ILDA test, this dynamic behavior is checked with the circle inside the square.
And the results are not as expected… As you can see the cylinders are not really round! So either the preform sampling space is too large (not enough points on the path / movement too fast) or my ‘peel’ axis amplifier board needs some adjustment.
My caliper measurements are:
Peel axis = 19.52 mm
Orthogonal axis = 19.99 mm
Peel axis = 19.5 mm
Orthogonal axis = 19.87 mm
Vertical axis = 19.96 and 19.92 mm
45 degrees cylinder:
Peel axis = 19.51 and 19.71 mm
Orthogonal axis = 19.91 and 19.75 mm
So conclusion while the Z (thickness) and Y (orthogonal to peel) axis seems to be close, my printer seems to have an issue on the third dimension. I hope Formlabs will have a calibration procedure to correct this issue.
Location Influence on the Print Quality
The other main issue I’ve encountered while printing technical piece was reliability of the print quality. In some occasions the peel process is making loud “clacks” noise when the surface to remove is large. As the tilt is starting from one side, the strength created on the prints is different depending where the geometry is placed on the base.
The picture under is showing two pieces that I had to reprint twice to get an acceptable result. The peel strength issue triggers supports break and non printed/delaninated walls.
The only difference between the two prints is the location on the platform. I didn’t had to regenerate the supports nor changed the material setting (grey resin 50 microns). On my first print (left side), only the C part came out well. So for the second try I removed the C part and moved back A and B as far away from the peel side as possible. Note that I had to print the pieces horizontal as it’s not possible to generate internal supports yet and any other orientation would have resulted in non supported features…
I’m not sure what to think about this issue, maybe reducing the peel speed when there is a large area to remove could help? If this issue is proven, that will mean the silicon layer will get damaged faster on one side triggering a replacement more often due to fogging…
Anyway I’ll keep on exploring the Form1, if you have any question please ask I’ll make more tests. Cheers!