Z offset calibration

This procedure is critical for obtaining quality prints with continuous fiber. The basic procedure is automated in the printer menu. Go to printer Maintenance menu and hit Calibrate – Printhead.

Choose Comp. Z-offset button and follow the instructions on the screen. It is important to understand, that composite Z-offset value is measured relative to Z axis position – it is just a distance between plastic and composite nozzles tips on Z. It means that this calibration always must be done after Z axis calibration.

The full calibration sequence is also shown in our education video. But how can you determine you need this calibration in the first place? This is simple: at every composite print start, you will see a calibration fiber line printed at the front edge of the buildplate.

Basalt fiber test line

If you see the line is to high above the glass and doesn’t stick, it means the composite nozzle is too high, so the offset needs some adjustment. If the line is too wide, or the nozzle scratches the glass so the fiber cannot go out, it means the nozzle is too low.

After calibration is done, you might want to check yourself with offset value in Settings. Typical values for z-offset will lie within 1.6-2.3 mm.

Z-offset in Settings menu

Printing the Bracket

Test part “Wall bracket” introduces you to capabilities of your Composer A4 and also serves as a combined quality test. You can find the gcode for this test preloaded on your Composer SD, or download it from Anisoprint Support Portal / Printing tests page. Choose the code sliced for the particular filament you have.

  • Use recommended adhesive for you plastic filament, e.g. Magigoo Original for transparent PETG, or Magigoo PA for Smooth™PA.
  • After print start, both extruders, plastic and composite, start to heat. When composite extruder reaches extrusion temperature, composite nozzle will print a short purge line(composite thread) in front of the build plate. It must be glued to the surface and look smooth and uniform. At the end of printing the purge line you will hear a characteristic sound of the fiber cutter.
  • After printing the purge line, the machine will start with the first plastic layer. Check if the plastic perimeters look the same everywhere along the part. The first layer must be nicely glued to the build plate. At the same time, wipe tower will be started on the left side of the build plate.
  • After several plastic layers, the machine will go the first fiber perimeter and fiber cellular infill. Due to the process features, it may look a bit wobbly, but the layup visual quality will normalize later on. If the fiber goes off trajectory or doesn’t glue to the previous layer, check your Z-offset calibration.
  • During the next plastic-composite cycles, fiber perimeters will be surrounded by plastic ones. Make sure the plastic and fiber perimeters do not intersect, and fiber perimeters are laid without displacements.

Inspect the printed part, paying special attention to side walls quality. Check the surface smoothness visually. The typical print quality will be similar to the photo below:

1 – Plastic top solid infill(cover), 2 – outer plastic perimeters, 3 – fiber perimeters, 4 – cellular fiber infill, 5 – plastic shell

Buildplate preparation

  1. Unpack the printing glass, apply an adhesive varnish evenly to the top surface, place it on the buildplate and fix with the clamping clips.
  2. Calibrate the buildplate via automatic procedure in Maintenance > Calibarate > Buildplate.
  3. Calibrate the Z-axis via automatic procedure in Maintenance > Calibrate Z-axis.
  4. Start the XY offset test by choosing Print > NozzleOffsetTest.gcode on the printer screen. The test procedure is described in detail in the Maintenance section.

Loading materials

  1. Take the 3 coils(Plastic, Composite Plastic and Fiber) out of dry bags and place them onto the holders.
  2. On the Composer screen, click Maintenance > Materials > and choose the material you want to load. Follow instructions on the screen. It is strongly suggested to load the composite plastic filament before the fiber.

Installation

Your Composer A4 printer requires several assembly steps to be performed before you start printing.

Unpack the printer and place it on a reliable flat surface, protected from strong vibrations. Adjust the printer feet to compensate for any unevenness of the surface if needed.

  • Using a hex key from the Supply Kit, attach the coil holders to the back mount of the printer
  • Install the wipe station part on the station bracket on the right. Size and color may vary by model.
  • Unpack the printing glass, apply an adhesive varnish evenly to the top surface, place it on the buildplate and fix with the clamping clips.
  • Plug in the power cord.