Volcano Hotend - Upgrade Mk3  

Re: Volcano Hotend - Upgrade Mk3

I also played with the idea of upgrading to the volcano. I even thought of making an exchangeable print head. But as the MK3 in stealth mode on my paver/bike tube setup is silent enough to run overnight, I put this on hold. Also the MK3 has still many problems and I don't think it is a good idea of attempting such a radical modification when the base is not stable yet.

Regarding Software: https://github.com/prusa3d/Prusa-Firmware/tree/MK3 (see instructions)

I guess you did some forum search already:

https://shop.prusa3d.com/forum/original-prusa-i3-mk3-f30/how-to-compile-the-mk3-firmware--t13410.html
https://shop.prusa3d.com/forum/improvements-f14/e3d-volcano-height-adjust-t5896.html#p46085
particularly #define Z_MAX_POS 202
maybe ask stephanpark

Please keep us posted on your results!

- Martin

Re: Volcano Hotend - Upgrade Mk3

Fabian, how are things going? Any updates?

- Martin

Re: Volcano Hotend - Upgrade Mk3

Today is actually the first day I've got some time to work on that problem.

I'll keep you updated

Re: Volcano Hotend - Upgrade Mk3

OK,

Feedback.

I've been tinkering around and reading a lot.

The hole process isn't that complicated.

What really is complicated at the very least for me, is setting up arduino ide correctly for the prusa.

I already got one firmware out to switch the max z to 201, measuring above auto home and moving the z axis until
the motors start to skip.

Calibration won't work so I'm still tinkering around a bit more.

Re: Volcano Hotend - Upgrade Mk3

Calibrations seems to work now.

Didn't print yet.

Am tired.

😀

Re: Volcano Hotend - Upgrade Mk3

OK,

it's working very good now.

I can print PET at 250 degrees at a rate of about 75 mm per second, out of the largest 1.2mm nozzle.

The printer itself is very able to handle this speed and the acceleration perfectly, the volcano hits the wall at that speeds with
this diameter, even with the 40watts cartridge it can't melt the plastic faster than that.

The biggest hurdle was understanding the printer firmware and designing a new fan shroud.

It's not super nice and not really to my liking yet, but it gets the job done.

I'm using freeware to design the parts.

I use auto-cooling for "small" parts, for example the larger rook from thingiverse.

The parts are really strong.

Print time for the rook was about 25 minutes at 0.6 mm layers.

I'm also tinkering around with printing ABS through the large nozzle.

It really is hard to get that first layer to stick, onliest thing I didn't try yet is ABS-juice, I have my hopes high, that that will fix the problem.

BTW, the volcano prints REALLY good with the 0.6 mm nozzle.

OK, what else, yeah dripping is bad with PETG, at least at the very start of the print you have to grab the drops directly from the nozzle before auto-calibration starts.

During prints there is no problem, no dripping at all after setting up the correct extrusion-multiplier and retraction to 100 mm p/s, no problems with prusa PETG and stripping the filament.

If someone is interested I can write a little guide how I set-up the printer with the volcano.

Best regards,

Fabian

Re: Volcano Hotend - Upgrade Mk3

Fantastic, I had written off that already...

I can print PET at 250 degrees at a rate of about 75 mm per second, out of the largest 1.2mm nozzle.
What extrusion width/layer height are you using? I'm curious on what flow rate you get
http://manual.slic3r.org/advanced/flow-math

If someone is interested I can write a little guide how I set-up the printer with the volcano.

Definitely! I have fine detail prints where I have thought more than once about using a 0.25mm nozzle, but for larger structural parts the volcano would be great. Easiest way would be to buy a second printer - or make a quick change hotend.

- Martin

Re: Volcano Hotend - Upgrade Mk3

Hi Martin,

I'm sorry, I didn't use the biggest nozzle with that speeds.

I used the 0.8 one.

I'm using automatic slicer settings and am getting used to the different

The speed of the largest nozzle is at 35-45 mm depending on the part also playing around with the values to get more speed out of it, actually the extrusion is still limited by the melting power of the hotend, I can see little rings forming in the filament, when I'm extruding too fast.

Values for that were by about 750 mm / min so 12,5 mm / s. I could push it to 920 mm/min but only with lots of heat and the result was not very nice.

Still testing, but I'm definetly having a lot of fun playing around and testing things out.

Re: Volcano Hotend - Upgrade Mk3

Hi Fabian,

did you finished the testing with the Vulcano?
My Prusa hotend is damaged and i found the vulcano hotend. Can you tell, what exacly i have to do, to install the longer nozzle right.
I think the vulcano is better for printing parts which are mechanicly used.

Sincerly

Florian

Re: Volcano Hotend - Upgrade Mk3

The minimum you have to do on purchased parts is the Volcano heater block and a Volcano nozzle.

On printed parts for the minimum you have a choice print a modified extruder cover in PETG or a modified print nozzle in ABS. Both can be found on Thingverse and searching the forums here.

Software you will have to compile the firmware yourself with the reduced maximum print height of 202(round up there is a small amount of tolerance built in to the MK3).

Now if you are more ambitious like me, you will have to redesign a few parts.

The curent Prusa firmware can be used.

I am currently working on this design. My current attempt is a complete rework of the X-carriage to do the cable management.

A possible advanced method is all of the previous one and in addition a design a quick hot-end exchange mechanism. For this you would need the following extra hardware in addition to the basics:-

Design wise in addition to the ambitious parts the extruder body and cover would need a redesign.

When I have finished my version of the full volume volcano mod I will be publishing it but it will be a few weeks yet.

Regards,
Martin

Re: Volcano Hotend - Upgrade Mk3

Martin,
I have just upgraded to the Volcano, and flushed the modified firmware with the "Max print height to 202mm" to compensate to the longer HotEnd.

For some reason my first layer adhesion is horrible and Z value in the LCD monitor is an unpromising "?". The printer doesn't seem to know what is Z height.
(I have not made any hardware changes)

Did you experience something similar?

Re: Volcano Hotend - Upgrade Mk3

For some reason my first layer adhesion is horrible and Z value in the LCD monitor is an unpromising "?". The printer doesn't seem to know what is Z height.
(I have not made any hardware changes)

Did you experience something similar?

Look at the GitHub readme. You need to add some flags to platform.txt.

It's there, but pretty easy to skip over.

This may or may not be the voice of experience.

Re: Volcano Hotend - Upgrade Mk3

Some time ago I completed my Full Print Volume Volcano Modification if you want to avoid modifying the BIOS you can fit it to your printer instead.

Regards,
Martin

RE: Volcano Hotend - Upgrade Mk3

@martin-wolfe

For future google searchers like myself, these minimum prints aren't actually required are they? 

"On printed parts for the minimum you have a choice print a modified extruder cover in PETG or a modified print nozzle in ABS. Both can be found on Thingverse and searching the forums here.  Software you will have to compile the firmware yourself with the reduced maximum print height of 202(round up there is a small amount of tolerance built in to the MK3). Now if you are more ambitious like me, you will have to redesign a few parts. The Z-Motor mounts and Z-Tops to raise by 8.6mm."

This is all only if you want to maintain your volume, no?  If you are ok with losing a bit, the volcano just connects at the existing heatbreak and everything upstream stays the same, right?