What Are the Benefits of Autocalibration?

January 20, 2023

To achieve the best possible results, 3D printers must be calibrated before printing. That includes the correct positioning of the print bed and the extruder(s) to eliminate dimensional deviations of the 3D print as much as possible. At the same time, correctly adjusting the distance between the nozzle and the print bed ensures good adhesion resulting in better overall quality, less warpage, and fewer failed prints.

The complexity of calibration depends on the type of printer, machine equipment, and application used. It requires knowledge and experience with the machine and is time-consuming and costly. Calibration can also become a significant time factor in the case of frequent material changes or a switch between an operation with and without dual extrusion. To address this, the new BigRep PRO offers autocalibration, taking this task off your hands and saving you time and money.

Autocalibration on the PRO - How Does It Work?

The first step to ensure a properly calibrated BigRep PRO is bed leveling. This can be done by running the 'bed level' function, which initiates the ball sensor to scan a number of points on the print bed. The PRO's user interface will report which areas are not level within an acceptable tolerance and then you simply adjust the bed screws. Bed leveling does not need to be done frequently, but only after initial installation or semi-annual check ups.

The BigRep PRO performs several calibration tasks before each print. The first is bed mapping, which is also used during the bed leveling process. In this case, a sensor ensures that the distance between the print nozzle(s) and the bed is the same over the entire surface of the print bed.

If inconsistencies are measured, the PRO can automatically adjust the thickness of the print layers to compensate for differences. This is particularly crucial for the first print layer, which is essential for successful adhesion between an object and the print bed. This can save you a lot of time on the BigRep PRO. Without precise calibration, the first layer is typically over-extruded to ensure that the print sticks on the printer bed, but this results in sub-optimal quality, as seen in the image below.

The print on the left is over-extruded. The print on the right has appropriate extrusion, a result of printer autocalibration.

Secondly, the PRO calibrates the distance between the two extruders. This alignment is paramount when bringing out the full benefit of dual extrusion. Only when the control software knows the exact distance between extruders can perfectly aligned structures be printed. Doing this step manually can take a lot more time. Automatic calibration also enables a superior level of precision to manual calibration.

How Does Bed Mapping Work?

The flatness of a print bed, which usually consists of a solid aluminum plate, is an approximation as the surface may slightly deform when heated. This is the case with everything on the FFF printer. However, the larger the print bed, the greater the deviation from the ideal flat surface. Since 3D printers from BigRep - such as the BigRep PRO - are among the largest machines available on the market, a perfect calibration is crucial.

With the aid of the sensor, a network of measuring points is recorded over the entire surface of the print bed. The relative height of each measuring point above an ideal theoretical surface is automatically stored in the software. This enables the printer to adjust the size of the print head—the result is a perfect first layer with a constant material thickness and ideal material adhesion.

The principle used for distance measurement has a direct influence on calibration precision. BigRep decided to use mechanical-inductive surface scanning for the BigRep PRO. Compared to purely inductive or optical methods, it is independent of surface conditions or appearance and allows the detection of printed structures.

A sensor scans the print bed to measure any minor inconsistencies, which are instantly analyzed to adjust the print layers to compensate for bed irregularities.

How Does Extruder Calibration Work?

There are some scenarios when dual extrusion is beneficial - or even necessary.

When printing several identical parts at the same time. Both extruders move in parallel, cutting production time per part in half and increasing productivity.
When printing a part using a support material. Since different extruders process both primary and support materials, they can use other materials. For example, they can combine a stable primary material with a water-soluble support material.
When printing two different primary materials in the same component. This procedure allows chemically identical materials to be combined with other colors to achieve visually desirable effects. Alternatively, materials having different mechanical properties can be combined.

In the first case, the exact alignment of the extruders to each other still plays a minor role, as it only influences the position of two parallel created objects on the print bed. These are usually made with sufficient spacing, while exact compliance does not affect print quality.

In cases 2 and 3, extruder calibration is very important. Since printing occurs in the same component, any offset of the extruders is immediately visible and noticeable on the print surface. Support material misalignment results in inadequate support functioning, causing unclean overhangs and concave horizontal surfaces. If different materials are used to print a single part, incorrect extruder calibration can lead to poor material bonding. There are also adverse effects on appearance and dimensional accuracy. The larger the print, the bigger the deviations, resulting in more sunk costs.

A sensor measures the printed structures to calibrate the dual extruders before printing.

At the push of a button, the BigRep PRO measures printed test lines and uses them to calculate the relative positions of the extruders. In this way, measurement errors are avoided.

Extruders 1 and 2 create two patterns that are offset from each other. The sensor scans the printed structures and determines their distance. These values are now stored in the machine control system and are used to achieve maximum accuracy during dual extrusion. Once the calibration is complete, your BigRep PRO is ready for precise printing.

Get in touch with us to learn more!

BigRep PRO: Large-Format 3D Printer showcasing advanced technology and high-quality printing capabilities

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

Explore the PRO

About the author:

Michael Eggerdinger

Business Manager Materials

Michael is a toolmaker, a mechanical engineer, and a patent engineer. His years of working in manufacturing and as a project manager in various industries provide him with a profound knowledge of the main challenges in modern production processes. In 2017, he bought his first 3D printer to be used at home, and he has been hooked ever since!

PA12 CF

January 8, 2024December 19, 2022

PA12 CF

STIFF AND STRONG INDUSTRIAL PARTS

AVAILABLE COLORS

BigRep's PA12 CF is a strong and heat-resistant engineering-grade filament. Stiff, durable, and with a great surface quality, PA12 CF is suitable for many professional tooling and automotive applications. It is perfect for functional parts production in a variety of industries without the extra need for chemical or mechanical post-processing. Print and use the part right away.

Being compounded with 10% chopped carbon fibers, it's ideal for functional applications usually produced of ABS, such as jigs, fixtures, grippers, or end-of-arm parts. Its high resistance and durability make PA12 CF suitable for daily production usage under long-term stress. Able to withstand high temperatures and pressure in an autoclave, PA12 CF is a perfect solution for carbon fiber molding. A reliable and easy-to-use engineering performance material, BigRep PA12 CF is optimized for large-format 3D printing on BigRep machines.

MADE FOR

PRO PRO

Stiff and Durable
Parts

Industry-Recognized
Performance

High Heat Deflection
Temperature

Great Surface
Quality and Haptics

Very Good Chemical
Resistance

What is PA12 CF 3D Printing Filament?

PA12 CF is a high-strength engineering-grade filament with excellent mechanical, thermal, and chemical properties. The material is primarily composed of Nylon 12 (PA12), a polymer with wide industrial applications (in packaging, food manufacturing, electronics, and more), and has 10% chopped carbon fiber reinforcement. These carbon fibers enhance the material’s stiffness, heat resistance, and durability, creating even more applications for the 3D printing filament in industrial sectors.

Like all of BigRep’s filaments, PA12 CF has been optimized for large-format 3D printing. This filament in particular is engineered for the BigRep PRO, but it can also be used with fused filament fabrication (FFF) systems with open materials and 2.85 mm diameter nozzles. The material’s primary properties, which we’ll dive into in more detail, are high strength and heat resistance, durability, stiffness, and excellent surface quality—right off the 3D printer.

BigRep PA12 CF filament spool and sample print

Why Use BigRep PA12 CF Filament?

The combination of high strength and heat resistance make PA12 CF an excellent candidate for a range of functional applications. The BigRep 3D printing material is commonly used in the production of industrial tooling, such as molds, jigs and fixtures, as well as grippers and robotic end-of-arm attachments. This is because PA12 CF parts can withstand the stresses of an industrial manufacturing environment and be used reliably in combination with other machinery and industrial processes.

In addition to tooling, PA12 CF has end-use applications in various industries, such as automotive, electronics, engineering, and more. With a high heat deflection temperature of up to 130°C and long-term durability, the Nylon-based filament is also a popular option for metal replacement applications. Compared to printed metals, PA12 CF is more affordable and more lightweight.

End Use Parts

Factory Tooling

Carbon Fiber Molding

Functional Prototypes

Benefits of 3D Printing BigRep PA12 CF

When it comes to 3D printing PA12 CF filament, one of the biggest benefits to users is that the large-format filament is easy to work with and requires minimal post-processing. Right off the 3D printer, the material is characterized by a smooth surface finish, minimizing or even eliminating the need for additional chemical or mechanical post-processing. This has a huge benefit: you can save enormous time and resources by being able to use a printed component straight off the build platform.

In the printing process itself, PA12 CF also has certain advantages. For one, the carbon fibers embedded in the Nylon 12 matrix reduce warping on the print bed, which makes for a more reliable printing process and can even enable more complex part geometries. You can achieve the best print results by using an appropriate print bed surface, such as the BigRep SWITCHPLATE on the BigRep PRO.

In order to unlock the most benefits from BigRep PA12 CF filament and maximize the material’s properties, it’s important to use the right combination of print settings.

Recommended print settings

Nozzle temperature: 270 - 300 °C
Print Bed Temperature: 40 - 60 °C
Chamber Temperature: n/a
Print Speed: 30 - 60 mm/s

Mechanical Properties

PA12 CF is currently BigRep’s strongest 3D printing material, with a tensile strength of 71 MPa. For comparison, HI-TEMP CF has a tensile strength of 65 MPa, while ABS has a tensile strength of 30 MPa. This effectively means that parts made from PA12 CF can withstand greater stresses before breaking.

Thermal Properties

If you are looking for a material that must be able to withstand high temperatures and retain its strength in demanding environments, PA12 CF is a good bet. With its exceptional heat deflection temperature (HDT) of up to 130°C, higher than BigRep’s other high-temperature material HI-TEMP CF (115 °C). PA12 CF does require a high nozzle temperature (between 270 and 300 °C), and a moderate print bed heat (40 to 60 °C).

Chemical Properties

PA12 CF not only stands out for its mechanical and thermal properties, the large- format filament also boasts very good chemical resistance. The material can withstand exposure to various types of chemicals, including bases, alcohols, oils, and salts without adverse effect. This helps to increase the material’s durability for functional components.

What to Look Out for When 3D Printing BigRep PA12 CF

As with other carbon fiber reinforced filaments, it’s important to update your 3D printer hardware when working with PA12 CF. The fibers make for an abrasive filament that can quickly wear down printer nozzles made from brass. It’s therefore recommended to use a wear-resistant nozzle, such as a hardened steel nozzle, which can print PA12 CF without succumbing to rapid wear. Compared to BigRep’s other carbon fiber filament HI-TEMP CF, PA12 CF also has more demanding hardware requirements, particularly when it comes to nozzle temperature.

Carbon fiber reinforced filaments such as PA12 CF, while being stiffer than neat filaments, also tend to be more brittle. To account for this, you can orient parts strategically on the build platform to ensure that the part is strongest in the direction of stresses and loads. Finally, if you do plan to post-process PA12 CF parts, the material is compatible with a wide range of processes, including sanding, drilling, and milling, as well as coatings like fillers, paints, and epoxies. When post-processing, be sure to wear suitable protection, like safety glasses, gloves, and a dust mask.

Best Practices for Storing and Handling BigRep PA12 CF

To maximize PA12 CF’s resilient properties and final print quality, users should follow proper storage and handling guidelines for the material. The first thing to know is that PA12 CF is a highly hygroscopic material, meaning it easily absorbs moisture from the air. If the filament is stored in a humid environment, the material quality can degrade, and moisture in the filament can cause printing issues, like stringing.

To avoid any moisture-related problems, BigRep advises storing PA12 CF filament spools in a dry environment, such as the BigRep SHIELD or BigRep Keep Dry Box. This is particularly important once the spools have been opened. You can also dry your PA12 CF filament before printing at 80°C for 6 to 8 hours.

In terms of handling, the material requires very high printing temperatures, so users should take necessary precautions and avoid touching the printer nozzle or melted filament. Additionally, good ventilation in the printing environment is recommended (as with all filaments), and personal protection equipment should be worn when performing any post-processing.

Use Cases: Recommended Applications for BigRep PA12 CF

Within BigRep’s extensive filament portfolio, PA12 CF stands out as the most heat resistant and highest strength. These properties, in addition to its excellent chemical resistance, make the filament a good match for a broad range of industrial applications, including molds that can undergo multiple production rounds, jigs and fixtures, and various end-use components.

Along with BigRep’s other carbon fiber filament, HI-TEMP CF, PA12 CF has been of interest within demanding industries like aerospace and automotive, as well as in manufacturing, where custom tools that must withstand the pace and pressures of industrial processes are needed.

In the automotive sector, PA12 CF is ideal for the production of large-format end-use parts. Using the BigRep PRO platform, automotive manufacturers can benefit from the material’s excellent resolution and surface finish, cutting back significantly on time and money spent on post-processing—especially compared to near-net composite parts. The material’s excellent strength-to-weight ratio is also appealing to automotive adopters, who can increase a vehicle’s fuel efficiency by cutting down on weight without compromising on durability and performance.

Another notable use case for PA12 CF is carbon fiber molding. PA12 CF is engineered to withstand high temperatures and pressures, such as those present in an autoclave environment during the carbon fiber curing process. The filament can, therefore, be used to produce large and complex cure tools, which are then laminated with prepregs and placed in an autoclave to cure. Printing the mold directly can eliminate the need for a master pattern, resulting in a more streamlined carbon fiber production process.

Material properties:

Material:	Polyamide 12 Carbon Fiber
Filament Sizes:	5.0 kg
Diameter:	2.85 mm
Density:	1.06 g/cm³
Flexural Modulus (ISO 178):	3500 MPa
Tensile Strength (ISO 527):	71 MPa
Impact Strength, notched (ISO 179):	12.5 kJ/m²

Recommended printing conditions:

Nozzle Temperature:	270 - 300 °C
Print Bed Temperature:	>40-60 °C
Environmental Temperature:	n.a.
Printing Speed:	> 30-60mm/s

Specifications Safety Sheet

Buy BigRep PA12 CF

More Products

HI-TEMP CF

April 8, 2024October 26, 2020

HI-TEMP CF

STRONG AND HEAT-RESISTANT

AVAILABLE COLORS

BigRep's HI-TEMP CF is a strong, engineering-grade filament with a high heat deflection temperature. Compared to BigRep HI-TEMP, HI-TEMP CF boasts even greater stiffness thanks to the addition of 10% carbon fiber.

With the combination of durability and heat resistance, BigRep HI-TEMP CF is ideal for functional applications in demanding conditions and industrial environments. Thanks to its high stiffness, HI-TEMP CF is ideal for 3D-printed patterns and molds for a range of forming applications.

A reliable and easy-to-use material, BigRep HI-TEMP CF is optimized for large-format 3D printing on BigRep machines, producing lightweight yet rigid parts. Produce functional industrial parts at an accessible price.

MADE FOR

PRO PRO
PRO PRO
STUDIO

Stiff and Durable
Parts

Lightweight
3D Prints

Good Heat Deflection
Temperature

Easy to Print for
Wide Range of Uses

Excellent
Surface Finish

What is HI-TEMP CF 3D Printing Filament?

BigRep’s HI-TEMP CF is a tough engineering-grade filament known for its high heat resistance and durability. The 3D printing material is made up of BioPolymer (a PLA-based thermoplastic blend) and is reinforced with 10% chopped carbon fiber. The addition of the fibers provides additional stiffness and strength compared to BigRep’s HI-TEMP filament.

In addition to the aforementioned characteristics, HI-TEMP CF also has a good strength-to-weight ratio and has been optimized for large-format extrusion. The filament is compatible with many BigRep systems, including BigRep ONE, STUDIO G2, PRO, and other fused filament fabrication (FFF) systems.

Why Use BigRep HI-TEMP CF Filament?

Thanks to the material’s excellent toughness and heat deflection, HI-TEMP CF filament is a good choice for many engineering and industrial applications. In particular, HI-TEMP CF is ideal for manufacturing patterns and molds since it can withstand the temperatures and pressures of the thermoforming process as well as the temperatures involved in carbon fiber prepreg curing.

The engineering-grade filament can also benefit industrial users in segments like automotive, motorsport, and aerospace (to name just a few), who can benefit from the material’s combination of high heat resistance, lightweight, and durability. HI-TEMP CF also boasts good UV resistance and can thus be used reliably in outdoor applications.