Airwolf 3D AW3D v.4 User manual

3D PRINTER
USER MANUAL
model AW3D
(model AW3D v.4, v.5, v.5.5)
www.airwolf3d.com

February 13, 2013 Page 1
INSTRUCTIONS FOR OPERATING YOUR 3D PRINTER -
UPDATED 02/12/2013
THIS USER MANUAL IS MANDATORY READING BEFORE OPERATING YOUR
AIRWOLF 3D PRINTER
THIS 3D PRINTER IS NOT A TOY
KEEP OUT OF THE REACH OF CHILDREN AT ALL TIMES
KEEP HANDS AWAY FROM THE HOT END, HEATED BED, BELTS, GEARS,
AND POWER SUPPLY AT ALL TIMES UNLESS THE POWER SUPPLY IS
UNPLUGGED AND THE MACHINE HAS SUFFICIENTLY COOLED DOWN
IF ANYTHING MALFUNCTIONS, UNPLUG IMMEDIATELY!
THEN CALL OR EMAIL US. WE WILL HELP!

February 13, 2013 Page 2
1. SOFTWARE FOR YOUR 3D PRINTER
• Familiarize y urself with all the appr priate licenses f r using the STLs, s ftware,
and firmware included with the printer. Our website has a list f s urces f r this
inf rmati n. Much f the material is " pen s urce." While this generally all ws
y u t access the underlying file r pr graming, it d es n t necessarily grant y u
the right t repr duce r sell the item (read the license carefully). In m st cases
y u are als resp nsible f r crediting the auth r f r the w rk when y u repr duce
and/ r distribute the w rk. F r the AW3D v.4, v.5, and v.5.5, designs by Prusa
and Mecan were the primary inspirati ns f r the machines.
• Install the oftware included with your Airwolf AW3D v.4, v.5, or v.5.5
onto y ur c mputer as f ll ws (f r MAC, the s ftware will need t be
d wnl aded fr m the respective websites).
o Install Slic3r (v.7.2b) n y ur deskt p r in y ur C direct ry. It is a
simple install because it d es n t require any dependencies. F r printing
ut the included STL files that make up AW3D v.4, v.5, and v.5.5, we
rec mmend 7.2b because the parts were designed t be sliced n this
versi n. The later versi ns h wever (such as 9.8) are very s phisticated
and all w y u t alter a number f parameters which can greatly impr ve
the quality f y ur prints (MAC users refer t www.slic3r. rg).
o Install Pyth n 27 directly int y ur C: direct ry (MAC users refer t
http://www.pyth n. rg/getit/).
o Install Pr nterface (can als be d wnl aded as ZIP fr m
https://github.c m/kliment/Printrun) similarly and put a sh rtcut n
y ur deskt p. On lder versi ns f wind ws, y u may need t d wnl ad
Pyth n 2.7.3 fr m http://www.pyth n. rg/getit/. If y u g t pen up
Pr nterface and the user interface c mes up, everything is w rking
c rrectly (MAC users refer t http://k ti.kapsi.fi/~kliment/printrun/ and
https://github.c m/kliment/Printrun).

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• Once y u have bec me a pr with Pr nterface, d wnl ad Repetier H st fr m
http://www.repetier.c m/. This s ftware will all w y u t c ntr l the speed f
the print and pr vide y u with a visual bef re printing (b th very, very imp rtant
f r l ng 10-15 h ur prints). Y u will use this pr gram essentially t replace
Pr nterface.
• These are the nly pr grams y u will need t run the printer. Later, y u may
wish t install Arduin 23 t m dify the firmware, G gle Sketchup ( r an
alternative CAD pr gram) t create y ur 3 dimensi nal bjects, and Meshlab ( r
a similar pr gram such as Netfabb) t make sure y ur bjects are watertight.
• T get the printer running, y u may als need t d wnl ad the FTDI driver f r
the Gen6 circuit b ard. With m st versi ns f wind ws, it will l ad the driver
aut matically nce the printer is turned n, c nnected t y ur c mputer, and
y ur c mputer is connected to the Internet. If this d es n t happen, y u can
d wnl ad the appr priate driver fr m
here: http://www.ftdichip.c m/Drivers/VCP.htm. F r Wind ws 7 64 bit,
d wnl ad the "setup executable " under the C mments c lumn.
2. INSPECTION/ASSEMBLY OF YOUR 3D PRINTER
• If y ur 3D printer was shipped, inspect the machine carefully t rem ve all
packing material. Als rem ve all fasteners such as zip ties that were used t
steady the X, Y, and Z axis' during shipping.
• Connect the Z axis flexible c uplers. They were disc nnected t pr tect the
integrity f the c uplers during shipping. Line the t p f each c upler up with
the acrylic frame. Als , make sure there is ab ut 1/8" separating the threaded
r ds fr m the m t r shafts (t pr vide r m f r flex). Tighten b th b lts n each
c upler using a 2.5 mm allen wrench. Make sure they are very tight t av id
any slippage.

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• With s ftware installed, make sure all electrical c nnecti ns t the printer
are disc nnected (this includes the USB c rd fr m the c mputer).

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• Inspect the 3D printer t make sure there are n l se wires, l se b lts r
bstructi ns that w uld impeded the printer’s m vement in any f the three
directi ns (X (left/right),Y (fr nt/back),Z (up/d wn)).
• Make sure that n thing has br ken r fallen ff fr m shipping. Please n te that
the filament r d was l sely attached t the printer frame f r shipping
c nvenience and will need t be rep siti ned t h ld the filament r ll.
• Place the b r silicate glass plate nt the heated bed surface, making sure that
the rientati n f the glass is c rrect such that it lies between the heated bed
b lts n the left and right sides.

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• Imp rtant: this is a very special piece f glass made t withstand the h t
temperatures generated by the heated bed. If br ken, d n t attempt t replace
this plate with standard glass.
• Install the alligat r clips t secure the glass plate nt the heated bed.

February 13, 2013 Page 7
• N te that the glass plate is c vered with PET tape that must be facing up. DO
NOT RUN THE HOT END INTO THE GLASS PLATE because replacing
this tape (required f r a g d “stick”) is at first difficult if y u are n t familiar
with laying films. We carry the very best replacement tape, s feel free t c ntact
us when it c mes time t replace it. Further, additi nal c ated glass plates are
available f r extra c st if y u want t c ntinu usly “cycle” thr ugh builds. In the
alternative, y u can always use blue painter's tape (preferable f r PLA), h wever
f r ABS, the stick is n t as str ng as with the PET tape.
• IMPORTANT Place the fr nt clip appr ximately where the heated bed lettering
states “LED.”

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• L k under the bed t make sure that the heater wires are NOT c ntacting the
fr nt clip.
• Install the rear clip nt appr ximately the center f the rear p rti n f the glass
(tw clips can als be used t gain a str nger grip). Imp rtant: the rientati n f
the clips will affect the pr cess f leveling the bed. The bed sh uld already be
level if the clips are placed as sh wn in the ph t graphs.
• M ve the bed fr nt and back, making sure that the heater wiring (extending fr m
the left side f the frame and int the Gen6 b x) d es n t bind and test whether
the Y micr switch activates when the bed is in the rearward p siti n (y u will
hear a “click”).

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• M ve the X carriage left and right t ensure n binding and t c nfirm that the X
micr switch activates similar t ab ve.

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• Acquaint y urself with the machine and bserve all the m ving c mp nents.
Make sure the belts are snug.
• T tighten the Y belt, l sen the nuts n the fr nt f the machine h lding the M8
threaded r d t the frame and sm th r ds. Pull back n the r d t rem ve slack
fr m the belt and then tighten the nuts acc rdingly.

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• Do not over tighten. V.5.5 - y u may als tighten the Y belt underneath by
l sening the b lts running thr ugh the Y idler and then tightening the
tensi ning b lt and then re-tensi ning the Y idler b lts.
• T tighten the X belt, l sen the 13mm nut n the right X Bracket and pull back
n the b lt and nut t rem ve slack fr m the beltD NOT ver tighten.

February 13, 2013 Page 12
• v.5.5 - tighten the tensi ning b lt, but d NOT ver tensi n and then tighten the
13mm b lt and nut acc rdingly.
• Pay attenti n t the sm th r ds and threaded r ds f r the Z axis. Peri dically
these c mp nents will need t be greased t ensure ptimal perf rmance. F r
the sm th r ds, a thick aut m tive-style grease is rec mmended. F r the
threaded r ds, graphite lubricati n is rec mmended t av id dirt c ntaminati n.
3. LEVEL THE 3D PRINTER
• prior to turning the 3D printer on as the X, Y, and Z axis will freely m ve
with ut p wer supplied t the steppers.
• First, rient the h t end n zzle appr ximately ab ve the left rear Y assembly b lt
(reas n will bec me clear later).
• N w, unif rmly l wer the threaded r ds in the X Brackets such that there is
appr ximately a 1/16"- 1/8" gap between the n zzle tip and the glass plate (by
manually turning the Z c uplers).

February 13, 2013 Page 13
• Next, sl wly m ve the X carriage fr m left t right and vice versa. N te that the
gap between the n zzle tip and glass plate varies fr m left t right.
• Level the X assembly by h lding the threaded r d fr m ne X Bracket while
turning the ther (y u will need t h ld ne while turning the ther as they will
m ve in unis n therwise):
• M ve the X Carriage left t right and vice versa t c nfirm that the X Assembly is
leveled.
• N w m ve the bed (Y assembly) back and f rth t check if the bed is leveled fr nt
t back (Y directi n).

February 13, 2013 Page 14
• Adjusting the bed is relatively straightf rward. After m ving the bed back and
f rth, simply turn the 2.5mm allen b lts n the fr nt c rners f the bed t either
raise r l wer the c rners such that the n zzle is spaced ab ut 1/16"-1/8" ff the
bed.
• N w the printer sh uld be leveled. Fine adjustments can be made after y ur first
test print. The bed will tend t stay alm st perfectly level, s any adjustment
hereafter sh uld be minimal.
• Bef re m ving further h wever, adjust the Z axis micr switch b lts such that it is
actuated with the n zzle just ver the glass plate. This is IMPORTANT!!! It
will prevent the n zzle fr m crashing int (and BREAKING) the glass when y u
g t d y ur first print.

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4. CONNECT THE 3D PRINTER
• IMPORTANT - C nfirm that the p wer select r n y ur 240W (360W f r
v.5.5) p wer supply c nf rms t y ur supplied v ltage.
• If y ur supplied v ltage is n t 110 r 115, y u will pr bably als have t buy an
adapter f r the plug r fashi n ne y urself. D n t attempt t d this unless y u
are qualified t d s .
• Make sure the p wer supply is di connected from the wall. Plug the f ur (4)
pin p wer supply c nnect r fr m the p wer supply int the c rresp nding
c nnect r n the 3D printer.
• Attempt t place the p wer supply behind the 3D printer such that the
c nnect rs are riented n the left hand side f the 3D printer. Make sure that

February 13, 2013 Page 16
the p wer supply is lying flat and that there are n bstructi ns t the circular fan
vent r vented pening, which must be facing up.
• Plug in the p wer supply t y ur wall utlet. Make sure that the p wer supply
c rd is ut f the way f the m ving parts f the 3D printer.
• Check the perati n f the p wer switch (blue LED) and heater switch (red LED).
• Turn the p wer switch n and turn the heater switch ff (y u will use the heat
later). Y u will kn w which is n by the LED indicat r.

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• C nnect the small end f the USB c rd t the t p f the Gen6 b x thr ugh the
square-shaped h le n the t p f the b x,
between the tw p wer switches and then c nnect the USB c rd t y ur c mputer.

February 13, 2013 Page 18
• Make sure that y ur c mputer is c nnected t the Internet. It will need the
Internet t l cate and install the appr priate driver f r the Gen6 b ard. If this
pr cess fails, y u will need t l cate the driver s ftware and perf rm a manual
install as indicated ab ve. Thankfully, this is a rare ccurrence.
• Once the Gen6 driver is installed, pen y ur printer interface pr gram
(Pr nterface preferred t begin with).
• Click n "C nnect" and wait f r c nfirmati n fr m Pr nterface. Make sure the
baud rate is set t 250000.
• Click n “M nit r Printer” s that y u will receive c ntinu us updates n the
status f the 3D printer.
5. GETTING FAMILIAR WITH THE 3D PRINTER
• IMPORTANT!!! - do not attempt to heat up the nozzle or heated bed
yet. Al o, make ure the nozzle i till paced apart from the gla
plate to avoid breakage.
• T ggle the X axis lightly by clicking n the inside f the hemisphere in the “+X”
directi n. Check t make sure that the X carriage m ves as directed. If y u hear
l ud gnashing fr m the m t r (skipping steps), this is pr bably because the X
axis is at it’s maximum travel in that directi n. D n t c ntinue t subject the
printer t this. Try small steps in the reverse directi n t c nfirm perati n.
• T ggle the Y axis lightly by clicking n the inside f the hemisphere in the “+Y”
directi n. Check t make sure that the print bed m ves as directed. If y u hear
l ud gnashing fr m the m t r (skipping steps), this is pr bably because the Y
axis is at it’s maximum travel in that directi n. D n t c ntinue t subject the
printer t this. Try small steps in the reverse directi n t c nfirm perati n.
• BE VERY CAREFUL ABOUT THE Z AXIS!!!. T ggle the Z axis lightly by
clicking n the inside f the hemisphere in the “-Z” directi n. IF YOU MOVE
THE Z AXIS TO FAR IN THE “+Z” directi n, y u risk cracking the glass,
damaging the h t end, and thr wing ff the calibrati n f the 3D
printer. PROCEED WITH CAUTION. Check t make sure that the print head
m ves as directed. If y u see the h t end pressing the glass d wn,

February 13, 2013 Page 19
st p IMMEDIATELY and unplug the printer and regr up. Once regr uped, try
small steps in the reverse directi n t c nfirm perati n.
• SLOWLY m ve the Z axis in the “-Z” directi n such that the print head m ves
cl ser t the glass. This is a critical adjustment that y u will bec me very familiar
with. Initially adjust the Height Adjusting B lt ( n the left side X Bracket) such
that the micr switch activates BEFORE the print head c mes int c ntact with
the glass. Adjust the B lt such that there is a very small distanced between the
tip f the h t end and the glass. D n’t w rry, y u will eventually bec me very
familiar with this adjustment and it sh uld take sec nds nce y u have bec me
accust med t the 3D printer.
• C nfirm the print bed is level.
o Thr ugh Pr nterface, SLOWLY m ve the h t end n the X and Y axis.
Check t make sure the h t end is appr ximately the same distance fr m
the glass bed in all l cati ns.
6. GETTING READY TO 3D PRINT
• Thr ugh Pr nterface, set the h t end temperature t 240 degrees Celsius (240
C). It will take a few minutes t heat up. This is very, very h t s
be CAREFUL. NEVER TOUCH A HEATED HOT END.
• Flip the Airw lf Quick Release Latch up t exp se the filament in the extruder
(mid-v.5-v.5.5).