Filament Innovations BFP-ICARUS-TYPHOON User manual

1
BFP-ICARUS-TYPHOON
Gen 4 Manual-V1.0 (8/29/20)

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Table of Contents
Introduction......................................................................................................................................................... 3
Quick Fact Guide.............................................................................................................................................. 4
Quick Start Guide............................................................................................................................................. 5
Unboxing............................................................................................................................................................ 6
Component Names and Locations..................................................................................................................7
Touchscreen Interface.....................................................................................................................................10
Initial Setup and Calibration ........................................................................................................................11
Powering the Unit On, Off, and Troubleshooting ..........................................................................12
CW-3000 Water Chiller....................................................................................................................14
Filament Chamber................................................................................................................................15
Bed Height Adjustment and Automatic Leveling.............................................................................16
Automatic Bed Leveling and Baby Z Stepping ..............................................................................17
Moving the Printhead..........................................................................................................................18
System Preheating ...............................................................................................................................19
Filament Loading..................................................................................................................................20
Changing Heatcores (Nozzles) ..........................................................................................................22
Software and Internet Setup........................................................................................................................24
WiFi Connectivity.................................................................................................................................25
Duet Web Control................................................................................................................................27
Installing the Microsoft Surface .........................................................................................................28
Software Slicers and Profiles.............................................................................................................29
General Slicing Tips.............................................................................................................................32
Offline File Uploading and Printing.................................................................................................33
Maintenance and Support ............................................................................................................................34
General Maintenance .........................................................................................................................35
General Cleaning.....................................................................................................................35
Oiling and Lubrication .............................................................................................................35
Acrylic Cleaning........................................................................................................................35
Plate Prep and Use..................................................................................................................36
CW-3000 Water Chiller ........................................................................................................37
Typhoon Greasing....................................................................................................................37
Z-Offset Tuning.....................................................................................................................................38
Machine Maintenance Printout...........................................................................................................40
Helpful Links and Documentation ......................................................................................................41
Frequently Asked Questions (FAQ)...................................................................................................42

3
Introduction
To our newest Filament Innovations customer,
Congratulations on owning your very own BFP-ICARUS 3D Printer! These 3D
Printers are built to fill a clear need in the 3D Printing sector: large-scale,
high-flow, and reliable machines. These 3D Printers combine the latest
technology and hardware into one unit. By using this unit, you are
supporting American business and manufacturing, while helping to push
innovation in numerous fields such as medical research, education,
manufacturing, and rapid prototyping.
Filament Innovations is dedicated to making sure that your experience
with our 3D Printers goes smoothly. Extra support is always available
through these easy methods:
Website: https://filamentinnovations.com/pages/support
E-Mail: [e-mail]
Phone/Text: [phone]
Tech Hours: M-Th: 8:00am –5:00pm EST
F: 8:00am –12:00pm EST
We thoroughly hope you enjoy using your Filament Innovations 3D Printer.
Please remember your machine was built by hand via trained individuals
in Pennsylvania –supporting American Manufacturing.
Welcome to Industry 4.0!
Happy printing!
The Filament Innovations Team

4
Quick Fact Guide
The following quick fact guide will give you a brief overview of your printer
and its components.
Machine Size:
ICARUS Size: 47 x 29 x 72 (in)
Right Door Swing: 27 (in)
Front Door Swing: 37 (in)
Weight: 400 (lbs)
Print Envelope:
ICARUS Print Area: 405 x 356 x 890 (mm)
15.95 x 14.01 x 35.04(in)
Mechanical Components:
X, Y and Z Motion: HiWin Linear Rail and C7 Precision Ballscrews
Motors: CNC Grade Stepper/Servo Hybrid NEMA23s
for X, Y, and 10:1 Geared NEMA23s for Z
Hotend Nozzle (mm): 0.60, 0.90, 1.20, 1.80, 2.50
Filament Diameter: 2.85mm
Electronic Components:
Wall Power: 110VAC
Minimum Breaker: 15A
Amperage Draw: 13A
System Voltage:
Printer Electronics: 24VDC & 48VDC
Heated Bed: 110VAC
LEDs: 24VDC White and Blue
Camera: Wyze IP/Internet Webcam
Motherboard: Duet 2 Wifi with Duet Expansion Board
Screen: PanelDue7i and Microsoft Surface

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Quick Start Guide
The following guide allows you to check and monitor the progress of
setting up your ICARUS unit.
1. Remove the four L-brackets from the bottom of the printer that attach
it to the crate. Adjust the casters, so the wheels are on the pallet.
2. Remove the machine from the pallet by gently rolling it off and move
the machine to the general area where it will be used.
3. Remove the shrink wrap from the machine and open the main door.
Inside the printer, please remove your included CW-3000 water chiller,
filament and any other boxes you see. Check under the blue bearing
plate for boxes.
4. From the back of the printer, connect the two water lines to the back
of the chiller, it does not matter what hose goes into what port. Pour
roughly 1.75 gallons of blue windshield washer fluid into the chiller (fluid
not supplied).Plug the CW-3000 water chiller into the back of the
printer with the power switch on. The chiller turns on with the printer.
5. Plug the 110VAC cord into the wall which is located on the rear right of
the unit, twist the red emergency stop clockwise to disengage it, and
flip the red toggle switch. The unit should now be powered on and you
will hear a series of beeps when the chiller turns on. If you do not hear
these beeps, please be sure the chiller switch is on and plugged in.
6. From the touch screen, temporarily disable to WiFi by pressing:
Console > Keyboard Icon > Type “M552 S0” > Enter
Note: This step is not relevant if you have the CAT5/6 version.
7. From the touch screen, select and run the following macro by pressing
the Macro button:
Macro > “Bed Leveling” > “Mesh Bed Leveling - RT”
8. Connect to a Wifi Network (page 21). Check that you can connect to
the Duet Web Control interface afterward (detailed in this manual).
Install the webcam, if desired, following the instructions from the Wyze
Cam app on your phone or tablet.
9. Install the slicer profiles from the website and –HAPPY PRINTING

6
Unboxing
The BFP-ICARUS 3D Printer ships in a wooden crate, weighing between 500
- 550 lbs. The crate dimensions are as follows:
ICARUS-X Crate Size: 52 x 40 x 76 (in)
Using the tools and instructions listed below, you should be able to easily
remove your ICARUS from the palette and remove the shrink wrap. The
unboxing process will require two people.
Required Tools Not Included for Unboxing
•Powered Drill with a #2 Philips bit
•Crowbar or Hammer
•Basic metric Allen key set
•19 mm or adjustable wrench
Steps for Unboxing
1. To remove the outside panels, use a crowbar or hammer to remove the
staples around the outside of the box.
2. Once the panels are removed, use a hammer or crowbar to remove
the wooden frame around the printer.
3. Once the crate is open, locate the metal L-brackets securing the
printer to the pallet. Remove the pallet side of the bracket using a drill
and the printer side using a number 4 Allen key
4. Use the 19 mm wrench to raise the stabilizer feet so the wheels are
touching the floor of the crate.
5. You and another person can now remove the printer from the crate by
carefully rolling it off. The printer should still be in the shrink wrap at this
time.
6. Move the printer approximately where it will be operated and remove
all the shrink wrap from the machine. After the shrink wrap is removed,
move the printer into its final position. As a reminder, the filament
chamber is on the right side of the machine and needs an additional
27 inches to open properly.

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Component Names and Locations
Before we go any farther, let us take a few minutes to understand the
various components of your ICARUS unit. These components will be
referenced later in the manual. At this time, the unit should NOT be
powered on.
#
Component
Description
Image
1
Extruder
Stepper motor that pushes
filament through the
hotend.
2
Heatcore
Interchangeable heater
assemblies with different
nozzles sizes. Able to be
swapped out with dial
indicated with 2.1.
3
Part Cooling
Fans
Fans that cool the part
during printing
4
Inductive
Probe
German designed sensor
that detects the distance
from the nozzle to the bed –
teal tip.
5
X-Endstop
Sensor that detects the x
home position of the printer.
6
X Motor
Stepper motor responsible
for moving print head
assembly left to right.
8
Z Motor
One motor on each side
controlling up and down
movement of the bed.
These have a 10:1 gear box
on them to increase power.
There are four of these.
8
3
4
1
2.1
2
5
6

8
9
Filament
Sensor
Detects when filament has
run out. This is found in the
control case on the right
side.
10
Casters
Allows the printer to roll or
be locked in place with
retractable feet. The feet
can be raised and lowered
by rotating the leveling feet.
11
Switch Panel
Controls the printer power:
See the Powering the Printer
On section to see what
each control does.
12
Control Case
Houses all of the electronics
for the printer. This includes
power supply, duet board,
relays, and cooling fans.
13
Duet 2 Wifi
Screen
The interface used to
interact with the printer.
14
Heated Bed
Indicator
Red indicator light that turns
on when the heated bed is
above 40C. The Print Plate
should not be removed if
this light is on
15
Hotend
Indicator
Red indicator light that turns
on when the hotend is
above 40C.
10
9
15
5
12
11
13
1
14

9
16
Print Plate
Removable print surface for
easy remove prints.
17
MIC6 Plate
The plate that is heated by
the heated bed.
18
Insulation
Retains heat from the
heated bed.
19
Base Plate
Creates a stable base for
the print bed.
20
Y Motor
Stepper motor responsible
for moving print head
assembly front to back.
There is one on the left and
right of the machine.
21
Y Endstop
Sensor that detects the y
home position of the printer.
There is one on the left and
right of the machine.
22
Microsoft
Surface
Assists in operating the
machine from the Duet Wifi
Control Screen as well as
performing onboard slicing
using Simplify3D.
23
Filament
Chamber
Holds up to six spools of
filament. Use the top right
spool holder to feed
filament into the machine.
17
18
16
19
20
21
22
23

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Touchscreen Interface
The BFP-ICARUS is equipped with a 7” PanelDue7i LCD touchscreen from
Duet3D and a Microsoft Surface to easily interact with the printer. In this
section, we will cover the basics required to understand how to operate
your printer using the touchscreen. For more in depth documentation,
refer to the Official Duet3D Documentation
Red: Software controlled emergency stop.
Yellow: Heated Bed (Left) and Hotend (Right) icons.
Blue: Current temperature in Celsius.
Orange: Temperature the printer is set to.
Green: Current position of the X, Y, and Z axis in millimeters.
Purple: Home command for each axis. The left icon is a Home All.
to home all three axes. You must Home All before attempting
to use the Move commands. You can individually home each
axis with the other three buttons.
Black: All gCode files for printing that are stored on the onboard 4 GB
MicroSD card. These gCode files are loaded via the Duet
Web control interface on a computer browser.
Brown: The Macro button is used to store custom commands that can
be written and stored via the Duet Web control interface.
Some basic Macros are included to help with setup.

11
Initial Setup and Calibration
Initial Setup and Calibration

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Powering the Unit On, Off, and Troubleshooting
Your printer has come with the following tools and accessories:
Accessories
•
Filament
•
CW-3000 Water Chiller
•
Desiccant Dryer for Filament Chamber
•
Wyze IP/Internet WebCam
•
PTFE Oil for Linear Rails
•
White Lithium Grease for Ballscrews
The ICARUS printers run on 110 VAC power, standard USA household
electricity –the unit needs a 15A circuit for operation. The switches on the
front of the control box are responsible for turning on and off the printer.
As a reminder, the function of each control is listed below.
•Red Toggle Switch: Controls power to the printer (Red Arrow)
•Blue Toggle Switch: Controls internal LED lighting (Blue Arrow)
•Emergency Stop: Kills all power in case of emergency. If pressed, turn
the button clockwise to disengage. (Green Arrow)
•Main Power Plug: Plug for 110 VAC power cord. (Yellow Arrow)
REAR
FRONT

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Steps for Turning on your ICARUS
1. Use the supplied 110 VAC power cord to plug the printer into a wall
outlet. The unit should be on a minimum 15 amp breaker; however, we
suggest a 20 amp breaker.
2. Ensure that the emergency stop is disengaged - turn clockwise to
disengage the button.
3. Flip the red toggle switch to turn on the printer. At this point the screen,
water chiller, and the cooling fans on the control box should turn on.
You may also turn on the LED’s using the blue toggle switch.
Steps for Turning off your ICARUS
1. Press the System Cool Down button on the home screen to turn off the
heated bed and hotend.
2. Wait for the red Heated Bed and Hotend indicator lights to turn off.
3. Flip the red toggle switch down to power the unit off.
Troubleshooting the Power
The BFP-ICARUS is a straight forward machine to power on and off,
however there may be times when troubleshooting may occur.
•20amp Breaker –A breaker is located inside the control box, on the
bottom right. If the unit does not turn on, there may have been a
power surge on the electrical line the printer is plugged into. Please
check to see if the breaker has a green(off) or red (on) color on it. If
it is green, please flip the breaker to power the unit back on
•Emergency Stop –Is the emergency stop pressed in? This will cut
power immediately to the unit. Turn this clockwise to disengage it.
•Power Plug –Please check that the plug is fully inserted into the
control case on the back of the machine.

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CW-3000 Water Chiller
The Gen-4 ICARUS is water-cooled and we include the CW-3000 water
chiller to keep the Typhoon high-flow extruder operating at the
appropriate temperatures, between 18C and 28C.
IMPORTANT –FROM THIS STEP FORWARD - IF THE MACHINE IS ON, THEN THE
CHILLER NEEDS TO BE ON. ALWAYS LEAVE THE CHILLER SWITCH TO THE “ON”
POSITION AS THE POWER IS DERIVED FROM THE PRINTER ITSELF. THE CHILLER
WILL TURN OFF WHEN THE POWER TO THE PRINTER IS TURNED OFF. THE
CHILLER WILL BEEP MULTIPLE TIMES WHEN TURNED ON.
Please note –you will need to source 2 gallons of blue windshield washer
fluid. This is commonly sold at any general store or automotive store.
1. Place the water chiller next to the machine and connect the two water
lines coming out on the back. It does not matter which line goes into
the Input line or the Output line. Secure these lines to the chiller using
the included clamps.
2. Fill the reservoir (located on the top of the chiller), with roughly 1.75
gallons of windshield washer fluid.
3. Plug the power cord into the chiller. The power for the chiller is taken
from the power cord hanging from the back of the printer.
4. With the two hoses connected, the reservoir filled, and the power cord
plugged in, flip the power switch on the chiller. If the printer is powered
on, the water chiller will beep a few times and fluid will flow. Check the
Typhoon connections for any leaks. If the chiller does not turn on, check
that the power cord is plugged, the chiller is turned on, and the printer is
on.

15
Filament Chamber
The Gen-4 ICARUS has a dedicated filament chamber, capable of
holding six filament spools, each 2.3kg in size.
Please place the desiccant dryer on the bottom of the filament chamber.
This will help keep moisture out of the chamber and the filament dry. Using
the included power cord, please dry the desiccant dryer every two
weeks, or as needed. The orange beads, located inside the dryer, will turn
green when the device needs to be recharged. Please check it weekly
and charge as needed.

16
Bed Height Adjustment and Automatic Leveling
Keeping a level bed is critical for accurate 3D Printing. Every ICARUS unit
comes equipped with mesh bed leveling to ensure a flat bed. Even
though your bed leveling, and Z-offset is factory set, it is important to
check that no damage occurred during shipping.
Steps for Checking Bed Height and Leveling
1. Every Gen-4 ICARUS unit ships with four Z axis ballscrews, which replace
the need for manual tension springs. These ballscrews will automatically
level the plate in four corners. Every ICARUS ships within 200-300 micron
bed variance.
2. Use the Home All button to home the X, Y, and Z axes. The printer axes
will now start to move. This is shown in yellow
3. Navigate to the Bed Tilt Compensation macro by going to:
Macros > Bed Compensation > Bed Tilt Compensation

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Automatic Bed Leveling and Baby Z Stepping
3D Printing requires a very flat bed and surface for large, successful prints.
Because of this, we have included two forms of bed leveling for your
machine. This section of the guide is to inform you of what these two bed
leveling options do.
Inductive Probe: This durable and extremely accurate German
designed sensor is responsible for detecting the metal print plate to
allow for the following functions to be run. This sensor can be found on
the hotend with the circular green cap at the bottom where it senses.
Tilt Compensation: Prior to every print, the ICARUS will automatically
perform a Tilt Compensation which probes each corner of the print
bed. The software will automatically calculate the deviations of the
bed and independently adjust all four Z motor ballscrews to level the
bed to ensure your print bed is flat every time.
Mesh Bed Leveling: Changes in bed temperatures from printing with
different filaments will slightly affect the levelness of the bed. A Mesh
Bed Compensation is a 5 minute Macro that will probe the bed at
numerous points, twice, and create a virtual height map of the bed. It
is found under:
Macros > Bed Compensation > “Mesh Bed Leveling”.
Run this macro every time you load a new filament to ensure a proper
print surface. There are presets from 50C through 100C bed
temperature, choose the temperature that best suits your printing
needs. Our ICARUS units come pre-calibrated with a mesh variance
under 300 microns.
Baby Step: To ensure you get the perfect first layer every print, the Duet
system allows you to move the print bed up or down at the beginning
of a print to account for small variations in bed leveling from normal
use. When a print is started, a button on the lower right of the
touchscreen called “Baby Step” will allow you to adjust the spacing of
the print head to the print bed in 0.02mm increments. The two arrows
pointing together will raise the print bed to the nozzle. The two arrows
pointing away will lower the print bed from the nozzle.

18
Moving the Printhead
The print head can be moved using the Move tab on the touchscreen.
After selecting the Move button on the home screen on the touchscreen,
the Move window appears. This gives a variety of options for moving the
printer a certain number of millimeters in all directions.
The printer must be homed before it can be
moved manually. If a move button is pressed
without the printer being homed, an error
message will appear. This is necessary to
prevent damage to the machine by moving
the printer too far in one direction.
Moving in the X and Y Direction
The X and Y direction moves the PRINTHEAD. Once the printer is homed, it
can be moved in the X and Y direction freely without fear of moving the
printer too far in either direction.
Moving in the Z Direction
The Z direction moves the BED up and down. More caution must be given
when moving in the Z direction because it is possible to ram the bed into
the nozzle which can SEVERELY damage the machine. Take extra caution
when moving the Z axis. The negative Z buttons move the print bed UP
while the positive Z buttons move the print bed DOWN.
The diagram below shows what the positive direction of movement is for
each axis. The origin of the x and y axis of the printer is in the front left.

19
System Preheating
In order to preheat the entire system, the desired temperature needs
to be set for the hotend and heated bed individually. Other than
preheating for a print, the heated bed must be preheated for Mesh
Bed Leveling, and the hotend must be preheated when changing
filament. For more information about preheating instructions when
changing filament, see the next section Filament Loading.
Steps to Preheating the Bed and Hotend
1. Press the temperature button in the “Active”
row for the hotend.
2. Use the + and –buttons to select the desired
temperature and then press the “Set”button.
3. Initiate the heating process by pressing the
hotend icon. The active temperature fields
should turn red, and heating should begin.
4. The same process is followed for preheating
the heated bed. Press the temperature
button in the “Active” row for the heated
bed, set the desired temperature, and press
the heated bed icon to initiate the process.
Alternative Method for Preheating
There are also Macros made for system
preheating ABS, ASA, Nylon, PETG, PLA, TPU and
more. When one of these is engaged, the
system will heat the heated bed first and then
the hotend. Find these under
Macros > “Pre-Heating”
Always print at the manufacturer’s suggested
temperatures. Our preheating macros should be
treated as guidelines for that polymer.
1
2
3

20
Filament Loading
To begin printing with your printer, or to change filament, it is important to
know how to load filament into your ICARUS. Follow the two guides below
for Loading Filament for the First Time and Changing Filament.
Loading Filament for the First Time
1. Put the desired spool of filament on
any of the filament holders in the
filament chamber.
2. Preheat the hotend to the correct
temperature for that filament.
3. Cut the end of the new filament at a
45 degree angle to allow it to more
easily be fed through the tube.
4. Push the lever on the extruder to the
left –this opens the extruder. Image 4
shows the open extruder position.
5. Start feeding the filament through the
tube, through the sensor, and continue
feeding it until you feel it stop –it has
now entered the extruder.
6. With the hotend heated and
filament in the extruder, release the
filament lever by pushing it back to
the right –this engages the extruder.
Image 6 shows the extruder in the
closed position.
7. On the Duet Screen, press the Extrusion
button to extrude 100mm of filament
at 5mm/s –twice –so you extrude
200mm of filament. If the extruder does
not move, then press the Home All
button to home all the axes as a safety
precaution and repeat this step.
7
1
4
6
3
an
5
6