MakerBot Replicator 2X User manual

USER MANUAL | DUAL EXTRUSION
®

AWELCOME, LET’S GET STARTED. 04
Specifications 06
How It Works 07
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER 08
What’s in The Box 10
MakerBot Replicator 2X Diagrams 11
Unpacking Your MakerBot Replicator 2X 13
Installing Enclosure Door Handle 15
Installing Filament Guide Tubes and Spool Holders 16
Mounting Filament Spools and Attaching USB Cable 17
Installing Enclosure Lid 18
Attaching Power Supply and Powering On 19
CSTARTUP PROCESS: LEVELING, LOADING, TESTING 20
Leveling the Build Plate 22
Loading MakerBot Filament 25
Unloading MakerBot Filament 31
Making a Test Object from the SD Card 32
DMAKING AN OBJECT WITH MAKERBOT MAKERWARE 36
ETROUBLESHOOTING, DIAGNOSTICS, AND MAINTENANCE 46
Troubleshooting 48
Extruder Disassembly 50
Diagnostics 51
LCD Panel | Top-Level Menu 51
LCD Panel | Utilities Menu 52
LCD Panel | Info and Settings Menu 53
Maintenance 54
Updating Firmware 54
Applying Kapton Tape 54
Lubricating Threaded Rod and X-Axis Idler Pulley 55
Glossary of Terms 57
Contact Us 59
FTERMS OF SERVICE 60
03TABLE OF CONTENTSV2
TABLE OF CONTENTS

Welcome,
Let’s get started.
A

05
WARNING: The MakerBot Replicator 2X Experimental 3D Printer generates high temperatures and
includes moving parts that can cause injury. Never reach inside the MakerBot Replicator 2X while
it is in operation. Always allow the MakerBot Replicator 2X to cool down before reaching inside.
WARNING: Do not leave the MakerBot Replicator 2X unattended during operation.
CAUTION: If opening the MakerBot Replicator 2X for service, ensure that the power supply is turned
o and the cord is disconnected.
This User Manual is designed to start your journey
with the MakerBot®Replicator®2X Experimental 3D
Printer in the right direction. Your MakerBot Replicator 2X
is optimized for ABS, a traditional thermoplastic
that can be tricky and unpredictable. In order to
achieve great results, you will need to experiment and
tinker. That’s why it’s so crucial to take the time to
learn about your new machine.
In this User Manual, you will learn the basics of
the MakerBot Replicator 2X, as well as how to unbox
it safely and get it set up. Chapters C through E will
take you through calibration, printing, maintenance,
and troubleshooting.
We are so excited to welcome you to the MakerBot
community. Let’s get started!
AWELCOME, LET’S GET STARTED.

06 A WELCOME, LET’S GET STARTED.
PRINTING
Print Technology: Fused Filament Fabrication
Build Volume: 9.7”W x 6.4”L x 6.1”H
[24.6 cm x 16.3 cm x 15.5 cm]
High 100 microns [0.0039 in]
Medium 270 microns [0.0106 in]
Low 340 microns [0.0133 in]
Positioning Precision: XY: 11 microns [0.0004 in];
Z: 2.5 microns [0.0001 in]
Filament Diameter: 1.75 mm [0.069 in]
Nozzle Diameter: 0.4 mm [0.015 in]
SOFTWARE
Soware Bundle: MakerBot MakerWare™
File Types: .stl, .obj, .thing
Supports: Windows [XP/7],
Ubuntu [11.10+],
Mac OS X [10.6+]
PHYSICAL DIMENSIONS
Without Spools: 19.1 x 12.8 x 14.7 in [49 x 32 x 38 cm]
With Spools: 19.1 x 16.5 x 14.7 in [49 x 42 x 38 cm]
Shipping Box: 22.75 x 22.75 x 16.75 in
[57.8 x 57.8 x 42.5 cm]
Weight: 27.8 lbs [12.6 kg]
Shipping Weight: 40.0 lbs [18.1 kg]
[All packages]
TEMPERATURE
Ambient Operation 15°–32° C [60°–90° F]
Temperature:
Storage Temperature: 0°–32° C [32°–90° F]
ELECTRICAL
AC Input: 100–240V, ~4 amps, 50–60 Hz
Power Requirements: 24V DC @ 9.2 amps
Connectivity: USB, SD card [FAT16, max 2 GB]
MECHANICAL
Chassis: Powder-coated steel
Body: PVC Panels
Build Platform: 356 aluminum
XYZ Bearings: Wear-resistant,
oil-infused bronze
Stepper Motors: 1.8° step angle with
1/16 micro-stepping
SPECIFICATIONS
Layer Resolution
Settings:

07AWELCOME, LET’S GET STARTED.
The MakerBot Replicator 2X Experimental 3D Printer makes solid, three-dimensional objects
out of melted MakerBot Filament. Your 3D design files are translated into instructions for
the MakerBot Replicator 2X and sent to the machine via USB cable or SD card. Then the
MakerBot Replicator 2X heats the MakerBot Filament and squeezes it out through a nozzle
onto a heated surface to build a solid object, layer by layer. This method is called Fused
Filament Fabrication [FFF].
HOW IT WORKS

Setting Up Your
MakerBot®Replicator® 2X
Experimental 3D Printer
B

09
When you set up your MakerBot®Replicator®2X
Experimental 3D Printer, remember that it was built
and packaged very carefully at the MakerBot
factory. We hope you’ll take your time and be just
as careful unpacking it and getting set up.
NOTE: Do not force or tear anything during unpacking and setup.
This may damage the MakerBot Replicator 2X.
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER

10 BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
WHAT’S IN THE BOX
MakerBot ABS
Filament [1lb Spools]
2 2 2 1
Spool holders Handle and boltsFilament guide
tubes
Power supply
and cable
1 1 31
MakerBot tape
applicator
Kapton tape sheetsUSB-A to
USB-B cable
SD card
1 4 1 1
PTFE-based grease Support cardHex wrenches
*More options available at makerbot.com/store
*

11BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
MAKERBOT REPLICATOR 2X DIAGRAMS
[1] GANTRY SYSTEM
[2] LCD PANEL
[3] HEATED BUILD PLATE
[4] BUILD PLATFORM
[5] THREADED Z-AXIS ROD
[6] ENCLOSURE DOOR HANDLE
[7] FILAMENT GUIDE TUBES
[8] EXTRUDER CABLE
[9] EXTRUDERS
[10] FILAMENT SPOOLS
[11] SPOOL HOLDERS
10
11
9
7
8
1
5
3
6
4
2

12 BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
MAKERBOT REPLICATOR 2X DIAGRAMS CONTINUED
[1] FAN GUARDS
[2] EXTRUDER FANS
[3] EXTRUDER NOZZLES
[4] EXTRUDER LEVER ARMS
[5] FAN BOLTS
[6] CARTRIDGE HEATERS
[7] THERMAL CORES
[8] DRIVE BLOCKS
[9] EXTRUDER CABLE MOUNT
[10] MOTOR CABLE
CONNECTORS
[11] EXTRUDER MOTORS
[12] HEAT SINKS
[13] BAR MOUNT
[14] SPACERS
[15] EXTRUDER
CARRIAGE
1
2
5
3
6
7
4
89
10
11
12
13
15
14

13
UNPACKING YOUR MAKERBOT REPLICATOR 2X
1a. Place the MakerBot Replicator 2X box on
the ground. Open the box and remove the top
cardboard sheet.
1b. Remove the MakerBot Replicator 2X User
Manual. We recommend that you review
the manual to guide you through the setup
process and keep it handy as you unpack the
contents of the box. If you find that anything
described in the manual is missing, email us
at [e-mail].
1c. Remove the layer of foam and the sheet of
cardboard underneath.
1d. Remove the two protective foam pieces
from the sides of the MakerBot Replicator 2X.
1Opening the Box 1
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
2a. Open the plastic covering and firmly grasp
the frame of the MakerBot Replicator 2X.
Be careful not to grip the rods and belts of the
gantry system. Li it out of the box and place
it on a stable surface.
2Removing the MakerBot Replicator 2X from the Box

14 BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
UNPACKING YOUR MAKERBOT REPLICATOR 2X CONTINUED
3a. Remove the two remaining protective
foam pieces from the bottom of the
MakerBot Replicator 2X’s box.
3b. Li out the accessory box. This box
contains the remaining items from the
“What’s in the Box” section.
3Removing the Accessory Box 1
4a. Use strong scissors or a wire cutter to
cut the zip ties holding the gantry system
in place. Discard the zip ties and the plastic
pieces holding them in place.
NOTE: Operate scissors with care.
4b. A small plastic piece attached to the
X-axis belt and gantry rods prevents the
extruder from moving. Carefully snap the
piece o of the rods and tilt it to slide it o
of the belt.
4Freeing the Extruders

15
INSTALLING THE ENCLOSURE DOOR HANDLE
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
5a. Locate the handle kit in the Accessory
box. The kit includes your enclosure door
handle and two buttonhead bolts.
5b. Open the enclosure door. To do this,
reach through the top of the MakerBot
Replicator 2X, push the door outward,
and raise it to a 90° angle.
5c. Place the handle on top of the enclosure
door. Align the holes in the ends of the handle
with the pre-drilled holes in the enclosure door.
5d. Use your fingers to thread each bolt
through the holes in the enclosure door and
the handle. Use a Phillips head screwdriver to
tighten the bolts. Close the enclosure door.
5Installing the Enclosure Door Handle

16 BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
INSTALLING GUIDE TUBES & SPOOL HOLDERS
6a. Locate the two filament guide tubes.
Insert one end of a filament guide tube into
the hole in the top of one of the extruders.
Push the filament guide tube in as far as it
will go. Insert the end of the other filament
guide tube into the hole on the top of the
second extruder. Push the filament guide
tube in as far as it will go.
6b. Insert the other end of one filament guide
tube into the corresponding guide tube holder
on the back of the MakerBot Replicator 2X.
Make sure that the end of each filament
guide tube is flush with the bottom of its
guide tube holder. The filament guide tube
should not hang down past the bottom of the
guide tube holder. Repeat this process for the
second filament guide tube.
6c. Locate the spool holders. Install the spool
holders in the two rectangular openings on
the back of the MakerBot Replicator 2X.
To install a spool holder, tilt it and insert
the square end into one of the openings.
6Installing the Filament Guide Tubes and Spool Holders

17
MOUNTING FILAMENT SPOOLS & ATTACHING USB CABLE
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
7a. Open the boxes containing the
MakerBot ABS Filament. Remove the spools
from their bags.
7b. Fit each spool onto a spool holder. Ensure
that the spool on the right [when viewed from
the back] will unwind clockwise and that the
spool on the le will unwind counterclockwise.
To install a filament spool, squeeze the spool
holder and push the spool on until it locks. Do
not let the filament uncoil or tangle as you
load the spools onto the back of the MakerBot
Replicator 2X. Both spools should spin so that
the MakerBot ABS Filament will unwind from
the bottom of the spool.
7Mounting the Filament Spools
8a. Locate the USB-A to USB-B cable.
Insert the USB cable into the USB-B port on
the back of the MakerBot Replicator 2X. Do
not attach the other end of the USB cable to
anything yet.
8b. Do not plug the AC power cord into an
electrical outlet until step 11 of this section.
8Attaching the USB Cable
Spool
Holder
USB cable

18 BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
INSTALLING ENCLOSURE LID
9a. Locate the box containing the acrylic
enclosure lid. The enclosure lid is shipped
in a separate box and is not included in the
same box as your MakerBot Replicator 2X.
The box containing the enclosure lid should
have arrived with the box containing your
MakerBot Replicator 2X.
9b. Unpack the enclosure lid and place it
over your MakerBot Replicator 2X so that it
covers the top of the MakerBot Replicator 2X,
the extruder cable, and the filament guide
tubes. The small indentations at the corners
of the lid should line up with the bolt heads on
the top of the MakerBot Replicator 2X’s frame.
9Installing the Enclosure Lid

10a. Locate the power supply and cable.
Attach the cable to the power supply.
10b. Ensure that the power switch on
the MakerBot Replicator 2X is set to the
OFF position.
10c. Insert the power supply connector into
the power input port on the back of the
MakerBot Replicator 2X. Ensure that the
flat side of the connector faces down.
NOTE: If at any time you need to unplug the
MakerBot Replicator 2X, pull on the connector
itself to release it from the power input port.
10 Attaching the Power Supply
19
ATTACHING POWER SUPPLY AND POWERING ON
11a. Plug the AC power cord into an
electrical outlet.
11b. Set the power switch to the
ON position.
11c. The MakerBot Replicator 2X will display
welcome text on the LCD panel. This is the
beginning of the startup script that will
guide you through initial calibration and
your first 3D print.
NOTE: The socket-outlet shall be installed near
the equipment and shall be easily accessible.
11 Powering On the MakerBot Replicator 2X
BSETTING UP YOUR MAKERBOT REPLICATOR 2X EXPERIMENTAL 3D PRINTER
Power Supply

Startup Process:
Leveling,
Loading,
Testing
C