NWA3D A5 User manual

NWA3D A5 User Manual
1. NWA3D A5 3D Printer Part Diagrams
2. Assembling the Spool Holder
3. Leveling the Build Plate
4. Loading and Unloading Filament
5. Operation: The Four Steps of 3D Printing
6. Troubleshooting
7. Glossary of 3D Printing Terms
8. Additional Resources
© 2018 NWA3D LLC Version 3.1

NWA3D A5 User Manual
1. NWA3D A5 3D Printer Part Diagrams
(Detailed description of all terminology in Section 7. Glossary of 3D Printing Terms)
© 2018 NWA3D LLC 2

NWA3D A5 User Manual
2. Assembling the Spool Holder
1. Loosen the nuts on the two bolts
installed on the spool holder side
pieces until they are near the end
of the bolt threads—but don’t
remove them completely.
2. Slide the base of the spool holder
into the side piece while at the
same time sliding the nut into the
small groove in the base.
3. Attach the side piece to the base by
tightening the bolt with a 3mm hex
key (Allen) wrench. Do not
over-tighten or it will crack.
4. Repeat Steps 2 and 3 to attach the
other side piece.
© 2018 NWA3D LLC 3

NWA3D A5 User Manual
3. Leveling the Build Plate
Video Tutorial: How to level the build plate
To 3D print good parts, the build plate needs to be level and at the correct distance
from the nozzle. If it’s too close to the nozzle, the nozzle will dig into the build
surface, or the melted plastic will not be able to come out of the nozzle. If it’s too far
from the nozzle, the part will not stick to the build surface or will warp.
If you use blue painter’s tape as your print surface, the nozzle needs to be about
0.10mm from the build plate in all locations. This is about the thickness of a single
sheet of copier paper. If you use a LokBuild print surface, the nozzle needs to be
about 0.20–0.25mm from the build plate in all locations. This is about the thickness
of two sheets of copier paper (or one sheet folded in half to double its thickness).
You want to adjust the height of the build plate so that you can slide the paper
between the nozzle and the build plate with some resistance. You should feel the
paper vibrating and dragging when you move it between the nozzle, but not so close
that the copier paper buckles.
1. Select Setup > Auto home. This will move the nozzle to the home position at the
front left corner of the build plate, where the X, Y, and Z axis are set to 0,0,0.
2. When the motors stop, select Setup > Disable motors. This will allow you to
move the hot end of the extruder assembly (X axis) and build plate (Y axis) by
hand.
Pro Tip: The Z axis motor is also disabled, and you don’t want it to move at all. So
you should handle the printer gently during the leveling process. Keep it on a flat
surface and don’t tip it while leveling.
3. For painter’s tape print surfaces, slide a piece of copier paper between the nozzle
and the build plate. For LokBuild print surfaces, first fold the paper in half to
double its thickness, then slide it between the nozzle and build plate.
4. Move the hot end (X axis) and build plate (Y axis) so that the nozzle is directly
© 2018 NWA3D LLC 4

NWA3D A5 User Manual
above front right corner nut under the bed. Adjust that nut until the paper slides
with just a tiny bit of drag, then move the nozzle and repeat the process at the
other two nut locations. We recommend adjusting the nut on the front right first,
then the back one on the right, then the one in the center of the left side.
5. Repeat Steps 1–4 until the amount of tension on the paper is consistent at all
locations, including the center of the build plate.
6. The first layer of the print will show whether the distance between the nozzle
and build plate is correct. Refer to the following graphic for clarity.
a. If the bed is too high, the extruded plastic will squeeze out the sides of the
nozzle. The nozzle will plow the plastic and leave a first layer that is too thin.
© 2018 NWA3D LLC 5

NWA3D A5 User Manual
Or it may be so close that no plastic is extruded at all.
b. If the bed is too low, the extruded plastic may not stick to the build plate.
Even if it does stick to the build plate, parallel lines of filament on the first
layer will look mounded, with gaps in between them.
Pro Tip: You can “Hot Level” your printer by carefully adjusting the nuts during
the first layer of the build while the plate is moving until the distance between
the build plate and the nozzle is producing smooth extruded lines. Be careful of
the moving parts to not get pinched. After you have fine-tuned the bed level
during the first layer, you may want to stop the build, clear the build plate, and
restart the build so it will look better on the bottom.
© 2018 NWA3D LLC 6

NWA3D A5 User Manual
4. Loading and Removing Filament
Video Tutorial: How to remove clogs, load, and change filament
1. Loading filament
a. Load a spool of filament into the spool holder. Slide the bolt through the
spool’s center hole, and then place the bolt into the recessed grooves on the
spool holder.
b. Cut the end of the filament at an angle so the irregular melted plastic at the
end doesn’t cause a clog. It will also be easier to feed into the extruder and
Bowden tube.
c. Feed the end of the filament into the extruder by hand as you squeeze the
extruder release lever.
d. Push the filament all the way through the Bowden tube until it stops when it
© 2018 NWA3D LLC 7

NWA3D A5 User Manual
hits the back of the nozzle.
e. Select Setup > Preheat PLA.
f. When the printer is fully heated, remove all of the filament color left in the
printer from previous prints before you start a new print. To do this,
manually push filament through the extruder as you squeeze the extruder
release lever until the new color starts coming out of the nozzle.
Pro Tip: Never leave the printer preheated with material inside of it when it
is not printing. The filament will bake inside of the nozzle assembly and
create a clog.
2. Removing filament
To remove the filament cleanly, you should do a “soft pull.” This involves heating
the nozzle to 100°C, then pulling the filament out of the printer.
a. Select Setup > Preheat soft pull and wait until the nozzle temperature
reaches the set temperature
b. Wait a minute for the temperature to become stable.
c. When the nozzle temperature is a stable 100°C, squeeze the extruder release
lever and pull the filament out of the extruder with a steady, firm motion.
d. Cut the end of the filament to remove the irregular melted plastic at the end.
Pro Tip: Feed the end of the filament into the hole on the side of the spool.
This will insure it doesn’t get tangled and cause a build to fail the next time
you use it.
e. Remove the filament from the filament spool holder.
© 2018 NWA3D LLC 8

NWA3D A5 User Manual
5. Operation: The Four Steps of 3D Printing
3D printing involves these four steps:
1. Create a 3D file (Make)
2. Slice the file for 3D printing (Slice)
3. Send the file to the printer (Transfer)
4. Select the file on the printer (Print)
1. Create or find a 3D file
a. You can create a 3D model—a digital geometry—using any CAD (computer-
aided design) software program. We recommend free programs, such as
TinkerCAD and OnShape. Autodesk’s Fusion360 is free to students. Another
is SketchUp, which has free licenses available for schools. These programs
take some time to learn, and can be challenging. But they are also rewarding,
especially when you see your own creation being printed on your 3D printer!
Every CAD program allows users to save or export digital files for 3D
printing. You want to save your file as an STL file (“filename.stl”). The STL file
is the standard file format for 3D printing. In some programs, it’s as easy as
the Save command. In others, you need to select the File > Export option, and
choose the STL format. OBJ files can also be sliced and 3D printed.
b. You can find 3D models in many online libraries of digital content.
Thingiverse, GrabCAD, and Instructables are examples, and many other sites
exist.
2. Slice the file for 3D printing
Video Tutorial: How to set up Cura 3.1
Slicing is the process of converting your 3D model into the layered print
language your printer can understand, called G-Code. We recommend using free,
open-source slicer programs. Our favorite slicers are Ultimaker Cura and
Repetier Host. Both are free and easy to use. We’ve included Cura and its setup
profile on your printer’s SD card because it’s easier for beginners. For beginning
users, we recommend that you install Cura on a single PC or Mac and use it to do
your slicing.
There are a lot of slicers that will create G-Code automatically for your printer.
All you have to do is input the correct settings for your printer (using the files we
included), import your 3D model, and save the G-Code. It’s that easy!
© 2018 NWA3D LLC 9

NWA3D A5 User Manual
a. Install Ulitmaker Cura on a PC or Mac (both the .exe and .dmg versions are
included on your microSD card).
b. Open the Cura application. When it’s opened for the first time, you’ll see the
“Add Printer” window. Select “Custom > Custom FDM machine.” In the lower
left, type “NWA3D A5” for the printer name,  and then click the “Add Printer”
button on the lower right.
© 2018 NWA3D LLC 10

NWA3D A5 User Manual
c. In the Machine Settings window, enter the following settings:
X (Width): 125 mm
Y (Depth): 150 mm
Z (Height): 100 mm
Build plate shape: Rectangular
Origin at center: unchecked
Heated bed: unchecked
GCode flavor: RepRap
Number of Extruders: 1
Material Diameter: 1.75 mm
Nozzle Diameter: 0.4 mm
d. Don’t change any other settings. Click the “Finish” button at the bottom right
of the window.
© 2018 NWA3D LLC 11

NWA3D A5 User Manual
e. Select Settings > Profile > Manage Profiles then click on the Import button.
Select “NWA3D A5 Printer Profile.curaprofile” from the microSD card. This is
the medium-quality settings for the NWA3D A5. We recommend that you use
this profile as your default. If you modify your Cura settings, you can always
reload this profile from the microSD card to reset your profile to this default.
f. Here are the key Cura parameters for the NWA3D A5:
Layer Height 0.2mm Wall Thickness 0.8mm
Top/Bottom Thickness 0.8mm Infill Density 20%
Gradual Infill Steps 0 Printing Temp 220°C
Diameter 1.75mm Flow 100%
Enable Retraction On Print Speed 50mm/s
Travel Speed 120mm/s Initial Layer Speed 15.0mm/s
Enable Print Cooling On Generate Support On
Support Placement Everywhere Build Plate Adhesion Skirt
Print Sequence All at Once
© 2018 NWA3D LLC 12

NWA3D A5 User Manual
g. The following images show these settings, visible with the default visibility
settings in Cura. Initial Layer Speed is an advanced slice setting, activated by
clicking the gear icon next to each input box.
© 2018 NWA3D LLC 13

NWA3D A5 User Manual
h. The document “Complete Cura Settings for NWA3D A5.pdf” is included on the
microSD card. Refer to it if you want to compare your settings. The images in
that document show all the settings for the NWA3D A5 Cura profile. You can
always reset your settings to the original default NWA3D A5 settings by
importing the  “NWA3D A5 Printer Profile.curaprofile” from the microSD
card.
i. You may need to check “Generate Support” and select the “Everywhere”
support placement, depending on the shape of the part you are printing. Also,
you can change the layer height from 0.2mm to 0.1mm for a smoother, higher
quality part, although the print will take longer.
j. As you become more advanced with 3D printing, you may want to
experiment with many settings. Remember that you can always revert to
these default settings at any time by reloading the “NWA3D A5 Printer
Profile.curaprofile” on your microSD card, or ask us for help by filling out a
Troubleshooting Request.
k. Load a model file in Cura. Rotate and move the file to the best orientation for
printing. You may want to scale the file at this point as well.
Scale Tool:
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Rotate Tool:
l. When you are satisfied with the Cura settings and the position, orientation,
and scale of the model, you are ready to print! Insert your microSD card that
came with your printer into your computer and select “Save to Removable
Drive” to save the file to the microSD card.
Pro Tip: You can also save the file to the computer by selecting “Save to File”
or connect your printer to your computer and print over USB using the
“Monitor” feature.
3. Send the file to the printer
a. Remove the microSD card from the computer.
b. Insert the microSD card into the slot on the front of the A5 control board,
underneath the control knob.
c. By using this method, no computer needs to be plugged into your printer and
it will run autonomously until the print is finished.
4. Print!
a. On the NWA3D A5 control screen, select Refresh SD card (the last selection
on the bottom of the main screen). and select “Print from SD.”
b. Select your print (.Gcode) file.
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c. Watch the 3D printer create your model!
6. Troubleshooting
This section covers the most common printing problems and how to fix them.
Because 3D printing is still an emerging technology, a small level of tinkering and
troubleshooting is needed. But if this section doesn’t solve your printing problems,
then contact us by filling out the Troubleshooting Request on our website. We’re
here to help you every step of the way to get you 3D printing!
1. Step-by-Step Troubleshooting
a. Step 1: Diagnose the problem.
This may seem obvious, but many problems can be solved if you take
a step back and see exactly what the printer is doing incorrectly.
b. Step 2: Determine if the problem is mechanical or digital.
●Mechanical problems are in the actual operation of the printer,
such as the motors that drive the X, Y, and Z axes, the motor that
pushes the filament, the nozzle heater, and the level of the build
plate. The most common mechanical problems are caused by a
build plate that is not adjusted correctly, a clogged nozzle, or an
unplugged connector on a motor or limit switch.
●Digital problems are in the slice file that you prepare in Cura or
other slicing program. Important slice file settings include layer
height, print (nozzle) temperature, and print speed.
c. Step 3: Fix the problem.
Once you’ve discovered what the actual problem is, you can fix it with
the following procedures. (If none of these fix the problem, contact
us!)
2. Mechanical problem #1: Leveling the build plate
Video Tutorial: How to level the build plate
a. If the nozzle is digging into the build plate or is so close that no
filament can extrude, you’ll know the build plate is too close.
b. If your print looks like spaghetti or the nozzle knocked the model off
of the build plate, then you’ll know the build plate is too far away.
c. Many of the failures in 3D printing are caused by a build plate that is
not level or is not the correct distance from the nozzle. See the section
“Leveling the Build Plate” in this manual.
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3. Mechanical problem #2: Filament is not coming out of the nozzle
Video Tutorial: How to remove clogs, load, and change filament
When filament is not coming out of the nozzle, the nozzle may be clogged.
You have three good options for clearing a clogged nozzle:
1. You can pull the clog out of the nozzle using the “soft pull” method.
2. You can “floss” the clog out of the nozzle using a nozzle cleaner.
3. You can heat the nozzle and push the clog through the nozzle.
Pro Tip: Do NOT remove the nozzle or disassemble the hot end of the
printer when you have a clog. Instead, try these three options. If they
don’t fix the problem, complete a troubleshooting request and our
Service Team will help you.
Pro Tip #2: Never leave your printer nozzle at build
temperature (220°C) while the printer is idle. The melted
plastic remaining in the nozzle will “bake” onto the nozzle
and become a hard carbon blockage.
a. Try to pull the clog out of the nozzle using the “soft pull” method:
1. Turn the machine on, select Setup > Preheat soft pull, and wait
until the temperature reaches 100°C.
2. When the nozzle temperature stabilizes at 100°C, squeeze the
extruder release lever with one hand and pull the filament out of
the extruder with your other hand with a steady, even force.
3. Inspect the end of the filament. If the end of the filament has the
shape of interior of the nozzle—a thicker cone-shaped plug—you
have successfully pulled all of the filament out of the nozzle,
including the clog.
4. If the clog did not clear using the “soft pull” method, clip the
melted end of the filament off, reload it, and select Setup >
Cooldown and wait five minutes for the hot end to cool down.
Then repeat the soft pull process.
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Pro Tip: Every time you change filament on your 3D printer,
remove the filament with the nozzle at around 100°C. This
“soft pull” method usually removes all the old color of
filament from the hot end, so when you begin printing again,
the new color will begin printing immediately.
b. Use a nozzle cleaner to clear the nozzle:
1. Remove the filament using the “soft pull” method.
2. Select Setup > Preheat PLA. Wait for the nozzle to reach the set
temperature of 220°C for PLA.
3. Raise the Z axis carriage by selecting Controls > Move axis > Move
1mm > Move Z and spinning the knob. (You can also manually
rotate the leadscrew to move the gantry up.)
4. When the nozzle has reached 220°C, use pliers to carefully insert
the nozzle cleaner up into the tip of the nozzle. IT IS VERY HOT, SO
BE CAREFUL NOT TO BURN YOURSELF!
5. Squeeze the extruder release lever with one hand and push the
filament into the extruder manually.
6. Alternate “flossing” with the nozzle cleaner and pushing the
filament through the extruder until a consistent bead of filament is
extruded through the nozzle.
c. Try to push the clog through the nozzle:
1. Select Setup > Preheat PLA. Wait for the nozzle to reach the set
temperature of 220°C for PLA.
2. When the nozzle has reached 220°C, squeeze the extruder release
lever and load the filament. When the filament would normally
stop, keep pushing to manually push the filament out of the hot
end nozzle of the extruder assembly.
3. Watch the filament to ensure it is not curling as it comes out of the
nozzle. After pushing several inches of filament through, it should
be going relatively straight. If it isn’t, turn off the printer and do
another soft pull (step a).
4. Digital problems: Slicer settings
Video Tutorial: How to set up Cura 3.1
Sometimes, models don’t print correctly because the settings in the
G-Code are wrong. Here are some steps to make sure your Cura settings
are correct.
© 2018 NWA3D LLC 18

NWA3D A5 User Manual
a. Check your slice file in Cura. Make sure the print is centered in the
build area, is making good contact with the build surface, and isn’t too
big for the build envelope.
b. Check the slice settings.
●Make sure that the layer height is between 0.1mm (high-quality
prints) and 0.3mm (low-quality prints).
●Check the speed and temperature. For PLA, they should be set to
30–50mm/s and 220°C.
●Make sure the filament diameter is 1.75mm and the flow rate is
100%.
●Make sure the Heated bed checkbox is unchecked in the Machine
settings window (the NWA3D A5 does not have a heated bed). To
view the Machine settings window, select Settings > Printer >
Manage printers …, then click the Machine Settings button in the
popup window.
●Check the Fill Density (infill) and make sure it is at least 5%. You
may need to adjust this value to your liking for your model.
●Refer back to the “Operation” section of this manual for other
slicer settings and to better understand Cura.
c. Your part may need supports. If it’s rounded you may need to select
“Everywhere” for the support type. If it’s intricate, it may need to
select “Raft” for the Build Plate Adhesion Type. (A raft is a hatch
pattern on the build plate that the model will print on.) If the part
warps when you begin to build it, you may need to select the “Brim”
adhesion type and reslice the file. (A brim will help the part stick so it
doesn’t curl up at the edges.)
d. If you think your slice settings are really messed up, try re-loading the
file “NWA3D A5 Printer Profile.curaprofile” from the microSD card.
The profile will restore the slicer settings to a medium-quality profile
that will work well. Click Settings > Profile > Manage profiles. In the
Profiles Preferences window, click on the Import button, navigate to
the printer profile “NWA3D A5 Printer Profile.curaprofile” that came
on the microSD card in the Cura folder, and open it. Your slice and
build parameters are now reset to our default settings for the NWA3D
A5.
© 2018 NWA3D LLC 19

NWA3D A5 User Manual
7. Glossary of 3D Printing Terms
3D
Three-dimensional
3D Printing
The process of creating a three-dimensional object from a digital file. Usually, it
is achieved by stacking two-dimensional layers of material to form a physical 3D
object. There are many different 3D printing processes that use many different
materials, but the most common process is material extrusion—also known as
Fused Deposition Modeling and Fused Filament Fabrication—which uses
thermoplastic filament. Also known as additive manufacturing.
3D Printer
It’s basically a crazy robotic hot glue gun! A type of industrial robot that prints
three-dimensional objects from a digital source. This machine usually reads
g-code files that give it specific instructions on how to print an object. Examples
include the A5, A31, and all the other awesome printers we carry.
3D Design Program
A type of software used to visualize, design, and manipulate 3D products while
providing a test environment for strength and dynamic analysis. Also known as a
Computer Aided Design (CAD) program or 3D Modeling Software. Free examples
for educators include Autodesk Inventor, Fusion360, SketchUp, Onshape, and
Tinkercad.
3D Modeler
A type of multimedia artist or animator who creates three-dimensional models
or visuals of items using a variety of different computer software programs and
tools. Also, a program used to manipulate 3D shapes to create objects for
animation or production.
A5
The A5 is an open source material extrusion 3D printer design that prints 125 x
150 x 100mm. NWA3D heavily modifies this original design to meet the rigorous
classroom environment and calls the version an NWA3D A5. We build, modify,
and test every printer. We are the sole-source provider of the NWA3D A5.
© 2018 NWA3D LLC 20