Upgrades and changes to the BCN3D Sigma 3D Printer including Bondtech extruders

SIGMA v2016 3D Printer upgrades, changes and tweaks

In this blog post I'm collecting up all the modifications, changes, upgrades and general improvements I have done to the Sigma (2016 version) over the last ~18 months.

This blog post and video is for the Sigma 2015/16 versions, and may not be the same for the new Sigma R17 (2017 model).

A lot of the information here is also relevant for any 3D printer, things to check, changes to make and improvements.

The main goals were to improve complex print performance - especially dual colour or dual material 3D Printing on Sigma, and also to reduce the noise.

Thank you to the team at BCN3D for the allowing me to test out some of the upgrade boards in this machine, and also to Emvio Engineering and Bondtech for the dual drive Extruder upgrade kit.

All the info is in the video below, and feel free to use the quick jump point index if there is something you specifically want to know about -

Quick jump index -
00:10 - Intro to Sigma 2016 changes
02:20 - Auto Fan control for hot-ends
04:30 - Hot-end Thermistor changes (PTFE removal)
07:50 - Adding heatsink compound to Hot-ends
12:10 - Fitting Bondtech Extruders to Sigma
16:00 - Updating Firmware eSteps/mm for Extruders
17:10 - Printing with Sigma and Bondtech extruders
18:00 - Further thoughts on testing and upgrades
19:00 - Compare print results
Final thoughts and wrap-up.

Video is also over on YouTube if you wish to watch in HD and also subscribe to my channel for more videos, help and advice.

I'll post a few images below as they are easier to see than in the video. My thoughts and advice are in the video so I'll keep the post short and look forward to any comments or questions - feel free to post here or in the YouTube comments. Thanks.

In the video I look at a number of significant changes Including -

Automatic fan speed control for both hot-ends -

Hot end improvements -

I replace the original hot-end thermistor sleeves (PTFE Max temperature 250 Deg C) with Fibreglass (300+ Deg C)

Still using the grub-screw to clamp for now, but I comment on why this is not really a good idea.

 I show you how to remove the Hot-ends and improve their thermal performance by adding thermal heatsink compound.

I then fit Bondtech dual drive Extruders into Sigma and compare print results.

In all comparison testing I used exactly the same Gcode for both system configurations of extruders (just the eStep/mm setting was changed in firmware for the new Bondtech gear rate).

The Hollow Draudi printed small with standard 0.4mm nozzles is a very tricky small print for FFF 3D printers - Designed by BCN3D

You can get the file here from Youmagine.

"The Hollow Draudi is designed to be created on resin 3D printers mainly due to their empty geometry. In addition, all orifices, modeled with Rhinoceros and Grasshopper, give it a unique personality and a plus of difficulty that will challenge any 3D printer FFF."

This is a tricky print - the extruders need some tweaking, but even with exactly the same Gcode used we can see less stringing and better formed structures between the holes.



Smoother extrusion on the feet - easier to see on the Brim rings - less indications of the individual extruder stepping points on the Bondtech print.

Low-Poly Bulbasaur - Multi and Dual Extrusion version - by- Agustin Flowalistik

Get this great 3D model from Youmagine here

Smoother extrusion and less problems with filament control here using the Bondtech extruders.

And yes, I know you can get better results out of the Sigma, by slowing down the print speed and being slightly less aggressive with the extruder settings, but I wanted to do a like-for-like comparison of exactly the same Gcode here to show the difference a gearbox and dual drive teeth make to a 3D printers extrusion system.

Sigma 2017 -

I also now have the new Sigma R17 machine now, so do keep an eye out for another comparison of the above tests along with the new Sigma R17 version.

If you have a Sigma 3D printer and need any help or advice, please catch me on twitter and I'll do my best to help out. I have been printing with Sigma for a few years now and have (I think) mastered using it for single and dual colour/material printing. It's my go-to printer for all dual 3Dprinting.

I'm really excited for the new Sigma 2017 and can't wait to show you what it can do.

Thank you for reading & watching, see you next time.


Rich.

Please join me on Twitter @RichRap3D   -  https://twitter.com/RichRap3D

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Files and designs shared on YouMagine - https://www.youmagine.com/users/richrap

Files and designs shared on GitHub – https://github.com/RichRap

Files and designs shared on Repables - http://repables.com/u/richrap/

My Youtube channel is here, all 3D Printing and Hi-Def video content.

Autumn 2016 3D Printing Adventures Update - TCT Show 2016 highlights, projects and new machines & materials

Autumn 2016 3D Printing Adventures Update 

The TCT Show was back at the Birmingham NEC Arena. This is one of the very best 3D Printing exhibitions anywhere in the world, if you get a chance to visit, make sure you register for next year and give yourself plenty of time. There are lots of suppliers, manufacturers and interesting people to meet and talk too.

I was at the show again this year for both days, here is a brief rundown of some highlights from the show, it's by no means all. This was one of those shows that I wished I had taken more photo's. I did manage to speak to many different people and visited almost all the exhibitors this time around.

My video update for Autumn is below, and contains both information from the TCT show along with materials, machines and an update on current and future projects.

You may also want to check out the new 3DHubs 2017 3D Printer guide - https://www.3dhubs.com/best-3d-printer-guide I mention a few machines that won awards in the video including the BCN3D Sigma, LulzBot TAZ6 and the Prusa MK2 i3

This is also over on YouTube in HD, click here for my channel.

First up a big thank you to everyone at E3D for providing me and Thomas Sanladerer with an operational base and generally looking after everyone in the desktop printing sector. The E3D stand's were buzzing all day, all the time, it was a great place to talk and meet people. Even the after-show party managed to congregate all around the E3D stand for most of the evening until around forty of us all packed into a local pub for a cracking roast dinner :)

So let's start with E3D and all the great things they had on show (and a few more that are/maybe coming soon) -

Firstly E3D had doubled the size of their stand this time, one half showing off their range of Spoolworks filament materials, and the other dedicated to hot-ends, nozzles, the Titan extruder and many other goodies.

E3D Copper Nozzles...

For anyone with a keen eye, you may have spotted that E3D had some copper nozzles on show. This may sound like an odd choice of material for a nozzle, but they will be appearing on 3D printers soon, so keep a lookout for more news.

Talking of nozzles, the E3D team have been working on some very special 'tiny' nozzles for super small and detailed 3D models.

These were printed with a 0.15mm nozzle in ABS. You really have to see them to fully appreciate the level of perfect detail and stunning quality being achieved with these nozzles.

More info - E3D Tiny little nozzles - http://e3d-online.com/High-Res-015-Nozzles

The detail in this chess set is astonishing for any 3D printing method, let alone FFF (FDM). A spool of filament would last for many, many models at this tiny scale.

These were also printed on a standard Mendel90 fitted with an E3D V6 hot-end, nothing special - but with a dedicated high-resolution machine we could see even more capabilities for these tiny sized nozzles.

E3D has invested heavily in expansion of their business in the past 18 months, taking on more people in development and research, we should be seeing many more great things coming from E3D so do keep an eye out.

Bondtech extruders and Emvio Engineering - https://emvioeng.com/extruder-mechanism-upgraded-bondtech-dual-drive/

Emvio Engineering had a really nice BCN3D Sigma setup with custom mounted Bondtech extruders.

They also kindly sent me a set for fitting and feedback in my BCN3D Sigma 3D Printer.

I'm doing a separate video and blog post on the entire process of fitting, setup and using the Bondtech extruders in a Sigma 3D Printer.

I'm really impressed with the upgrade and initial printing results. I'll post more as soon as I have completed more comparison prints and tested as many different materials.

LulzBot (Taz 6) - 

LulzBot was at their first international show for the TCT event. It was a total pleasure to talk to them and discuss all aspects of the LulzBot company, machines and amazing way they go about Open-Source 3D printing.

James Bruton from Xrobots.co.uk was also on the LulzBot stand, if you don't already know who James is, then do please check out his amazing YouTube channel (lots of robotics, 3D Printing and Cosplay)

James also did a great TCTshow video about LulzBot you can see here 

LulzBot also sent me a TAZ 6 in November, so look out for more video's, blog posts and discussion about my experience of using the TAZ 6 3D Printer soon.

Simple to setup right out of the box.

After a few minor issues, I was up and running - with a quick Benchy3D print in Colorfabb nGen.

The TAZ6 is very busy printing all sorts of models in different materials (lots of Christmas) so look out for an update soon on setting up and using the LulzBot TAZ 6.

Lulzbot (Taz 6) - https://www.lulzbot.com/store/printers/lulzbot-taz-6



More TCT Show and links - 

This time at the show there was almost too many more companies to list, but here are a few more I spotted and talked to at the 2016 TCT Show.

eMotion Tech - (Micro Delta Rework printer) - https://www.reprap-france.com/

Hawk3DProto was another great base for me to use during the TCTShow. A big thank you to Ben and also all the team from BCN3D.

Ben was also very kind to give me some Proto-Pasta Matt Fibre HTPLA Filament for testing - https://www.proto-pasta.com/collections/matte-fiber-htpla

I hope to be doing some hands-on 3D Printing training with Ben on-site at Hawk3DProto in the new year. If you are in any way interested in taking part of getting involved too, do get in contact with me on Twitter about this @RichRap3D

Hawk 3D Proto and BCN3D Technologies - http://www.hawk3dproto.co.uk/bcn-3d-sigma.html

HP and their Multi-jet fusion technology - http://www8.hp.com/uk/en/printers/3d-printers.html

Photocentric -

Photocentric - http://www.photocentric3d.com/

Polymaker (Polysmooth Polysher - Kickstarter etc.) - https://www.kickstarter.com/projects/polymaker/polysmooth-and-polysher-3d-prints-without-layers/description

Prusa Printers / Prusa Research (MK2 + 4 extruder add-on) - http://shop.prusa3d.com/en/printer-upgrades/118-original-prusa-i3-mk2-multi-material-upgrade.html

Silicone 3D Printing - http://www.picsima.com/

Magigoo (3D Printing bed adhesive) - https://magigoo.com/

Printrbot Simple V2 (2016) - https://printrbot.com/shop/simple-v2/

The team at 3D Filaprint had a great selection of materials, components and items to make 3D printing easier.

3DFilaprint (3D Printed Working Pinball machine - Wow!) - http://3dfilaprint.com/tonys%20pinball/

Haloween 3D Printing - (mostly testing out the Prusa i3 MK2 with lots of different materials) -

Halloween coffin pot (Design by Martin Moore - Files over on MyMiniFactory) Printed in Filamentum Cinnamon wood filament - https://www.myminifactory.com/object/halloween-coffin-pot-decoration-24554

Spider Pendant (Design by upalermo - Files over on Thingiverse) Printed in Flexfill 98A soft filament - http://www.thingiverse.com/thing:1785811

Treat bowl (Design by Tony Short - Files over on Thingiverse ) Printed in Polyalchemy Elixir Green and Orange using the colorprint software by Prusa research - http://www.thingiverse.com/thing:1074374

Autumn leaves (Designed by Faberdashery - Files over on Youmagine) - Printed in Recycled PLA filament - https://www.youmagine.com/designs/autumn-leaves

Graphica Mega Ghost (Designed by 3Dkitbash - Files over on Youmagine) - Printed in Fillamentum Extrafill PLA Luminious Orange filament - https://www.youmagine.com/designs/graphica-mega-ghost-print-play-via-3dkitbash-com

Ghosts (Designed by muzz64 - Files over on Thingiverse) Printed in Polyalchemy Elixir natural PLA (glossy white) - http://www.thingiverse.com/thing:1777164

We printed a lot more to add to the ever growing Halloween collection - Above includes many more objects that have been printed for Halloween over the last few years.

Lots and lots of Christmas printing at the moment, testing out lots of materials, devices and even a very cool Laser engraver upgrade (for 3D printers) - more on these projects soon.

It was really great to talk to so many people and companies at the TCTshow. If I missed you out in this post I'm sorry it was just such an amazing event this year, I spent almost all my time talking to people and not enough time taking pictures or video to share.

I'll try to get in a few more posts and video's before Christmas, I still have lots and lots more to share, many more projects and adventures with all manner of 3D printing devices.

See you all very soon.

Richard.

Twitter - @Richrap3d
Google+ - RichardHorne_RichRap3D
YouTube Channel RichRap