Setting up a dual extruder 3D printer is a fantastic way to expand your 3D printing capabilities. With a dual extruder, you can print with two different filaments simultaneously, allowing for multi-color prints, different material combinations, or the use of support structures that can be easily removed (such as PVA with PLA). However, setting up and configuring a dual extruder printer requires more precision and planning compared to a single extruder printer. The setup process involves hardware installation, software configuration, and careful calibration to ensure optimal performance.
In this guide, we’ll walk you through the entire process of setting up a dual extruder 3D printer, from installation to troubleshooting common issues.
What Is a Dual Extruder 3D Printer?
A dual extruder 3D printer is a type of 3D printer that has two separate extruders (or hotends) mounted on the printhead. This configuration allows the printer to print with two different filaments at once, giving you the ability to:
- Print multi-color designs.
- Use two different materials (e.g., PLA and PVA for support structures).
- Combine flexible and rigid materials in a single print.
A dual extruder system can either use two completely independent extruders or a staggered design where the second extruder moves in and out of the print area when needed.
Benefits of a Dual Extruder 3D Printer
Before we dive into the setup process, it’s important to understand the potential benefits of having a dual extruder:
- Multi-Color Prints: Dual extruders allow you to print objects using two different colors, adding visual appeal and versatility to your prints.
- Complex Material Combinations: You can use different materials in a single print, such as combining a rigid material like PLA with a flexible one like TPU.
- Support Material: Dual extruders make it possible to use a soluble support material (like PVA or HIPS) with your primary filament, allowing for easy removal of support structures after printing.
- Higher Productivity: With two extruders, you can print complex objects without requiring post-processing to change filaments mid-print.
Steps to Set Up a Dual Extruder 3D Printer
Step 1: Unboxing and Preparing the Printer
- Unbox Your Printer: Carefully unbox your dual extruder 3D printer. Ensure that all components are accounted for, including both extruders, mounting hardware, wiring, and any additional tools.
- Check the Printer’s Parts: Verify that the printer’s frame and print bed are properly assembled. Most dual extruder 3D printers come pre-assembled, but you may still need to install the extruders, hotends, or wiring.
- Ensure Both Extruders Are Installed: Some dual extruder printers come with one extruder pre-installed, while others require installation. If needed, attach the second extruder according to the manufacturer’s instructions.
Step 2: Wiring the Extruders
- Locate the Wiring Ports: Depending on your printer model, each extruder will have its own wiring ports for connecting the motors, thermistors, and heaters.
- Connect the Wiring: Use the provided cables to connect both extruders to the corresponding ports on the printer’s mainboard. Ensure the wiring is securely connected and free from any tension that could cause disconnections.
- Secure the Cables: Tidy up the cables using cable ties or clips, making sure they don’t obstruct moving parts such as the printhead.
Step 3: Installing the Filament Feed
- Install Filament Rollers: Both extruders will require filament feed systems. Typically, these systems include filament rollers or spools that guide the filament into the extruders. Install the filament rollers as directed in your printer’s manual.
- Load the Filament: For each extruder, load the filament into the appropriate feeder. Make sure the filament is securely placed and that it moves smoothly through the feed tube or path.
Step 4: Leveling the Print Bed
Bed leveling is an essential step in 3D printing to ensure your prints stick well to the print bed. However, with a dual extruder printer, this process requires a bit more attention:
- Auto Bed Leveling: Some dual extruder printers have an auto-bed leveling system that automatically measures the distance between the bed and the nozzle. If your printer has this feature, follow the instructions to initiate the auto-leveling process.
- Manual Bed Leveling: If your printer doesn’t have auto-leveling, use the provided knobs or screws to adjust the height of the print bed. Ensure the nozzle of both extruders is at the correct distance from the print bed by performing a manual leveling procedure.
- Start by moving the extruder to each corner of the bed.
- Adjust the height so that a piece of paper can slide between the nozzle and the bed with slight resistance.
- Test for Leveling Accuracy: Run a test print to ensure that the bed is correctly leveled for both extruders. If one nozzle is printing higher or lower than the other, adjust the bed height accordingly.
Step 5: Configuring the Printer’s Firmware
Once the hardware setup is complete, you’ll need to configure the printer’s firmware to work with the dual extruders.
- Check Printer Firmware: Many modern 3D printers with dual extruders come with firmware pre-configured for dual extruder printing. However, if your printer requires manual configuration, you’ll need to make adjustments in the firmware (often via G-code or in the printer’s settings menu).
- Set Up Extruder Parameters: In your printer’s settings, ensure that both extruders are correctly identified. This includes specifying the type of filament for each extruder (e.g., PLA, ABS, etc.) and setting the correct temperatures for each hotend.
- Configure Retraction Settings: Because you have two extruders, fine-tuning retraction settings is important. Adjust the retraction length and speed to minimize stringing or oozing when switching between filaments.
Step 6: Installing Software and Slicing for Dual Extrusion
- Install Slicing Software: Most dual extruder printers require slicing software that supports multi-material printing. Popular slicing programs like Cura, PrusaSlicer, and Simplify3D offer dual extrusion options.
- Select the Dual Extruder Printer Profile: Open your slicing software and choose the correct printer profile for your dual extruder 3D printer. If your printer is not listed, you may need to manually configure it using the printer’s specifications.
- Assign Filament to Extruders: In your slicing software, assign each material to the appropriate extruder. For example, you may choose PLA for extruder 1 and PVA for extruder 2.
- Set Print Settings for Each Extruder: Adjust the temperature, speed, and retraction settings for each extruder based on the filament you are using. Be sure to set different print temperatures for different materials to avoid any compatibility issues.
- Generate the G-code: Once you’ve configured the settings, slice your model and generate the G-code. The G-code will contain all the necessary instructions for the dual extruders, including commands for switching between filaments during the print.
Step 7: Running a Test Print
Before you begin your first multi-material print, it’s important to run a test print to ensure everything is working as expected.
- Load the G-code: Load the generated G-code onto your printer via SD card or USB drive, depending on your printer’s setup.
- Start the Print: Initiate the print and closely monitor the process, especially the filament switching between the two extruders.
- Check for Issues: Watch for any problems such as clogging, filament tangling, or poor adhesion. Adjust the settings if necessary to optimize the print.
- Inspect the Print Quality: After the test print is finished, inspect the print for any defects. Check if the two materials are properly bonded and whether the filament changes between the extruders were smooth.
Troubleshooting Common Dual Extruder Issues
While dual extruder setups can significantly enhance your 3D printing capabilities, they can also introduce new challenges. Here are some common issues and tips for troubleshooting:
1. Clogged Extruder Nozzles
Dual extruders are more susceptible to clogs due to the added complexity of managing two filaments.
- Solution: Perform regular cleaning and maintenance on both extruders. Use a cold pull or a cleaning filament to clear any buildup inside the nozzles.
2. Filament Jams
Filament jams can occur if the extruders are not properly calibrated or if the filament isn’t feeding smoothly.
- Solution: Ensure that the filament is properly loaded and that the feed tubes are clear. Check that both extruders are receiving adequate tension and not slipping.
3. Extruder Motor Issues
If one of the extruders is not working or is under-extruding, the motor might be the problem.
- Solution: Check the wiring and connections to ensure they are secure. Test the motor with manual extrusion commands to ensure it’s functioning correctly.
4. Poor Adhesion Between Materials
If the two materials are not adhering properly, it could be due to temperature discrepancies or incorrect settings in the slicer.
- Solution: Ensure that both extruders are printing at the correct temperatures for the materials. Adjust the extrusion rates and test with different print speeds.
Conclusion
Setting up a dual extruder 3D printer opens up a wide range of possibilities for complex prints, multi-color projects, and the use of soluble support materials. However, achieving optimal performance requires a thorough setup process, including hardware installation, calibration, firmware configuration, and slicing settings. By following the steps outlined in this guide and taking the time to troubleshoot potential issues, you’ll be able to fully harness the power of your dual extruder 3D printer.
With the right setup, you can print more complex, detailed, and high-quality models, making your 3D printing projects even more exciting and versatile.