AO-100 Dual Material Setup

thingiverse

In the past three weeks, we have been working on improving the AO-100 from Aleph Objects by focusing on certain areas that needed enhancement. Initially, we encountered a Z axis alignment issue that caused severe wobbling. This problem was resolved by using brass bushings and designing a mount to keep them at the same level as the nozzle. We also utilized nophead's coupler from Thingiverse. Our next task involved adding support for dual materials, initially considering two eMinebea motors but opting for a mirrored jonas'-greg's-wade design with a custom carriage and two fans. Using Slic3r 0.8.4 and dob71's Marlin fork, we achieved dual material printing. However, we encountered issues with PVA and ABS not sticking together, leading us to explore other options such as PLA/ABS and ABS/PEO. For those who have information on sacrificial support for ABS, please share. The project was made possible thanks to Mill-Max Mfg, and more details about the setup can be found by reaching out through IRC or email. To assemble, mirror the Aleph Objects spool mount and Greg's Wade Reloaded, using the included mirrored and repaired files from Netfabb. Print one of the X carriages like the other extruder, adjusting the nozzle heights with shimmy_shim_shim for evenness. Then, print the nozzle_align.gcode after achieving perfect X and Y alignment using a calibration model such as Thingiverse's "Cube with Support." The final result showcases our red ABS and black ABS prints without any sagging due to accurate alignment.