Experimenting with the Development of an Unattended Filament Switching System
In the pursuit of seamless multi-material 3D printing, LayerLab, an Australian 3D printing enthusiast, embarked on a quest to find a reliable automatic filament changer (AFC) solution. The journey wasn't without its challenges, as they discovered with the Wisepro Auto Refill Filament Buffer and the Bambu Labs AMS 2.
Initially, LayerLab attempted to utilise the "auto refill" features on the Bambu Labs AMS 2, but found that it frequently made filament changes in outside wall areas of a print, resulting in unsightly marks and poorer quality parts. The Wisepro Auto Refill Filament Buffer, while used by LayerLab, faced issues with unreliability when changing from one spool to another, despite attempts to modify it into a larger twin-spool rig.
Despite these setbacks, LayerLab's goal remained steadfast: to create a system that allows a 3D printer to automatically switch to a second spool of filament when the first one runs out, without ruining the print.
The search for a satisfactory AFC solution proved to be elusive for LayerLab. One issue was the Wisepro's feeder motors triggering the filament snag cutters that LayerLab had included in their design. Additionally, the Wisepro device did not come with a proper mounting solution to work with consumer printers, and bearings popping out of the top of the housing was another problem they encountered.
Moreover, LayerLab, being based in Australia, found it difficult to access products from InfinityFlow, a renowned brand in the AFC market.
However, LayerLab's journey wasn't all in vain. They learned valuable lessons about what not to do in their search for a viable AFC solution. Reliable automatic filament changer solutions, apart from the Wisepro and InfinityFlow, include systems like the Box Turtle automatic filament changer, MMU-style (Multi-Material Unit) single nozzle changers, and tool changer 3D printers which swap entire tool heads for multi-material or multi-filament printing.
The Box Turtle Automatic Filament Changer, once initial issues are resolved, handles multiple spools and automates filament feeding without manual intervention, providing a functional AMS alternative. Using custom G-code scripts in firmware like Klipper combined with filament runout sensors allows filament swapping during optimal print points (e.g., infill layers) to avoid print artifacts, a method that doesn't require additional hardware.
Investing in a tool changer 3D printer system for robust multi-material handling is another robust, hardware-intensive alternative. These systems swap the entire extruder/tool head rather than just the filament, improving speed and reducing issues like oozing and clogging common in multi-material single-nozzle designs.
LayerLab is still actively seeking a good way forward for an automatic filament changer solution that suits their needs. The journey may be challenging, but the pursuit of seamless multi-material 3D printing continues.
Sensors became crucial in LayerLab's quest for a reliable automatic filament changer (AFC) solution, as custom G-code scripts in firmware like Klipper, combined with filament runout sensors, enabled filament swapping during optimal print points.
The Box Turtle automatic filament changer, once initial issues are resolved, handles multiple spools and automates filament feeding without manual intervention, making it a functional AMS alternative that relies on sensors for its operation.
