3D Printing Guide

Chapter 4: Printing Your Cap

Printer Requirements

Minimum Specifications

Build volume: 120 x 120 x 30mm
Nozzle temperature: 260°C capability
Bed temperature: 80°C heated bed
Layer resolution: 0.2mm or finer

Recommended Features

Enclosed chamber (helps with PCTG)
All-metal hotend
Automatic bed leveling
Part cooling fan control

Slicer Settings

PCTG Main Body (NoDrip XL Cap)

Layer height: 0.2mm
First layer: 0.3mm
Perimeters: 3
Top layers: 4
Bottom layers: 4
Infill: 15% gyroid (more recommended)
Print speed: 40mm/s
Temperature: 255°C
Bed temperature: 80°C
Retraction: 3mm @ 35mm/s
Ironing: All top surfaces
Supports: Suggested for locking tab overhang

TPE Disc Gasket (Optional)

Layer height: 0.2mm
Perimeters: 3
Infill: 95%
Print speed: 20mm/s
Temperature: 230°C
Bed temperature: 50°C
Retraction: Disabled
Note: Print separately as a disc

Critical Print Considerations

Bed Adhesion

Clean glass bed with isopropyl alcohol
PEI sheet provides excellent adhesion
Glue stick as backup for stubborn prints
No brim needed if bed is properly prepared

First Layer

Watch the first layer completely
Should be slightly squished but not transparent
Uniform width across entire perimeter
No gaps between lines

Support Material

Locking tab overhang may need supports with droopy PCTG
Use tree supports for minimal contact
Remove carefully to preserve tab integrity
Rest of design prints support-free

Multi-Material Printing

Option 1: Separate Prints

Print PCTG body first
Print TPE gasket separately
Press-fit assembly

Option 2: Multi-Material

Use MMU or tool changer
Print both materials in one go
Requires careful purge settings

Quality Checks During Printing

Layer Adhesion

No visible gaps between layers
Walls appear solid and uniform
No stringing between features

Dimensional Accuracy

Measure critical dimensions:
- Outer diameter: 67.5mm ±0.1mm
- Inner diameter: 63.0mm ±0.1mm
- Height: 12.0mm ±0.1mm

Common Issues and Solutions

Warping

Problem: Corners lifting from bed Solution: - Increase bed temperature to 80°C - Add enclosure or draft shield - Check for drafts in room

Poor Layer Adhesion

Problem: Layers separating Solution: - Increase nozzle temperature 5°C - Reduce print speed to 35mm/s - Check for partial clogs

Stringing

Problem: Fine strings between features Solution: - Increase retraction to 4mm - Lower temperature 5°C - Increase travel speed

Elephant’s Foot

Problem: First layer bulges out Solution: - Reduce first layer flow to 95% - Raise nozzle 0.05mm - Reduce bed temperature 5°C

Post-Processing

Required Steps

Remove from bed carefully when cool
Inspect all surfaces for defects
Test fit with AeroPress XL
Clean thoroughly before use

Optional Improvements

Light sanding of contact surfaces
Compressed air to clear holes
Acetone wipe for fingerprints (PCTG safe)

Print Time Estimates

PCTG body: ~90 minutes
TPE gasket: ~25 minutes
Total time: ~2 hours

Troubleshooting Guide

Print Fails at Holes

Reduce speed to 30mm/s for small features
Ensure part cooling fan at 100%
Consider 0.15mm layers for detail

TPE Won’t Stick

Clean bed extra thoroughly
Use hairspray or TPU adhesive
Increase first layer temperature 10°C

Dimensions Off

Calibrate E-steps
Check filament diameter
Adjust horizontal expansion

Success Tips

Dry filament is crucial for PCTG
Take your time with bed leveling
Print a test piece before full cap
Keep notes on successful settings

Multiple design iterations showing different hole patterns and flow restrictors

Next chapter: Time to brew some coffee!

--- title: "3D Printing Guide" --- # Chapter 4: Printing Your Cap ## Printer Requirements ### Minimum Specifications - **Build volume**: 120 x 120 x 30mm - **Nozzle temperature**: 260°C capability - **Bed temperature**: 80°C heated bed - **Layer resolution**: 0.2mm or finer ### Recommended Features - Enclosed chamber (helps with PCTG) - All-metal hotend - Automatic bed leveling - Part cooling fan control ## Slicer Settings ### PCTG Main Body (NoDrip XL Cap) ``` Layer height: 0.2mm First layer: 0.3mm Perimeters: 3 Top layers: 4 Bottom layers: 4 Infill: 15% gyroid (more recommended) Print speed: 40mm/s Temperature: 255°C Bed temperature: 80°C Retraction: 3mm @ 35mm/s Ironing: All top surfaces Supports: Suggested for locking tab overhang ``` ### TPE Disc Gasket (Optional) ``` Layer height: 0.2mm Perimeters: 3 Infill: 95% Print speed: 20mm/s Temperature: 230°C Bed temperature: 50°C Retraction: Disabled Note: Print separately as a disc ``` ## Critical Print Considerations ### Bed Adhesion 1. **Clean glass bed** with isopropyl alcohol 2. **PEI sheet** provides excellent adhesion 3. **Glue stick** as backup for stubborn prints 4. **No brim needed** if bed is properly prepared ### First Layer - Watch the first layer completely - Should be slightly squished but not transparent - Uniform width across entire perimeter - No gaps between lines ### Support Material - Locking tab overhang may need supports with droopy PCTG - Use tree supports for minimal contact - Remove carefully to preserve tab integrity - Rest of design prints support-free ## Multi-Material Printing ### Option 1: Separate Prints 1. Print PCTG body first 2. Print TPE gasket separately 3. Press-fit assembly ### Option 2: Multi-Material 1. Use MMU or tool changer 2. Print both materials in one go 3. Requires careful purge settings ## Quality Checks During Printing ### Layer Adhesion - No visible gaps between layers - Walls appear solid and uniform - No stringing between features ### Dimensional Accuracy - Measure critical dimensions: - Outer diameter: 67.5mm ±0.1mm - Inner diameter: 63.0mm ±0.1mm - Height: 12.0mm ±0.1mm ## Common Issues and Solutions ### Warping **Problem**: Corners lifting from bed **Solution**: - Increase bed temperature to 80°C - Add enclosure or draft shield - Check for drafts in room ### Poor Layer Adhesion **Problem**: Layers separating **Solution**: - Increase nozzle temperature 5°C - Reduce print speed to 35mm/s - Check for partial clogs ### Stringing **Problem**: Fine strings between features **Solution**: - Increase retraction to 4mm - Lower temperature 5°C - Increase travel speed ### Elephant's Foot **Problem**: First layer bulges out **Solution**: - Reduce first layer flow to 95% - Raise nozzle 0.05mm - Reduce bed temperature 5°C ## Post-Processing ### Required Steps 1. **Remove from bed** carefully when cool 2. **Inspect all surfaces** for defects 3. **Test fit** with AeroPress XL 4. **Clean thoroughly** before use ### Optional Improvements 1. **Light sanding** of contact surfaces 2. **Compressed air** to clear holes 3. **Acetone wipe** for fingerprints (PCTG safe) ## Print Time Estimates - PCTG body: ~90 minutes - TPE gasket: ~25 minutes - Total time: ~2 hours ## Troubleshooting Guide ### Print Fails at Holes - Reduce speed to 30mm/s for small features - Ensure part cooling fan at 100% - Consider 0.15mm layers for detail ### TPE Won't Stick - Clean bed extra thoroughly - Use hairspray or TPU adhesive - Increase first layer temperature 10°C ### Dimensions Off - Calibrate E-steps - Check filament diameter - Adjust horizontal expansion ## Success Tips 1. **Dry filament** is crucial for PCTG 2. **Take your time** with bed leveling 3. **Print a test piece** before full cap 4. **Keep notes** on successful settings ![Multiple design iterations showing different hole patterns and flow restrictors](images/IMG_0051.jpeg) Next chapter: Time to brew some coffee!