Dual Extruders and the AO-100

Here’s some information on our AO-100 and the dual extruder setup.

The earlier work can be found on our development server. You can find some Slic3r configs and scad files as well.

sjkelly has a nice setup on Thingiverse: AO-100 Dual Material Setup

Sound made Fan mounts for sjkelly’s dual carriage for cooling the hot ends vs the printed part.

Marlin dual firmware (from latest git, no special branch/fork)

Here is the “Quick and dirty” docs on how this was done.

jebba: crispy1: see the source here: > http://devel.lulzbot.com/AO-100/hardware/dual/biz_card_code/ > In particular the difference() in here: > http://devel.lulzbot.com/AO-100/hardware/dual/biz_card_code/biz_triple_lulz.scad
crispy1: jebba: so it looks like you build the STLS to properly overlap when brought into slic3r’s plater at the same coordinates?
jebba: crispy1: kind of like this:
jebba: 1) grabbed biz cardholder off thingiverse. Any of them will do
jebba: 2) convert our font to openscad
jebba: 2) convert font with OpenSCAD-Font-Importer …
jebba: 3) do mini file that has the STL in openscad
jebba: Like this line:
jebba: color(“green”) import(“PlainBusinessCardHolder.stl”, convexity=5);
jebba: Then you render that.
jebba: Then bring in the text and move it around changing the values at the top until you have it how you want.
jebba: So you can F5 and see the biz card + the text exactly how you want the final piece.
jebba: Then uncomment the difference() line and render/compile it.
jebba: This took forever with openscad current, so i grabbed the latest git and it was reasonbly fast.
jebba: Then export the STL, which will be the card holder with holes in it where the text is.
crispy1: jebba: sounds like quite a quiteflow
crispy1: *workflow
jebba: Then comment out the bizcard holder itself
jebba: and render just the floating text
jebba: then export the floating text as an STL
jebba: then go into slic3r and do: Combine multi-material STL files
jebba: do the biz card first, then the text.stl
jebba: then export that as an AMF.
jebba: Then load the AMF into slic3r itself, and export the gcode.
jebba: Then print with pronterface.
jebba: crispy1: and you’re done!

Holy crap! I was working on a similar design for my AO-100! This is perfect but how much build area do you lose?

We’ve actually been doing this for quite awhile. The original carriage was by sjkelly and is on thingiverse:


I have a few more photos here:


This one is ABS letters with wood holder:


And a quick & dirty HOWTO on how I did it:


We have a dual mount for the TK-0 too, but it has only printed a few parts.

For the AO-100/AO-101 the bed size narrows to 164 x 200mm.

How can this setup be used to build supports out of one of the water soluble plastics like PVA? Do you need a special slicer program? We have been searching but can’t seem to find much info on it. We mainly build with ABS, not sure if that matters.

I don’t know of people using PVA successfully. HIPS can be used and breaks off reasonably easily (unless made too thick). The slic3r software supports multiple extruders and support.

Would you guys mind putting up the steps/tutorial of how you did the dual extrusion conversion? I have the lulzbot ao100 and I’ve been looking into dial extrusion for a while on this printer and this is the only thing i found on the topic! Btw great job with the conversion!

Here’s some more info on dual: