How to use the 3D Printer at SIL-EE (Ultimaker S5 pro)

The 3D printer available in the Systems Integration Lab is an Ultimaker S5 Pro. To prepare a print, you will need slicing software. This is a program that takes your 3D model and converts it into a path the printer can follow. The recommended slicer for this machine is Ultimaker Cura, which can be downloaded here.

Once Cura is installed:

1. Open Cura and add a new printer. Select Ultimaker S5 from the list of non-networked printers.
2. Load your 3D model by dragging the file onto the build area, or via File → Open. Cura supports most common 3D file types, including .stl, .obj, and .3mf.
3. Position and orient the model on the virtual build plate. Adjust print settings (see the sections below for filament, nozzle, and quality recommendations).
4. Slice the model and either save the resulting file to a USB stick or send it directly to the printer.

On the first booking, a lab assistant will walk you through loading filament, levelling the bed, and starting your first print.

When using the 3D Printer, please remember the following:

1. Do not touch the nozzle, print head, or heated bed during or immediately after a print. The nozzle reaches temperatures of 200–280 °C depending on the filament, and the bed can reach up to 140 °C. Allow the printer to cool down for at least 5 minutes before reaching inside, and 30 minutes before performing any maintenance.
2. Keep hands and loose clothing clear of the print head while the printer is in motion; the head moves quickly along the X and Y axes and can pinch fingers. The build plate also moves with enough force to cause injury, so stay clear during operation.
3. Keep the glass doors closed while a print is running. This maintains a stable temperature inside the build chamber and prevents accidental contact with moving or hot parts.
4. Ensure adequate ventilation when printing ABS or other styrene-based filaments, as they release fumes that can be irritating in enclosed spaces. PLA and PETG are generally considered safe but ventilation is still recommended for long prints. Check the safety data sheet for any third-party material you are unsure about.
5. Never leave a print fully unattended for extended periods, especially the first layers. Failed adhesion, clogged nozzles, or filament tangles are the most common causes of print failure and, in rare cases, fire. Usually the lab assistant is there to keep an eye, but regular check-ups are necessary.
6. Allow the print bed to cool before removing prints. Forcing prints off a hot glass bed can crack the plate or cause burns.
7. If something seems to go wrong (grinding noises, smoke, filament jam, head crash), pause or stop the print from the touchscreen and contact a lab assistant. Do not attempt to fix the printer yourself.

1. Booking is required to use the machine. Without a confirmed booking, your print will be cancelled.
2. An introduction is mandatory before first use. You must also submit a Safety Form to be granted access.
3. Use the computer to access the 3D printer and submit print jobs. The USB slot is blocked.
4. Filament slots are assigned:
   1. Slots 1–3 are reserved for filament provided by the lab.
   2. Slots 4–5 are available for your own filament.
   3. Retrieve your filament after your print finishes; otherwise, it may be used by anyone.
5. Filament usage policy: small prints may use the lab's filament. For larger prints, you must provide your own.
6. Apply a thin layer of glue stick to the glass build plate before each print to ensure good first-layer adhesion. This is included next to the printer.
7. After your print, clean any residue from the build plate before leaving the machine for the next user.
8. Dispose of waste filament and related material in the dedicated 3D printer bin next to the machine.

The material the printer extrudes is called filament. Spools are stored in the humidity-controlled chamber underneath the printer, where you can place the material you would like to use. If you have no specific requirements for the part, the standard plastics to use are PLA and ABS, make sure to select the matching material in Cura so it uses the correct temperatures.

For support structures, the easiest option is breakaway filament, which can be snapped off the print by hand once it is finished. Use water-soluble PVA support only for prints with cavities or overhangs where breakaway supports would be hard to remove, as PVA requires soaking the print in water afterwards.

The Ultimaker S5 uses interchangeable print cores rather than standalone nozzles. Each print core contains its own nozzle and is identified by a letter and size combination:

• AA 0.4: The standard print core for general use, suitable for most prints with PLA, ABS, PETG, and similar build materials.
• AA 0.8: For large prints where precision is less important and speed matters more.
• AA 0.25: For very precise, detailed prints (slower).
• BB 0.4: Optimised for water-soluble PVA support material. Use this in the second print head slot whenever you are printing with PVA supports.

To swap print cores, open the print head and follow the procedure on the touchscreen. After installing a new combination, the printer may prompt you to recalibrate the XY offset — instructions for this are in the Ultimaker manual (section 4.7) and the XY calibration sheet can be found in the drawer underneath the printer.

For most prints, the default Cura profiles work well. Recommended starting points:

• Quality: Normal (0.15 mm layer height) for a balance of speed and detail. Use Fine (0.1 mm) for detailed parts, or Fast (0.2 mm) for quick prototypes.
• Infill: 20% for general use. Increase for stronger functional parts, decrease for lighter aesthetic prints.
• Supports: Enable for any model with overhangs greater than ~45°.
• Build plate adhesion: Enable "Skirt" or "Brim" to help the first layer stick, especially for tall or narrow prints.

Feel free to experiment with settings! Cura's defaults are tuned to the printer's capabilities, so most adjustments are safe to try. Be aware that non-standard settings are more likely to fail, so avoid pushing them too far for important prints.

Once your print is complete and the bed has cooled:

1. Open the build plate clamps and slide the glass build plate out of the printer. Place it on the drawer table next to the printer.
2. Carefully detach the print from the plate. If it does not come off easily, gently work a spatula underneath the print parallel to the plate.
3. Remove support material:
   1. Breakaway supports: snap off by hand or with pliers.
   2. PVA supports: soak the print in water until the PVA fully dissolves (this can take several hours; warm water and stirring speed it up).
4. Use a file or flush cutters for final cleanup of any leftover support traces or brim edges.
5. Clean any glue residue or print debris from the glass build plate with lukewarm water and a non-abrasive sponge, then dry with a microfiber cloth before returning it to the printer.
6. Leave the printer ready for the next user: build plate installed, filament unloaded if you brought your own, and any waste disposed of.

For more information, please check the User Manual