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====== tys - PPS-CF Printing on the Voron v2.4 ======

The easiest high-temperature, high-strength polymer to print is [[filaments:pps|PPS-CF]]. Unfortunately, this (allegedly) cannot be printed on a regular printer such as an unenclosed Ender. As a result, I set out to chart the shortest, cheapest, most direct possible route to successfully print PPS-CF with a Voron 2.4.

===== Printer Construction =====

After selecting the Voron 2.4 as the target platform, a 300mm kit was purchased from [[https://www.formbot3d.com/products/voron-24-r2-pro-corexy-3d-printer-kit-with-m8p-cb1-board-and-canbus-wiring-system?VariantsId=10470|Formbot]]. Printed parts were from the Voron PiF community, arriving with eSUN black ABS with minimal Fusion Filaments ABS1.5 Plutonic Purple. Non-PIF parts were printed with black Hatchbox PETG. This printer was successfully assembled with the standard v6 hotend and successfully calibrated.

===== Changes Required =====

PPS-CF was identified as having the following requirements:
  * Hotend - <340C
  * Bed - 100C(+)
  * Chamber - 60C+
While the bed is capable of these temperatures, achieving the targeted hotend and chamber temperatures would require modification. To safely sustain the chamber temperatures, internal-chamber plastics would be reprinted from annealed [[filaments:pet|PET-GF]]. PET-GF was noted to have the following requirements:
  * Hotend - <320C
  * Bed - 80C
  * Chamber - ~40C
From these two lists, the following modifications and equipment were identified as necessary:
  * PET-GF chamber plastic reprint
  * Abrasive Filament Nozzle (Undertaker TC 0.4mm)
  * High Temperature Hotend (Dropeffect neXtG Fiber)
  * Printer Insulation
  * Filament Dryer (capable of 90C)
  * Annealing Oven (capable of 200C)
  * [[equipment:drybox|Drybox]]
  * PET-GF Filament
  * PPS-CF Filament
  * Chamber temperature sensor (PT1000)

===== Filament Pipeline =====

With PET and PPS being extremely sensitive to moisture, a dry filament pipeline would be necessary. The Drybox was constructed with a large plastic bin, utilizing threaded pneumatic couplers to allow printing directly from the enclosure. Delta Adsorbents molecular sieves were used as dessicant with their 10/20/30% humidity indicator cards to ensure a moisture-free atmosphere.

A Hamilton Beach Sure-Crisp Toaster Oven Air Fryer Combo (31403) was then modified with an Inkbird PID Controller to provide precise temperature control. This functioned as both the filament dryer and annealing oven, and was capable of holding +/-5C and reaching temperatures in excess of 220C.

===== Printer Modification =====

The standard StealthBurner v6 hotend was used to print the Dragon compatible stealthburner. This was used to replace the v6 hotend with the Dropeffect neXtG Fiber hotend with Undertaker Tungsten Carbide 0.4mm nozzle.

This combination was then utilized to reprint all internal chamber and toolhead plastics with Phaetus aeForce PET-GF (Blue) filament. Those items were subsequently annealed at 120C with an approximate annealing time of 1hr/mm based upon part thickness.

A chamber temperature sensor was added to the front center of the rear gantry - all temperatures are as-reported from this sensor. While a valuable data point, this singular sensor is unable to capture all of the various temperatures and gradients experienced throughout the volume of the printer.

As a final step, the printer was externally insulated by covering it with a moving blanket. This allowed chamber temperatures to reach 60-62C. Due to concerns of overheating, the cable door was removed from the stealthburner to improve toolhead canboard (SB2209 RP2040) cooling. Although the RP2040 claims to have a thermal limit of 80C, no issues have yet been observed up to 98C. Typical conditions are for the RP2040 to report temperatures 20C above chamber.

This printer was also modified to utilize Clee's Beefy Z Idlers and Beefy Front Idlers. THE (Screw) FILTER was also added (printed from ABS) to speed chamber heating.

===== PPS-CF Printing =====

At this point, the printer was able to reach the targeted temperatures for PPS-CF. Printing occurred successfully post-calibration at speeds no greater than 20mm/s. Annealed parts were observed to have the "ring" characteristic of PPS-CF's high tensile modulus.

Note that the "ring" is only achievable on prints with relatively thin components. It should not be expected to occur on larger prints, e.g. Voron Cube.

===== Additional Notes =====

Special thanks to Armchair Heavy Industries and the community therein for the support and insight on this project.

Special Special thanks to the PET-GF Rat himself for the assistance and prior research on PET-GF, which has in large part informed this wiki.