LUME v1 — Printer Pre-Flight

LUME v1 — Printer Pre-Flight

> Printer setup notes only, 2026-04-30: the machine setup and ASA calibration notes are still useful, but the referenced print queue/plates are old. Use `PRINT_APPROVAL_QUEUE_CURRENT.md` for current LUME part order.

Checklist from unboxing the Neptune 4 Max to starting the first LUME plate. Target: printer arrives Wed AM → first ASA part printing Wed +4h.

1. Unbox + physical setup (~30 min)

• [ ] Unbox, remove all foam + zip ties (check gantry, bed, hotend, belts — N4M has 6 transit ties).
• [ ] Mount spool holder + filament runout sensor. Plug in both.
• [ ] Power cord to 120V. Ensure switch on rear is OFF before plugging.
• [ ] Boot. Touchscreen should light — firmware version visible.
• [ ] Connect to 2.4GHz WiFi via touchscreen. Note IP for Orca LAN upload.

2. Level + Z-offset (~20 min)

- [ ] Run auto-level from touchscreen (Prepare → Level → Auto). 49-point mesh. ~8 min.
- [ ] Set Z-offset by live-feedback method:
1. Heat bed to 100°C, nozzle to 260°C (ASA conditions — we level hot because ASA warps on cold bed).
2. Home all. Disable steppers.
3. Slide a sheet of standard A4 paper under nozzle. Lower Z until paper drags with light friction.
4. Save Z-offset to profile.
- [ ] Accept auto Z-offset or nudge −0.03mm if paper tears (too close) or glides freely (too far).

3. Load ASA (~10 min)

• [ ] Pre-heat hotend to 260°C (wait for stable).
• [ ] Snip filament end at 45° angle.
• [ ] Feed through runout sensor → extruder → into hotend. Push gently until extruder motor grips.
• [ ] Extrude 50mm via touchscreen. Purge should come out grey, smooth, no bubbling or popping.
• [ ] If popping (moisture in ASA): dry spool 6h in food dehydrator at 70°C before using. If ASA came from a sealed Polymaker bag, skip drying.

4. Bed prep for ASA (~5 min)

• [ ] With bed cold (<40°C): wipe PEI surface with 99
• [ ] Apply Elmer's purple glue stick in an even thin layer covering print area (entire 420×420 for shell halves). One pass vertical, one horizontal.
• [ ] Heat bed to 100°C. Glue will turn clear — this is correct.
• [ ] Re-apply glue between plates when it starts flaking or a part fails to stick on first layer.

5. Calibration print (~15 min)

• [ ] Run the Elegoo default calibration cube (ships pre-loaded on SD card as `Benchy_v3.gcode` or equivalent).
• [ ] Use PLA test filament from the bundle IF you have one — OR use the ASA you loaded at 260/100°C.
• [ ] Inspect: layer lines even, no ghosting, no warped corners, no under-extrusion. If warp on a 10mm cube: check bed level + glue; do not proceed to LUME.

6. Slice profile setup in OrcaSlicer (~20 min)

• [ ] Install OrcaSlicer latest (≥2.1) on Mac1.
• [ ] Add printer: Elegoo Neptune 4 Max (built-in preset).
• [ ] Import filament profile: Polymaker PolyLite ASA (community preset) OR duplicate Generic ASA, set:
• Nozzle: 260°C (first), 255°C (others)
• Bed: 100°C first layer, 100°C others
• Fan: **0
• Retraction: 1.0mm @ 40 mm/s
• Flow ratio: start 0.98
• [ ] Duplicate profile → rename "ASA-LUME-0.20". Settings per `print-queue.md` Slice Profile section.
• [ ] Duplicate again → "ASA-LUME-0.16" for bezel.
• [ ] Add clear PETG profile (Overture Clear PETG): nozzle 240°C, bed 80°C, fan 40
• [ ] Configure network: Orca → Device → add Neptune 4 Max by IP → test upload.

7. First LUME print: coupons

• [ ] Open `lume-commerce/hardware/cad/exports/coupon_tongues.stl` + `coupon_grooves.stl` + `splice_pegs.stl` + `splice_pockets.stl` in Orca.
• [ ] Arrange on plate (Orca auto-arrange — all four fit on 420×420 easily).
• [ ] Apply "ASA-LUME-0.20" profile. Slice. Verify estimate 45–60 min, filament ~12g.
• [ ] Save as `plate_coupons.3mf`. Upload to printer. Start.
• [ ] Gate: after print, test-fit tongue/groove and peg/pocket at each labeled clearance. Pick tightest that seats without force. Note winner (expected 0.20mm for both).
• [ ] If winner ≠ 0.20, update `LIP_CLEAR` in `lume-config.scad` and `SPLICE_POCKET_D` in `lume-shell.scad`, then re-render shell STLs before starting plate 2.

8. Enclosure improvisation (~15 min during coupon print)

Neptune 4 Max is open-frame. ASA on open frame on shell halves (500mm × 120mm footprint) is the #1 warp risk in PRINT_PLAN.md. Cheap mitigations, in priority order:

1. Cardboard tent: 2× large moving-box panels taped into a 3-sided box around printer. Leave top open for Z travel. Cuts draft. ~$0.
2. Chamber temp target: 35–45°C inside tent during shell prints. Measure with any kitchen thermometer. If <30°C, add a second layer of cardboard.
3. Close nearby windows + HVAC vents in the print room. Drafts are the enemy.
4. Don't open the room door during the first 3 layers of any shell half.

Full polycarbonate enclosure is ideal but $150+ and not on the critical path. Cardboard tent gets us through v1.

9. Safety + monitoring

• [ ] ASA off-gasses styrene. Room must be ventilated (cracked window + door). Do not sleep in the same room during prints.
• [ ] Install Octoprint or use Elegoo Cloud for webcam monitoring of overnight plates 2+3.
• [ ] Smoke detector + fire extinguisher accessible. Never leave first-layer unattended.
• [ ] Emergency stop: power switch on rear. Memorize its location.

10. Ready to print LUME checklist

• [ ] All 4 auto-level gates pass (mesh deviation <0.3mm)
• [ ] Calibration cube prints clean
• [ ] Coupons print and a LIP_CLEAR winner is picked
• [ ] Orca profiles imported and tested (coupons were the test)
• [ ] Cardboard tent installed
• [ ] Room ventilated, monitoring up
• [ ] `plate_shell_front_LR.3mf` sliced and uploaded

When all 10 above are ✓: start plate 2 overnight. PRINT_PLAN takes over.