TITLE: Freequenza Box - Production and Assembly
AUTHORS: Matthew  Meyer, Katarzyna  Dobaczewska, Zbigniew  Mikulski

[DESCRIPTION]
A histology aid for slide immunostaining. Improves staining consistency, reduces reagent use, and saves time. Works with Shandon Plastic Coverplates. For technical specifications, check out this link.

Total hands-on time to 3D-print and assemble a 5x3 model is approximately 5 hours, and 4 days including printing and gluing time

[BEFORE_START]
Make sure you understand and follow the safety guidelines for your 3D printer. Test the compatibility of the filament with the solutions you will be using in the future. See here for ideas.  

[STEPS]
SECTION: 3D-Printing
1. Navigate to the required 3D-printable files from the NIH 3D Print Exchange
SECTION: 3D-Printing
2. Select the desired model type from the below options and download the file in the "Other Files" section
2x1 Box.zip - (2 slide capacity)
3x2 Box.zip - (6 slide capacity)
5x3 Box.zip - (15 slide capacity)
7x4 Box.zip - (28 slide capacity)

  

SECTION: 3D-Printing
3. Extract the .zip file to retrieve the required files
Mac: Double-click .zip file
PC: Right-click .zip file and click "Extract All..."
Linux: Follow video tutorial

  

SECTION: 3D-Printing
4. Launch the 3D-printing slicing software. If you are experiencing a very poor performance of the software on a computer bound to a domain (often the case in large academic institutions) see this post for a potential remedy    

  

SECTION: 3D-Printing
5. Open the .stl files +Rack*, -Rack*, End, and Insert in the slicing software 

  

* suffix will differ depending on the model type
SECTION: 3D-Printing
6. Multiply the above .stl files to the appropriate number based on the model type

 

  

SECTION: 3D-Printing
7. Use the default setting in a "High Detail" profile (i.e. ≤0.18mm layer height) and prepare/slice the design into a .gcode file

  
If your printed parts break easily try to inspect your sliced model in the Layer view to see if the infill creates a strong, interconnected lattice in the vulnerable part. Try increasing the wall size to 2 mm, changing the Infill Density to 80% density, and Infill Pattern to Cubic or Gyroid.
SECTION: 3D-Printing
8. Upload the .gcode file onto an SD card

  

SECTION: 3D-Printing
9. Insert the SD card into the 3D-printer
SECTION: 3D-Printing
10. Heat the 3D-printer nozzle to approximately 170°C
SECTION: 3D-Printing
11. Using a clean cloth, wipe the heated nozzle to remove debris

    
  
  

SECTION: 3D-Printing
12. Prepare printbed for maximum adhesion of filament (e.g. using a glue stick to cover the area of the printbed which objects will be printed on) 
SECTION: 3D-Printing
13. Select the .gcode file and print

  
  
   

SECTION: 3D-Printing
14. Carefully remove parts from the 3D-printer printbed using a razor blade

  

SECTION: 3D-Printing
15. Repeat steps 4-14 with the Box and Top .stl files with the "Infill" setting at 100%

  

SECTION: 3D-Printing
16. Inspect parts for defects
SECTION: 3D-Printing
16.1. Acceptable defects (e.g. small blemishes, strings, indentations, etc.) can be cleaned with razor blades, sand paper, or metal brushes

     
  
  

SECTION: 3D-Printing
16.2. Unacceptable defects (e.g. large holes, wall flaking, warping, etc.) cannot be repaired and will need to be reprinted

Many issues come from the moisture in the filament (it should be stored in a desiccated container with up to 20% relative humidity). Printer issues can be diagnosed with the help of this guide.  
   
  
  
  

SECTION: 3D-Printing
17. Fill the Box and Top with water to check if they leak
SECTION: 3D-Printing
17.1. If the part leaks, place the part in a larger container and fill the part with acetone*


* use caution and work under a chemical hood as acetone is flammable and produces hazardous fumes 
SECTION: 3D-Printing
17.2. Let the part sit until the acetone stops leaking through the previous leak hole
SECTION: 3D-Printing
17.3. If the part never stops leaking, the part will need to be reprinted
SECTION: Assembly
18. Connect Inserts and +Rack

  

SECTION: Assembly
18.1. Lay the long edge of the +Rack flat on a counter (rods facing upward) with the short edge oriented leftward
SECTION: Assembly
18.2. Lay the Inserts on their sides (holes facing upward) with the outward bump oriented leftward
SECTION: Assembly
18.3. Maintaining the above orientations, place the holes of the Inserts through the rods of the +Rack
SECTION: Assembly
19. Glue +Rack, -Rack, and End together

  

SECTION: Assembly
19.1. Apply 3M Scotch-Weld PR40 or superglue to all holes of the +Rack and -Rack
SECTION: Assembly
19.2. Align and connect the holes of the -Rack with the rods and studs of the +Rack
SECTION: Assembly
19.3. Orient the outward bump on the End  the same way as the Inserts
SECTION: Assembly
19.4. Connect the End  studs into the holes of the +Rack and -Rack
SECTION: Assembly
19.5. Wipe off excess glue with a paper towel
SECTION: Assembly
20. Rubberband the assembled rack together or use woodworking clamps 
SECTION: Assembly
21. Let the glue dry until the parts are completely set

SECTION: Assembly
22. Place the assembled rack into the Box with the outward bumps facing upward

   

SECTION: Assembly
23. Optional: Glue Handles to Box