Volterra-ALF

Volterra Adaptive Layer Fusion - Klipper Configuration for Large Format CoreXY 3D Printer

Overview

This repository contains the Klipper firmware configuration files for the Volterra-ALF (Adaptive Layer Fusion) 3D printer by Fracktal Works. The Volterra-ALF is a large-format industrial CoreXY printer designed for high-temperature materials with advanced thermal management features.

Printer Specifications

Specification	Value
Kinematics	CoreXY
Build Volume	400 × 400 × 435 mm
Max Velocity	200 mm/s
Max Acceleration	1500 mm/s²
Max Z Velocity	20 mm/s
Nozzle Diameter	0.4 mm
Max Hotend Temp	480°C
Max Bed Temp	150°C
Max Chamber Temp	160°C

Hardware Configuration

Motion System

• Stepper Drivers: TMC5160 on all axes (SPI mode with StealthChop)
• X/Y Motors: 1.2A run current, 16 microsteps
• Z Motor: 2.8A run current, 8 microsteps
• Extruder: Dual extrusion system with primary and side extruder steppers

Control Board

• MCU: STM32H723xx (BTT Manta M8P or similar)
• Serial: USB connection via /dev/serial/by-id/

Thermal System

• Hotend: PT1000 sensor, PID controlled (up to 480°C)
• Heated Bed: ATC Semitec 104GT-2 thermistor, watermark control
• Chamber Heater: PID controlled with dedicated heater
• Filament Heater: Separate heating zone for filament preheating
• AOF Fan: Always-on fan for hotend cooling

Sensors & Probing

• Z Probe: Bed-mounted probe with automatic mesh leveling
• Bed Mesh: 5×5 probe grid with bicubic interpolation
• Bed Screws: 3-point manual leveling (Front Left, Front Right, Rear Centre)

File Structure

Volterra-ALF/
├── printer.cfg              # Main printer configuration
├── CORE_GCODE_MACROS.cfg    # Core G-code macros for Marlin compatibility
├── macro.cfg                # Additional custom macros
├── mainsail.cfg             # Mainsail web interface configuration
├── moonraker.conf           # Moonraker API server configuration
├── KlipperScreen.conf       # KlipperScreen touch interface settings
└── config_backups/          # Timestamped configuration backups

Key Features

G-code Compatibility

The configuration includes Marlin-compatible G-code macros for seamless operation:

Macro	Description
G28	Custom homing override (Z→Y→X sequence)
G29	Automatic bed mesh calibration
M106	Part cooling fan control (inverted PWM)
M114	Position reporting
M190	Heated bed temperature wait with tolerance
M218	Tool offset configuration
M290	Babystepping with persistent storage
M420	Bed mesh load/clear
M500	Save configuration
M503	Report settings
M851	Z probe offset adjustment
M900	Pressure advance configuration

Filament Sensors

• Runout Detection: Switch-based filament sensors (T0/T1)
• Jam Detection: Motion-based encoder sensors
• Macros: SET_FILAMENT_RUNOUT_SENSOR, SET_FILAMENT_JAM_SENSOR

Thermal Management

• Multi-zone heating (bed, chamber, filament)
• Automatic idle timeout with temperature management
• Configurable verify_heater settings for reliable operation

Installation

Prerequisites

• Raspberry Pi (or similar SBC) running Raspberry Pi OS
• Klipper firmware installed
• Moonraker API server
• Mainsail or Fluidd web interface

Setup Steps

1. Clone the repository:

   cd ~/printer_data/config
   git clone https://github.com/FracktalWorks/Volterra-ALF.git .

2. Flash Klipper to MCU:

   cd ~/klipper
   make menuconfig
   # Select: STM32H723, 128KiB bootloader, USB communication
   make
   make flash FLASH_DEVICE=/dev/serial/by-id/usb-Klipper_stm32h723xx_XXXXX

3. Configure Moonraker:

   • Update moonraker.conf with your network settings
   • Add trusted clients for your network

4. Restart Services:

   sudo systemctl restart klipper
   sudo systemctl restart moonraker

Usage

Initial Setup

1. Home the printer: G28
2. Level the bed screws: SCREW_ADJUST
3. Run bed mesh calibration: G29
4. Adjust Z probe offset: M851 Z=<offset>
5. Save configuration: M500

Print Preparation

; Preheat
M140 S60          ; Bed temperature
M104 S200         ; Hotend temperature
SET_HEATER_TEMPERATURE HEATER=Chamber TARGET=50  ; Chamber

; Home and level
G28               ; Home all axes
M420 S1           ; Load bed mesh

; Start printing

Babystepping During Print

M290 Z0.05        ; Raise nozzle by 0.05mm
M290 Z-0.05       ; Lower nozzle by 0.05mm

Web Interface

Access the printer through Mainsail at:

• Local: http://<raspberry-pi-ip>
• Default port: 80 (web) / 7125 (API)

Supported Interfaces

• Mainsail - Primary web interface
• KlipperScreen - Touch screen interface
• OctoPrint - Compatible via octoprint_compat

Configuration Backups

Configuration backups are automatically saved in config_backups/ with timestamps:

• Format: printer-YYYYMMDD_HHMMSS.cfg
• Useful for reverting to previous working configurations

Troubleshooting

Common Issues

Issue	Solution
Homing fails	Check endstop connections, verify position_endstop values
Probe not triggering	Verify probe pin configuration and wiring
Temperature errors	Adjust verify_heater settings, check thermistor connections
Stepper motor issues	Check TMC5160 SPI connections and run_current values

Useful Commands

QUERY_ENDSTOPS           ; Check endstop states
QUERY_PROBE              ; Check probe state
QUERY_FILAMENT_RUNOUT_SENSOR  ; Check filament sensor status
M503                     ; Report current settings

Contributing

Contributions are welcome! Please:

1. Fork the repository
2. Create a feature branch
3. Submit a pull request with detailed description

License

This project is licensed under the GNU General Public License v3.0 - see the included mainsail.cfg header for details.

Authors

• Vijay Raghav Varada - Fracktal Works
• Yashas B Padmashali - Fracktal Works

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For more information about Fracktal Works printers, visit fracktal.in