TSTAK, VersaStack, and ToughSystem 2.0 Labels

TSTAK and ToughSystem 2.0 Labels

Description

These labels are designed to fit either the VersaStack/TSTAK system or the ToughSystem 2.0. The ToughSystem 2.0 labels use the same attachment system as the TSTAK labels, they are just bigger.

They are printed via a new process I have been experimenting with. My previous labels were made with a process of printing the body of the label in one color, swapping to another color, and finishing the label. This new process involves printing the text of the label first so that it is flat against the print bed. This allows me to make more complex labels without using supports like my last label: the Low-Profile Packout Handle Label.

I’m including the model and only two examples because these are really designed to be customized. There’s one example for TSTAK and one for ToughSystem 2.0.

Files

Printer: Prusa i3 MK3
Slicer: PrusaSlicer
Material: Inland PET-G
Resolution: 0.3 mm with a 0.4mm nozzle
Wall Lines/Perimeters: 2
Infill: Minimum 10% Gyroid. The higher infill percentage the stronger the part.
Notes:

Instructions

Before you tackle designing your own labels, please try one of the examples to make sure you understand the printing process. Download the example for the system you are using and unzip it. There will be two files: * text.stl and *label.stl.

These instructions are for PrusaSlicer but the process should be similar for other slicers. To align the two prints, I am relying on the default feature of PRUSA Slicer to center the model on the print bed, if your slicer doesn’t automatically do this, you need to find the setting that forces it to center the models or use another slicer.

This isn’t the most efficient way to do overlapping prints in different colors, but it is the simplest way for a novice and shouldn’t be slice dependent.

Creating the gcode:

  1. Unzip the file drag the * text.stl file into a blank project where you’ve added the above “Print Settings” in your slicer.
  2. DO NOT MOVE THE TEXT!
  3. Goto Print Settings (Advanced or Expert Mode) find the “Skirt and Brim Settings” and set “Loops” to 0.
  4. Find the “Advanced” settings and set the Elephant’s foot compensation to 0.0 mm.
  5. Go back to the plater and hit the “Slice Now” button.
  6. Save the gcode to your SD card as “Text….gcode”.
  7. Delete the model, but stay in the project.
  8. Drag the * label.stl file into the project. DO NOT MOVE THE LABEL!
  9. Hit the “Slice Now” button.
  10. Save the gcode to your SD card as “Label….gcode”.

Printing the Labels:

  1. Switch filament to the text color (white in my photos).
  2. Print the “Text….gcode” file.
  3. DO NOT REMOVE THE TEXT FROM THE BED!
  4. Keep the bed preheated.
  5. Switch filament to the label color (black in my photos).
  6. Remove any stray filament from the bed (like in the wipe area).
  7. Print the “Label….gcode” file.
  8. Remove the print from the bed when done printing.

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