A dual extrusion 3D printer by Ultimaker that uses fused filament fabrication for large-format applications with its large build volume.

Ultimaker S5

<h3>Problem / Solution</h3>Weeks to months of traditional methods answer the need for quality manufacturing—a time-consuming process that requires more cost. Yet the advances in 3D printing are paving the way to a more time-efficient manufacturing process. It saves time and money by using technologies that remove the need for tooling, which consumes money and resources. The method likewise reduces labor costs given the increase in automation while allowing for printing multiple assembly parts simultaneously. 3D printing not only reduces the risks in prototyping but allows for more flexible designs that traditional processes cannot achieve. Given less wasteful processes and reusable filament materials in 3D printing, sustainability in the manufacturing field is within reach.Among Ultimaker 3D printers, which use engineering thermoplastics for fused deposition modeling, is a powerful 3D printer—the Ultimaker S5. This dual extrusion printer provides reliability as a user-friendly device for industrial and educational use. Ultimaker S5 has a large build volume for delivering accurate industrial-grade parts. It is capable of printing bigger models and achieves maximum efficiency when placing more parts on the build plate. Ultimaker S5 is the complete package in professional 3D printing, given its simple setup, reliable dual extrusion, and high uptime. The addition of Ultimaker Cura provides this 3D printer with a very high standard in reproducing 3D models.<h3>Design</h3>Including the Bowden tube and spool holder, Ultimaker S5 measures 495 x 585 x 780 mm (19.5 x 23 x 30.7 in). It weighs 20.6 kg (45.5lbs) and has a XYZ build volume of 330 x 240 x 300 mm (13 x 9.4 x 11.8 in). The operating sound is &lt; 50 dBA, while the build speed is &lt; 24 mm3/s. The layer resolution varies depending on the nozzle size, 150 - 60 microns for the 0.25mm nozzle, 200 - 20 microns for the 0.4mm, 300 - 20 microns for the 0.6mm, and 600 - 20 microns for the 0.8mm. The XYZ resolution measures 6.9, 6.9, and 2.5 microns with a compatible filament diameter of 2.85mm.Main ComponentsMoving in the X and Y direction, the dual extrusion print head releases filament from the nozzles with its auto-nozzle lifting system. Its two print cores are easily swappable. The heated build platform of the Ultimaker S5 is a glass build plate, which moves down per layer following the advanced active leveling. It has a 4.7-inch color touchscreen that efficiently displays menu options and information about the print.Geared feeders deliver the material into the print head. This dual-geared feeder is reinforced with composite materials. Feeder 1 will guide material 1 to slot 1 of the print head and feeder 2 follows the same sequence. There is also a flow sensor that informs when the filament runs out, thus increasing print success.Air ManagerUltimaker S5 has the Air Manager, which fully encloses the printer’s build chamber and prompts an inside-out airflow. Using the E10 filter, the Air Manager eliminates at most 95% of ultrafine particles (UFPs). This key addition provides a safer work environment even when printing extended ranges of either Ultimaker or third-party materials.The Air Manager consumes 490 x 503 x 350 mm (19.3 x 19.8 x 13.8 in) of the printer size and weighs 3.6 kg (7.9 lbs).It has optimized material compatibility as it can adjust its fan speed per material for quality print. The fan technology involves air extraction by a low-noise brushless fan. The fan speed calculation depends on the build plate temperature and ambient temperature. The Air Manager’s own sensors measure these parameters to maintain the specified chamber temperature.Its EPA filter technology can filter UFPs, which number can vary depending on the material type. It has an air refresh rate of 1 - 50 m3/h, while for most materials at 23°C, the nominal rate is 35 m3/h.The Air Manager has a physical barrier that encloses the top, preventing users from reaching into the machine while it operates. It likewise ensures outside particles from the environment cannot influence the print result.Material StationUltimaker S5 delivers a more flexible yet more efficient and reliable solution for material handling through the Material Station, which also adds storage. Achieving this performance involves simplifying the printing workflow, controlling humidity, and automating material switching. The process improves quality and increases the success rate of single and dual extrusion printing. The Material Station, measuring 491 x 438 x 400 mm (19.3 x 17.2 x 15.7 in) and weighing 17.7 kg (7.9 lbs), works with Ultimaker and third-party composite materials.The front of the Ultimaker S5 can load up to 6 material spools. The display flashes the material bays while the configuration menu allows changing of the user interface to reflect this. The auto material recognition powered by NFC Scanner has a dual-geared abrasion-resistant feeder and a filament diameter of 2.85mm.Ultimaker S5 also has an automatic filament switching that when the Material Station detects an end-of-filament situation, it switches to the next material spool available. The Material Station likewise hosts a built-in dehumidifier for controlling the humidity. The relative humidity rests under 40% using moisture-absorbing silica beads. The dehumidifier can regenerate the silica beads once they become saturated, ensuring the loaded materials do not absorb moisture. Although the Material Station cannot actively dry the said materials.Once the print finishes, the Pro Bundle initiates the deprime procedure, which guarantees the material is clean, tip-sharp, and has no strings. The process makes sure the material can reliably unload back into the station. However, the material does not unload right away. It takes 2 hours for most materials and 60 for PVA. The material remains parked above the print head and may stay until the next print job.Ultimaker S3 vs Ultimaker S5Belonging to the same printer family, Ultimaker S3 and Ultimaker S5 share many key features and technologies such material compatibility, but differ in certain aspects. While both open filament systems are compatible with the entire Ultimaker ecosystem, S3 has a smaller build volume of 230 x 192 x 200 mm compared to S5’s 330 x 240 x 330 mm. Ultimaker S5, unlike Ultimaker S3, benefits from peripherals like the Air Manager and Material Station. Although given Ultimaker S3’s smaller build plate, it consumes less power (350W max) when heated to the same temperature as the Ultimaker S5 (500W max).

Dimensions
Build volume	330 x 240 x 300 mm (13 x 9.4 x 11.8 inches)
Assembled Dimensions	495 x 585 x 780 mm (19.5 x 23 x 30.7 inches)
Print Technology	Fused filament fabrication (FFF)
Compatible filament Diameter	2.85 mm
Weight	20.6 kg (45.4 lbs)