The Method XL was released on May 23rd, 2023 as one of the most precise, mid-large build volume printers in the marketplace. Some of my contributions to this project were the following.

Swivel Clips
The interface between extruders and fillament tubes on the Method XL is bridged with swivel clips. For a long time, swivel clips had been a difficult part to both manufacture properly and prevent from fracturing during high-speed prints. I took on the task of improving the design and overseeing the manufacturer, FAI, texturing and more.

Levelness and Flatness
The dimensional accuracy of quality 3D prints is largely dependent on both the levelness and flatness of the print bed. Initially, the end-of-line leveling tests took more than 5 minutes to complete. I rewrote the script to be 3.5x faster to complete while improving fidelity. Additionally, I changed the sequence for which the assembly was put together to get produce the most flat assemblies possible (prior assemblies failed spec at a rate of ~40%). Lastly, I collected bead measurement data and did statistical analysis to determine whether the 0.31mm system levelness spec was too aggressive, it was, and I was able to increase it to 0.6mm producing a FPY rate of 95%.

Thermal Uniformity
Inside the Method XL, there are two heaters which push the chamber to as hot as 108C. For months the DVT printers were either incapable of heating to the desired temperature in the necessary time and or were not consistent. There were 6 individual variables: carriage position, heaters 1&2, fans 1&2 and HEPA filters. To find the root cause of the inconsistency, I had to ABA each part of the heater and then each fan and lastly the filters. Eventually, after hundreds of tests I determined the solution to inconsistent heating was a combination of fan DC, carriage position and filter quality.