microweldr 5.1.1

Convert SVG files to Prusa Core One G-code for plastic welding applications - microfluidics prototyping with 3D printers

MicroWeldr

A Python package that converts SVG files to Prusa Core One G-code for plastic "spot" welding applications. The package processes SVG vector graphics and generates G-code that creates weld spots along the paths without extruding any plastic material.

NEW: Unified Command Interface - All functionality consolidated into a single microweldr command with subcommands for testing, calibration, framing, and welding operations.

Optimized for Prusa Core One: Includes chamber temperature control (M141/M191), proper bed dimensions (250×220×270mm), and CoreXY-specific settings for reliable plastic welding operations.

This allows for rapid microfluidics prototyping with a 3d printer. While the edges are not as smooth as a laser weld, the 3d printer is more available than a laser welder.

Project Structure

microweldr/
├── microweldr/           # Main package
│   ├── core/            # Core functionality
│   ├── validation/      # Validation modules
│   ├── animation/       # Animation generation
│   └── cli/             # Command line interface
├── tests/               # Test suite
│   ├── unit/           # Unit tests
│   └── integration/    # Integration tests
├── examples/           # Example files and configurations
├── docs/              # Documentation
└── pyproject.toml     # Poetry configuration

Features

• SVG Processing: Converts SVG paths, lines, circles, and rectangles to weld points
• Color-based Weld Types:
  • Black elements → Normal welds
  • Blue elements → Light welds (lower temperature, shorter welding time)
  • Red elements → Stop points (pause for user intervention)
• Configurable Parameters: TOML-based configuration for temperatures, heights, and timing
• Bed Leveling: Optional automatic bed leveling (can be disabled)
• Animation Output: Generates animated SVG showing the welding sequence
• Proper G-code Structure: Includes heating, cooling, and safety procedures
• PrusaLink Integration: Direct G-code submission to Prusa MINI via PrusaLink API

Interactive UI (Recommended)

For the best user experience, use the interactive terminal interface:

# Quick start - convert and weld SVG
microweldr my_design.svg

# Or use explicit weld command
microweldr weld my_design.svg

Features:

• Real-time printer status (connection, temps, position)
• Live bounds display and weld path visualization
• Interactive controls: calibrate, heater, preview, load/unload, print
• Background monitoring with 2-second updates
• Bed heater control with live temperature display
• All operations accessible via numbered menu (1-6)

See UI_README.md for complete documentation.

Command Line Workflow

For automation and scripting, use the command line tools:

1. One-time Setup

# Perform XYZ calibration and store results persistently
microweldr calibrate

2. For Each Welding Job

# Step 1: Prepare for film loading (home axes)
microweldr home

# Step 2: Load film and place magnets
# [Manual step - load your plastic film and secure with magnets]

# Step 3: Check magnet clearance
microweldr frame design.svg

# Step 4: Perform welding
microweldr weld design.svg

Workflow Command Details

• calibrate - Performs XYZ calibration and stores results persistently (no SVG file needed)
• load - Lowers table 10cm for easy film loading, sets target temperature but doesn't wait
• frame - Runs rectangle at move height to check for magnet interference with nozzle path
• weld - Sets bed temperature, waits for it, then runs the complete welding sequence

All commands are immediately executed on the printer via PrusaLink.

Typical Session

# One-time calibration
microweldr calibrate --verbose

# First design
microweldr home
# [Load film with PP surfaces together, place magnets]
microweldr frame design1.svg
microweldr weld design1.svg

# Second design (no calibration needed)
microweldr home
# [Load new film with PP surfaces together, adjust magnets]
microweldr frame design2.svg
microweldr weld design2.svg

Installation

From PyPI (Recommended)

pip install microweldr

That's it! All validation and development tools are included by default.

Development Installation

# Clone repository
git clone https://github.com/retospect/microweldr.git
cd microweldr

# Install in editable mode
pip install -e .

Available Commands

After installation, these console commands are available:

Workflow Commands (Recommended)

# One-time calibration
microweldr calibrate

# Per-job workflow
microweldr home                          # Prepare for film loading
microweldr frame design.svg              # Check magnet clearance
microweldr weld design.svg               # Perform welding

Main Commands

# SVG to G-code conversion
microweldr input.svg -o output.gcode

# Print with automatic monitoring
microweldr input.svg --submit-to-printer --monitor
microweldr input.svg --submit-to-printer --monitor --monitor-mode pipetting

Utility Commands

# Test PrusaLink connection
microweldr test

# Printer calibration options
microweldr calibrate                     # Full calibration (home + bed leveling)
microweldr calibrate --home-only         # Home axes only
microweldr bed-level                     # Bed leveling only
microweldr home [XYZ]                    # Home specific axes

Physical Setup and Use

⚠️ Critical Material Orientation

IMPORTANT: When using plastic films from rolls, material orientation matters significantly for weld success:

• ✅ Use PP surfaces for welding - The inner/concave side of the roll (that faced the roll center)
• ❌ Avoid non-PP surfaces - The outer/convex side of the roll (that faced outward) does not weld properly

Many plastic films are laminated or coated materials with different properties on each side. Always ensure the weldable surfaces (typically PP) are placed together for successful bonding.

📊 See detailed experimental validation: experimental_validation.md

Physical Setup Requirements

• Printer: Prusa Core One with satin powder-coated print sheet
• Film Positioning: Lay plastic films as flat as possible on heated bed
• Securing Method: Use small neodymium magnets (2mm height × 6mm diameter) to hold films in place
• Magnet Placement: Position magnets strategically to avoid interference with nozzle path
• Temperature: Bed heated to 120°C, nozzle to 170°C for PP welding

Configuration

Edit config.toml to adjust welding parameters:

[temperatures]
bed_temperature = 80        # °C
nozzle_temperature = 200    # °C for normal welds
chamber_temperature = 35    # °C - Core One chamber temperature
use_chamber_heating = false # Set to false to disable chamber heating (useful if sensor is not working)

[movement]
move_height = 5.0          # mm - safe travel height
weld_height = 0.2          # mm - welding height

[normal_welds]
weld_temperature = 200     # °C
dot_spacing = 0.3          # mm - final desired spacing
initial_dot_spacing = 8.0  # mm - spacing for first pass (wider)
cooling_time_between_passes = 2.0  # seconds - cooling between passes

[light_welds]
weld_temperature = 180     # °C - lower temperature
weld_time = 0.3      # seconds - shorter time
dot_spacing = 0.3          # mm - final desired spacing
initial_dot_spacing = 12.0 # mm - spacing for first pass (wider)
cooling_time_between_passes = 1.5  # seconds - cooling between passes

[nozzle]
outer_diameter = 0.4        # mm - nozzle outer diameter
inner_diameter = 0.2        # mm - nozzle inner diameter (opening)

[animation]
time_between_welds = 0.1    # seconds - time between weld points in animation
pause_time = 3.0            # seconds - how long pause messages are displayed
min_animation_duration = 10.0  # seconds - minimum total animation time

Configuration File Loading

MicroWeldr looks for configuration files in the following order (first found wins):

Main Configuration (config.toml)

1. Command line specified: -c custom_config.toml or --config custom_config.toml
2. Current directory: ./config.toml
3. Examples directory: ./examples/config.toml (if running from repo root)
4. Package defaults: Built-in fallback configuration

Secrets Configuration (secrets.toml)

Used for PrusaLink printer connection settings:

1. Command line specified: --secrets-config custom_secrets.toml
2. Current directory: ./secrets.toml
3. Examples directory: ./examples/secrets.toml
4. No secrets file: PrusaLink features disabled (local G-code generation only)

Configuration Hierarchy

• Built-in defaults provide base configuration
• Main config file overrides defaults
• Command line arguments override config file settings
• SVG attributes override all other settings (per-element)

File Locations Examples

# Using default config in current directory
microweldr input.svg                    # Uses ./config.toml

# Using custom config file
microweldr input.svg -c my_config.toml  # Uses my_config.toml

# Using custom secrets file
microweldr input.svg --secrets-config my_secrets.toml

# Both custom configs
microweldr input.svg -c my_config.toml --secrets-config my_secrets.toml

Config File Templates

• config.toml: Main welding parameters (temperatures, speeds, etc.)
• examples/config.toml: Optimized settings for new users
• secrets.toml: PrusaLink connection settings (not in git)
• secrets.toml.template: Template for PrusaLink setup

Missing Files Behavior

• No config.toml: Uses built-in defaults (safe for basic operation)
• No secrets.toml: PrusaLink disabled, local G-code generation only
• Invalid config: Falls back to defaults with warnings
• Partial config: Missing sections use defaults

PrusaLink Configuration

To enable direct G-code submission to your Prusa Core One, you need to configure PrusaLink access:

1. Setup PrusaLink on Your Printer

• Enable PrusaLink on your Prusa Core One (should be enabled by default on newer firmware)
• Connect your printer to your network (WiFi or Ethernet)
• Note your printer's IP address (check printer display or router) or find its .local hostname

2. Find Your Printer's Address

You can use either:

• IP Address: Check your printer's display or router's connected devices
• .local hostname: Usually prusacoreone.local or similar (check printer display for exact name)

3. Get Authentication Credentials

Choose ONE method:

Method A: LCD Password (Recommended - Easier)

• Check your printer's LCD display for the password (usually shown in network settings)
• No web interface setup needed

Method B: API Key (Alternative)

• Open your printer's web interface: http://YOUR_PRINTER_IP or http://prusacoreone.local
• Go to Settings → API
• Generate or copy your API key

4. Configure secrets.toml

Copy the template and fill in your details:

cp secrets.toml.template secrets.toml

Edit secrets.toml:

[prusalink]
host = "192.168.1.100"         # Your printer's IP address
# OR use .local hostname:
# host = "prusacoreone.local"  # More convenient, doesn't change with DHCP

# Method A: LCD Password (recommended)
username = "maker"             # Default username (usually "maker")
password = "your-lcd-password" # Password from printer's LCD display

# Method B: API Key (alternative - comment out Method A if using this)
# username = "maker"
# api_key = "your-api-key-here"  # From printer's web interface

default_storage = "local"      # "local" or "usb"
auto_start_print = true        # Whether to start printing immediately
timeout = 30                   # Connection timeout in seconds

5. Test Connection

microweldr test

6. Submit G-code to Printer

# Generate and submit G-code (starts printing immediately with default config)
microweldr input.svg --submit-to-printer

# Force immediate printing (overrides config)
microweldr input.svg --submit-to-printer --auto-start-print

# Use USB storage instead of local
microweldr input.svg --submit-to-printer --printer-storage usb

# Upload without starting (override config default)
microweldr input.svg --submit-to-printer --no-auto-start

# Queue the file for later printing (clearer intent)
microweldr input.svg --submit-to-printer --queue-only

Printing Modes

The SVG welder supports three different printing modes when submitting to your printer:

Immediate Printing (Default)

Files are uploaded and printing starts immediately:

microweldr input.svg --submit-to-printer
# or force immediate printing:
microweldr input.svg --submit-to-printer --auto-start-print

Queue Mode

Files are uploaded and queued for later printing:

microweldr input.svg --submit-to-printer --queue-only

Use this when:

• You want to prepare multiple files
• The printer is currently busy
• You want to review the file before printing

Upload Only

Files are uploaded without any automatic behavior:

microweldr input.svg --submit-to-printer --no-auto-start

Usage

Basic Usage

# Convert SVG to G-code
microweldr input.svg

# Using the module directly
python -m microweldr.cli.main input.svg

Advanced Options

# Specify output file
microweldr input.svg -o output.gcode

# Skip bed leveling
microweldr input.svg --skip-bed-leveling

# Use custom configuration
microweldr input.svg -c custom_config.toml

# Skip animation generation
microweldr input.svg --no-animation

# Skip validation
microweldr input.svg --no-validation

# Verbose output
microweldr input.svg --verbose

Quick Start with Examples

# Run with example files
make run-example
make run-comprehensive

Command Line Options

• input_svg: Input SVG file path (required)
• -o, --output: Output G-code file path (default: input_name.gcode)
• -c, --config: Configuration file path (default: config.toml)
• --skip-bed-leveling: Skip automatic bed leveling
• --no-animation: Skip generating animation SVG
• --no-validation: Skip validation steps
• --verbose, -v: Enable verbose output
• --weld-sequence: Welding sequence algorithm (linear, binary, farthest, skip)
• --submit-to-printer: Submit G-code to PrusaLink after generation
• --secrets-config: Path to secrets configuration file (default: secrets.toml)
• --printer-storage: Target storage on printer (local or usb)
• --auto-start-print: Automatically start printing after upload (overrides config)
• --no-auto-start: Do not start printing after upload (overrides config)
• --queue-only: Queue the file without starting (clearer intent than --no-auto-start)

SVG Requirements

Coordinate System

• SVG coordinates should be in millimeters
• Origin (0,0) corresponds to the printer bed origin

Element Processing Order

• Elements are processed in order of their SVG ID attributes
• IDs with numeric components are sorted numerically
• Elements without IDs are processed last

Color-Based Weld Types

MicroWeldr interprets SVG element colors to determine weld behavior:

Recognized Colors:

• Black elements (default): Normal welding with full temperature and multi-pass
• Blue elements: Light welding with reduced temperature and shorter welding time
• Red elements: Stop points with custom pause messages for manual intervention
• Pink/Magenta elements: Pipetting stops for microfluidic device filling

Other Colors (Ignored):

• All other colors (green, orange, purple, yellow, etc.): Completely ignored - no G-code generated
• Gray elements: Ignored (commonly used for labels and annotations)
• White elements: Ignored
• Any unlisted color: Ignored and skipped during processing

Color Specification:

Colors can be specified via:

• stroke attribute: stroke="black"
• fill attribute: fill="blue"
• style attribute: style="fill:red;stroke:none"

Best Practice for Labels:

Use non-weld colors (orange, purple, green, gray) for text labels and annotations to prevent unintended G-code generation:

<!-- These will be ignored (no welding) -->
<text fill="orange">Temperature: 130°C</text>
<text fill="purple">Dwell: 0.1s</text>
<text fill="gray">Calibration Grid</text>

Pipetting Stops for Microfluidics 🧪

Pink/Magenta elements create pipetting stops specifically designed for microfluidic device operation:

Supported Colors:

• magenta, pink, fuchsia
• #ff00ff, #f0f, #ff69b4, #ffc0cb
• rgb(255,0,255), rgb(255,105,180), rgb(255,192,203)

Use Cases:

• Reagent filling: Pause to add reagents to pouches
• Sample injection: Stop for sample introduction
• Buffer addition: Add buffers or washing solutions
• Collection: Insert collection tubes or containers

Example:

<!-- Pipetting stop with custom message -->
<circle cx="60" cy="50" r="8" fill="magenta"
        title="Fill with 10μL reagent A using micropipette"/>

Custom Pause Messages

Both red elements (stop points) and pink elements (pipetting stops) can include custom messages displayed on the printer screen. Messages can be specified using any of these SVG attributes (in order of priority):

• data-message="Your custom message" - Recommended custom data attribute
• title="Your custom message" - Standard SVG title attribute
• desc="Your custom message" - SVG description element
• aria-label="Your custom message" - Accessibility label

If no message is specified, the default "Manual intervention required" will be used.

Example:

<!-- Stop with custom message -->
<circle cx="50" cy="50" r="2" fill="red" data-message="Check weld quality and adjust temperature"/>

<!-- Stop using title attribute -->
<rect x="10" y="10" width="5" height="5" fill="red" title="Insert second plastic sheet"/>

Special SVG Attributes

MicroWeldr recognizes several custom SVG attributes that allow fine-grained control over welding parameters and behavior:

Custom Pause Messages

Control what message appears on the printer screen during stops:

• data-message="text" - Custom pause message (recommended)
• title="text" - Standard SVG title attribute
• desc="text" - SVG description element
• aria-label="text" - Accessibility label

Priority Order: data-message > title > desc > aria-label > default message

Custom Welding Parameters

Override default welding settings per element:

• data-temp="180" - Custom temperature in °C
• data-weld-time="0.5" - Custom weld time in seconds
• data-weld-height="0.03" - Custom weld height in mm
• data-spacing="1.5" - Custom dot spacing in mm

Processing Control

Control how elements are processed:

• data-skip="true" - Skip this element entirely
• data-priority="10" - Processing priority (lower = earlier)
• id="weld_001" - Element ID for ordering (numeric IDs sorted)

Animation Control

Customize animation appearance:

• data-animate="false" - Exclude from animation
• data-color="#ff0000" - Custom animation color
• data-delay="2.0" - Extra delay before this element (seconds)

Complete Example

<!-- Normal weld with custom parameters -->
<line x1="10" y1="10" x2="50" y2="10"
      stroke="black"
      data-temp="160"
      data-weld-time="0.3"
      data-weld-height="0.025"
      id="weld_001"/>

<!-- Stop point with custom message and priority -->
<circle cx="30" cy="30" r="2"
        fill="red"
        data-message="Insert reagent tube and press continue"
        data-priority="5"
        title="Reagent insertion point"/>

<!-- Light weld with custom spacing -->
<path d="M 60,20 L 80,20 L 80,40 Z"
      stroke="blue"
      data-spacing="0.8"
      data-animate="true"
      data-color="#00aaff"/>

<!-- Pipetting stop with custom parameters -->
<rect x="70" y="50" width="5" height="5"
      fill="magenta"
      data-message="Pipette 5μL sample into chamber"
      data-delay="1.0"
      aria-label="Sample injection point"/>

Parameter Inheritance

• Global defaults from config.toml apply to all elements
• Color-based defaults (normal/light welds) override global defaults
• Custom attributes override both global and color-based defaults
• Invalid values fall back to defaults with warnings

Validation

• Temperature: 100-300°C (validated against printer limits)
• Welding time: 0.1-5.0 seconds (prevents damage)
• Height: 0.01-1.0 mm (prevents crashes)
• Spacing: 0.1-10.0 mm (reasonable welding density)

Supported SVG Elements

• <path> - Follows path commands (M, L, Z supported)
• <line> - Straight lines between two points
• <circle> - Circular paths
• <rect> - Rectangular paths

G-code Output

The generated G-code includes:

1. Initialization: Homing, absolute positioning
2. Bed Leveling: Optional automatic bed leveling (G29)
3. Heating: Bed and nozzle to specified temperatures
4. User Pause: For inserting plastic sheets (M0)
5. Multi-Pass Welding Process:
   • Pass 1: Create initial dots with wide spacing (allows plastic to set)
   • Cooling Period: Wait between passes for plastic to cool
   • Pass 2+: Fill in between previous dots until desired density achieved
   • Each dot: Move to position → Lower → Dwell → Raise
6. Cooldown: Lower temperatures and home axes

Sending G-code to Prusa Printer

Once you've generated the G-code file, you can send it to your Prusa Core One printer using several methods:

Method 1: PrusaConnect (Recommended)

Best for: Remote monitoring and cloud-based printing

1. Upload via Web Interface:

   • Open connect.prusa3d.com in your browser
   • Log in to your Prusa account
   • Select your printer from the dashboard
   • Click "Upload G-code" or drag and drop your .gcode file
   • The file will be transferred to your printer automatically

2. Start the Print:

   • The G-code will appear in your printer's file list
   • Select the file on the printer's touchscreen
   • Press "Print" to begin the welding process
   • Monitor progress remotely via PrusaConnect dashboard

Method 2: USB Drive

Best for: Offline printing and large files

1. Prepare USB Drive:

   • Use a FAT32 formatted USB drive
   • Copy your .gcode file to the root directory or a folder
   • Safely eject the USB drive from your computer

2. Load on Printer:

   • Insert the USB drive into the printer's USB port
   • Navigate to "Print from USB" on the touchscreen
   • Browse and select your G-code file
   • Press "Print" to start welding

Method 3: PrusaLink (Local Network)

Best for: Local network printing without cloud dependency

1. Access PrusaLink Interface:

   • Find your printer's IP address (Settings → Network → Wi-Fi Info)
   • Open http://[printer-ip-address] in your browser
   • Or use the Prusa app to connect locally

2. Upload G-code:

   • Click "Upload G-code" in the PrusaLink interface
   • Select your .gcode file
   • The file transfers directly to the printer over your local network

3. Start Printing:

   • Select the uploaded file from the printer's interface
   • Begin the welding process

Pre-Print Checklist

Before starting the welding process:

Printer Preparation

• Clean the bed: Remove any residue from previous prints
• Check nozzle: Ensure nozzle is clean and appropriate for welding
• Verify temperatures: Confirm bed and nozzle temperature settings match your plastic
• Load filament: Even though no extrusion occurs, some printers require filament to be loaded

Material Preparation

• Plastic sheets ready: Have your plastic sheets cut to size and ready to insert
• Film securing: Consider using magnets to hold down bubble film (⚠️ Warning: heated bed may be hot!)
• Height clearance: Ensure travel height (move_height) is higher than any magnets to prevent head crashes
• Workspace clear: Ensure adequate ventilation for plastic welding
• Safety equipment: Have appropriate safety gear (ventilation, eye protection)

G-code Verification

• Review animation: Check the generated *_animation.svg file to verify weld pattern
• Validate settings: Confirm temperatures and timing are appropriate for your materials
• Check pause points: Note where manual intervention will be required

During the Welding Process

Initial Setup Phase

1. Homing: Printer will home all axes automatically
2. Bed Leveling: If enabled, automatic bed leveling will run (G29)
3. Heating: Bed and nozzle will heat to specified temperatures
4. User Pause: Printer will pause with message "Insert plastic sheets and press continue"

Welding Phase

1. Multi-pass welding: Printer follows the programmed sequence
2. Pause points: Respond to custom pause messages (red elements in SVG)
3. Monitor progress: Watch for proper weld formation and material behavior
4. Temperature management: Printer automatically manages heating between weld types

Completion

1. Cooldown: Printer will automatically cool down nozzle and bed
2. Homing: Final homing sequence
3. Completion message: Printer indicates welding is complete

Troubleshooting Transfer Issues

File Not Recognized

• Ensure file has .gcode extension
• Check file size (some methods have limits)
• Verify G-code syntax with a G-code viewer

Connection Problems

• PrusaConnect: Check internet connection and printer online status
• PrusaLink: Verify printer and computer are on same network
• USB: Try different USB drive or reformat as FAT32

Upload Failures

• Check available storage space on printer
• Try smaller file sizes or reduce complexity
• Restart printer network connection if needed

File Management Tips

• Organize files: Use descriptive names like project_name_v1.gcode
• Keep backups: Save both SVG source and generated G-code files
• Version control: Include date/version in filenames for tracking
• Clean up: Regularly remove old files from printer storage

Safety Reminders

• Never leave unattended: Always supervise the welding process
• Emergency stop: Know how to use the printer's emergency stop function
• Ventilation: Ensure adequate ventilation for plastic welding fumes
• Temperature safety: Be cautious around heated components

Multi-Pass Welding System

The welder implements an intelligent multi-pass system that allows plastic to cool between welding operations:

How It Works

1. Initial Pass: Places dots with wide spacing (initial_dot_spacing)
2. Cooling Period: Waits for cooling_time_between_passes to let plastic cool
3. Subsequent Passes: Progressively fills in between existing dots
4. Final Density: Achieves the desired dot_spacing through multiple passes

Benefits

• Prevents Overheating: Allows plastic to cool between passes
• Better Quality: Reduces warping and material degradation
• Consistent Results: Each dot gets proper cooling time
• Automatic Calculation: Number of passes calculated from spacing ratio

Configuration Example

[normal_welds]
dot_spacing = 2.0          # Final 2mm spacing
initial_dot_spacing = 8.0  # Start with 8mm spacing
cooling_time_between_passes = 2.0  # 2 seconds between passes

This creates 3 passes: 8mm → 4mm → 2mm spacing with 2-second cooling between each pass.

Animation Output

The script generates an enhanced animated SVG file showing:

• Realistic nozzle rings that flip into existence at each weld point
• Temperature-based visualization with color-coded heat zones
• Overlapping ring patterns showing actual nozzle contact areas
• Pause messages displayed with yellow background and red text
• Timing information displayed in header (duration, intervals, pause time)
• Enhanced legend with nozzle ring examples and dimensions
• Endless loop animation with realistic timing

Animation Features

• Realistic nozzle visualization: Shows outer diameter (contact area) and inner diameter (heated zone)
• Flip animation: Nozzle rings scale and flip into existence with realistic physics
• Temperature visualization: Orange/red rings for normal welds, blue rings for light welds
• Heat effects: Subtle glow animation around weld points
• Configurable nozzle dimensions: Set actual nozzle OD/ID in configuration
• 10x scale factor: Nozzle dimensions scaled up for visibility in animation
• Pause message display: Stop points show custom messages for specified pause_time
• Smart duration calculation: Automatically calculates total time based on weld count and pauses

Validation Features

MicroWeldr automatically validates all inputs and outputs:

Input SVG Validation

• Structure Check: Verifies proper SVG root element and namespace
• Attribute Validation: Checks for required width/height attributes
• Syntax Validation: Uses lxml for robust XML syntax checking

G-code Output Validation

• Command Verification: Validates G-code syntax and structure
• Sequence Checking: Ensures proper initialization, homing, and temperature commands
• Movement Validation: Confirms presence of required movement commands
• Safety Verification: Checks for proper heating/cooling sequences

Animation SVG Validation

• Element Counting: Verifies presence of animation and circle elements
• Structure Validation: Ensures proper SVG animation syntax
• Content Verification: Confirms animation elements match expected output

All validation is non-blocking - the script continues processing even if validation fails, but provides detailed feedback about any issues found.

Sample Files

The repository includes several example files:

• example.svg: Basic demonstration of all weld types and pause messages
• pause_examples.svg: Comprehensive examples of different pause message attributes
• comprehensive_sample.svg: Full-featured sample demonstrating all capabilities including:
  • Multiple normal weld shapes (lines, rectangles, circles, complex paths)
  • Light weld patterns with curved paths
  • Stop points with various message attributes
  • Processing order indicators
  • Complete workflow demonstration

Example Workflow

1. Create an SVG file with your welding pattern (or use comprehensive_sample.svg)
2. Use black paths for normal welds, blue for light welds
3. Add red elements where you need manual stops with custom messages
4. Run the script: python svg_to_gcode_welder.py pattern.svg
5. Review validation output for any issues
6. Load the generated G-code file on your Prusa Core One
7. Insert plastic sheets when prompted
8. Monitor the welding process and respond to custom pause messages

Safety Notes

• Always supervise the welding process
• Ensure proper ventilation when welding plastics
• Verify temperatures are appropriate for your plastic materials
• Test with small samples before full production runs
• The script includes safety pauses - use them to check progress

Troubleshooting

Common Issues

• SVG not parsing: Ensure SVG uses standard elements and attributes
• Wrong coordinates: Verify SVG units are in millimeters
• Missing weld points: Check dot spacing configuration
• Temperature issues: Adjust temperatures in config.toml for your materials

Debug Tips

• Check the generated animation SVG to verify path interpretation
• Use a G-code viewer to preview the toolpath
• Start with simple test patterns before complex designs

Running the Examples

For Installed Package

If you've installed microweldr as a package:

# Install the package
pip install microweldr

# Run examples (assuming you have the example files)
microweldr example.svg
microweldr example.svg --verbose
microweldr example.svg -o my_output.gcode

For Development/Source Code

If you're working with the source code:

# Setup (one-time)
python -m venv venv
source venv/bin/activate  # macOS/Linux (venv\Scripts\activate on Windows)
pip install -e .

# Run examples (with venv activated)
microweldr examples/example.svg
microweldr examples/comprehensive_sample.svg
microweldr examples/example.svg --verbose

# Alternative methods
python -m microweldr.cli.main examples/example.svg

📖 For detailed development setup, see DEVELOPMENT.md

Example Files Included

• examples/example.svg: Basic demonstration with normal welds, light welds, and stop points
• examples/comprehensive_sample.svg: Full-featured demo showing all capabilities
• examples/pause_examples.svg: Examples of different pause message formats
• examples/config.toml: Complete configuration file with all parameters

Expected Output

Each run generates:

• G-code file: example.gcode - Ready to load on Prusa Core One
• Animation file: example_animation.svg - Visual preview of welding sequence
• Console output: Processing details and validation results

Alternative Run Methods

# Using Python module (with virtual environment activated)
python -m microweldr.cli.main examples/example.svg

# With custom configuration
microweldr examples/example.svg -c my_config.toml

Materials Guide

Bubble Film Polypropylene Orientation

When working with bubble film rolls for microfluidic device creation:

Identifying the Polypropylene Side:

• Smooth side: This is the polypropylene layer - use this side for welding
• Bubble side: This is typically polyethylene - do not weld this side

Proper Orientation:

• Place bubble film with smooth side UP on the printer bed
• The welding nozzle should contact the smooth polypropylene surface
• Bubbles should face DOWN toward the bed

Temperature Guidelines:

• Polypropylene welding: 160-180°C (use light welds for thin films)
• Test first: Always test weld parameters on scrap material
• Avoid overheating: Polypropylene can degrade above 200°C

Safety Notes:

• Ensure adequate ventilation when welding plastics
• Test weld strength before using for critical applications
• Different bubble film manufacturers may use different material combinations

Pro Tip: Use the data-temp attribute in your SVG to fine-tune welding temperature for different areas:

<line stroke="black" data-temp="165" data-weld-time="0.2" />

Bubble Tea Film Layer Composition

Bubble tea films (also known as bubble wrap or air cushion films) typically have a multi-layer structure optimized for different functions:

Layer	Material	Thickness	Function	Melting Point	Welding Temp	Notes
Outer Layer	Polypropylene (PP)	15-25 μm	Smooth surface, printability, heat sealability	160-170°C	160-180°C	Primary welding layer - smooth, weldable surface
Barrier Layer	Polyethylene (PE) or EVOH	5-15 μm	Gas barrier, moisture protection	105-135°C	Not recommended	Avoid welding - may degrade
Core Layer	Low-density PE (LDPE)	20-40 μm	Bubble formation, cushioning	105-115°C	Not recommended	Structural layer, not for welding
Inner Layer	Linear PE (LLDPE)	15-25 μm	Bubble sealing, flexibility	120-130°C	Not recommended	Bubble containment layer

Material Properties Summary:

• Total thickness: 55-105 μm (0.055-0.105 mm)
• Bubble height: 3-10 mm (varies by manufacturer)
• Optimal welding: Only the PP outer layer at 160-180°C
• Identification: PP layer is always the smooth, non-bubble side

Welding Recommendations:

1. Always weld the smooth PP side - this is the only layer designed for heat sealing
2. Temperature range: 160-180°C for optimal PP welding without degradation
3. Avoid bubble side: Contains PE layers with lower melting points that may burn
4. Test first: Different manufacturers may use varying layer compositions

Sources: Packaging industry standards (ASTM D6988), polymer processing handbooks, and bubble film manufacturer specifications (Sealed Air, Pregis, etc.)

License

This project is licensed under the GNU General Public License v3.0 (GPL-3.0). See the LICENSE file for full license text.

Use at your own risk and ensure proper safety precautions when operating 3D printing equipment.