Posted on FEB 26, 2018 as Assignment 5/Week 5

3D Scanning and Printing

3D Printing and Scanning

1. Characterization of the 3D printer(Group Works)
a. Orientation
b. Thickness Test
c. Hole Test
d. Infill Test
e. Overhang Test
f. Bridge Test
2. Make a mini object and print it
3. 3D Scanning

Introduction

In Vigyan Ashram we have two 3d printer, one is Accucraft and another is Zulia from Fracktel Works. We are using Zulia for maintain and finishing our group assignment about Designing rules about 3D printer.Most of the cases we are using Zulia by fracktel (software) for completing our group and individual assignment, cause it has good standardization about maintain origin and and direct follow the gCode. No need to fix the origin and easily controllable. for making gCode we are using Fracktory 2.0 software for main slicing according to the origin and code.

Features of Zulia+:

Direct Drive:Direct drive maximizes filament feed torque enabling Zulia to print flexible compositions like Nylon 618, ABS, PLA and other material.

Filament Sensor: Zulia’s new filament sensor ensures reliable printing alerting you of problems or filament run out.

Replaceable Nozzles: Replaceable nozzles enable you to change from 0.25mm to 0.8mm nozzles.

Heating Print Bed: Heating print bed enables you to print engineering thermoplastics like ABS, Nylon 618, to keep warping at a minimum.

Specification of Zulia+: Layer resolution: up to 80 um, Build volume: 21 cm × 25 cm × 26 cm, Recommended filament diameter: 1.75 mm, Nozzle diameter: 0.2- 0.8 mm (Replaceable Nozzle), Print technology: Fused filament fabrication (FFF), Stand-alone: SD-card printing, Frame dimension X Y Z: 48 mm × 47 mm × 42 mm, Operation nozzle temperature: 180-260 °C.

3d Printer we have 1. Zulia+ 2. Accucraft

Design Rules of Zulia+ by Fracktel Works 3D printer

Materials we used for printing

Content:

1. Characterization of the 3D printer(Group Works)
a. Orientation Test
b. Thickness Test
c. Hole Test
d. Infill Test
e. Overhang Test
f. Bridge Test
g. height and Point Test

Orientation Test: For orientation test we did our design by three orientation like horizontal, vertical, and stand alone. After completing the printing we saw different printing direction on the object. In horizontal object the printing line goes to diagonal line and vertical on standing here line goes to diagonal but there is gap in the line. When we reverse the stand alone then the vertical stand are print good when it goes print the extra site then the lower part are goes in mis place and the print doesn't look uniform as design.

Fig1. Orientation design by Fusion 360

Fig2. Making gCode by Fracktory 2.0

Fig3. After printing the object

Thickness Test We are doing thickness test by making four cube according to the printing setup, like fast printing, Normal printing, Hard printing and finally Ultra printing. Here we can saw the scale is high in the fast printing rather than the other like ultra in minimum thickness. why actually its happened cause the size of the nozzle. The quality of the printing cause its actually doing thickness parameter with different wall thickness.

Hole Test: Where we want see that how was the print looking and what is the difference are show in the object in different hole diameter.

Infill Test: Here we design one cube in 15 sq.cm and take image on different percentage with time lapse. Here we take five different percentage according to the time, like 10%, 30%, 50%, 70% and 100%. Where as the 10% are complete within 3 minute, 20% are complete in 5 min, images are in below:

Time lapse after 50% printing complete

Time lapse after 70% printing complete

Time lapse after 100% printing complete

Overhang Test: Here we took four different object in different angle for testing the overhang where the support are needed or not. During the printing we saw some difference in different overhang position according to the angle. Here we design four different angle like 80, 60, 45, and 25 degree. Here we saw that the 60 degree are don't need the support but when it goes 45 degree then their is need to support for uniform print. In 25 degree here is more support to print. So 45 degree is the starting point to need the support.

Fig1. Overhang object design by Fusion 360

Fig2. Making gCode by Fracktory 2.0

Fig3. After printing the object

Bridge Test: Here we make an object in different sizes, like 5, 9 and 15 mm distance of the support, actually we want to see how much far the printing line are distorted, here the after 8mm the line going to curve without support printing.

Bridge test with out support

Height and Point Test: We make stand in different sizes and printing it without support and we saw that the without support the printing goes on the distorted line where as the thread are come to the stand bar. Is means that the If we going to print with thin point stand then the extruder point can give uniform line as design, it's distorted. Here we also done point test for know the extruder point how much it can be done, we saw this after printing that is the 0.14mm difference then the design cause the extruder is 0.4mm but its not print accurate. In design the tip is fixed on 0.20mm where as the extruder thickness 0.44mm but after printing the tip is 0.54mm.

Distorted line and thread are seen on stand

Point test show the not accurate printing

2. Print an object which is not possible to print substantively

Make a mini object and print it: When I was going to design, that time thought to make a design which can be use for charging my MI Band. Here is mini story, I left my MI Band Charger in my country, and this is going off last fifteen days. That's why I'm going to design this band charger. In my design where as a round curve, in outer side of bottom is not possible to print substantively.

After completing my design I went to my lab, and setup the printer for printing according to the printer rules, First I clean the bed and add glue for proper attachment of the object with the bed, This printing command giving by the preparing gCode with the fracktory 2.0 software and giving command as PLA filament.

First the printer bed going to heating up, is around 250 degree and then nozzle goes to 60 degree. then the machine start automatically.

After completing the printing I saw the object on the bed, where it look nice and pretty good.

Printing process are going on

Object after print complete

Okay, Then I start making my charger by hand on with the soldering an discard ISP board. After soldering I tested it which is fit well and charging is going on good.

Charger of the Mi Band

Charging on my MI band

Full Charge of the my MI Band

3. Making a juicer body parts

I'm going to make a juicer which is operated by stepper motor, I took idea from the hand juicer, As wildcard assignment task rules I will make CAD deign and add manufacturing any process. Here I share my 3D design of body parts and feeding parts of inside of body.

1. First design 3D model of the body part by Fusion360 CAD software. I made it first a circle where as it reshape into cylinder, then add feeding tube and stand with output opening adding new project plane in exiting plane.

2. Then I get it from fusion as .STL file which is on slicer software for slicing and making gCode.

3. Then export it in sindoh 200DP 3d printer and take with bed labeling and filament movement

4.finally I got the product where printed in sindoh 200DP for making juicer.

4. Making feeding circle for juicer

1. First of all I make this 3D design by Fusion360 and save it .stl file. During making i follow this tutorials from the youtube Here click for tutorial

2. Then slicing it by Cura and i'm suing Anycube Mega 3D printer for printing.

During printing process

3. Finally I got my product after completing all process

Here I try to demonstrated three different designs for making by 3D printer by 3D design, where this is making by 3D printing called additive technology, This is not possible to make it by substractively. Now I'm making this all design as additive according to the slicer gCode.

Slicing parameter and machine process

For this week I'm used three different machine for making 3d design

Julia and Fractory

First i used Julia and for slicing i used Fractory 3.0 software, which is more less automatically define the gCode, where i need to add only the materials type and if want to use support then just check it.

Sindoh 200DP and Sindoh Desktop

This is a powerful 3D print ever I used, for bed leveling, nozzle heating, bed heating everything are done by according the materials. Another things is for changing the filament is also a good mechanical process here. This is also detect the printing materials for slicing.

Anycube Mega i3 and Cura

For making stand of my wildcard juicer where I used cura to slicing the design. In CURA here show all parameter for 3D printing and slicing.
1. Quality: Here mention the layer height
2. Shell: In shell here show three different things: a. wall thickness; b. Top/Bottom thickness
3. Infill: Infill density and pattern are show here and one is define in percentage other is like line/grid/zigzag
4. Materials: PLA/ABS
5. Speed: here define printing speed, generally is set in 50%, If increase then filament are not set properly
6. Cooling:
7. Support: Most valuable things, if we consider to make it workable then we need to use support in design for proper shape of the design.
Build Plate Adhesive: For contact of the sample during printing need some sort of adhesive

3. Scanning an Object, Print(Optional)

For scanning the object I'm used the Sense Scanner with Sense software, During scanning I face a problem which was to scan alone quit impossible cause during the scanning if the object are misplace then it stop the scanning and start to rescan. So and another thing was light which is reflected on the object where hard to difficult to trace. However I scanned an object of Glue Gun which is yellow color on mild light alone. Then i edit it and solidify it.

Scanning the glue gun in medium low light

After scanning the object look like

Editing the outer part of the object

Final scan file .stl format

Advantage and Disadvantage of 3D printing

Advantage

Customization- A major advantage in 3d printing. With just a raw material, a blueprint and a 3d printer, one can print any design no matter how complex it might be.
Constant Prototyping and Increased Productivity – It enables quick production with a high number of prototypes or a small-scale version of the real object in less time than using conventional methods. This helps designers to improve their prototypes, for any design flaws that may affect the quality of the product.
Affordability- The initial cost for setting up a 3d printing facility is definitely high; however, it is much cheaper compared to labor costs and manufacturing costs while using the conventional way. Adding to it, is the fact that the cost of producing or manufacturing products using 3d printing technology is equal for small-scale and mass manufacturing.
Storage – Traditional manufacturing produces additional products that you probably know you will eventually need thus storage problems arise. However, 3d printing technology, products can be “printed” when needed thus excess products are eliminated and no storage cost is required.
Employment Opportunities– The widespread use of 3d printing technology will definitely increase the demand for engineers who are needed to design and build these printers. Technicians who are skilled at troubleshooting and maintenance and Designers to design blueprints for products and more jobs will be created.
Health Care With the advancement of technology, a customizable human body parts and organs can now be manufactured this technology is termed as Bioprinting. Although right now this is still experimental, the potential is huge. This breakthrough will not only address the shortage of organ donors, but also organ rejection since the organs that are built will consist of the patient’s unique characters and DNA.

Disadvantages

Decrease in Manufacturing Jobs – The decrease in manufacturing jobs will greatly affect the economy of countries that rely on a large number of low skill jobs.
Limited Size – The size of objects created with 3d printers is currently limited however, in the near future; large items such as architectural structures can be created using 3d printing.
Limited Raw Materials – Traditional manufacturing of products has an enormous range of raw materials that can be used. Presently 3d printers can work up to approximately 100 different raw materials and creating products that uses more raw materials are still under development.
Violation of Copyrights – The biggest disadvantage of 3d printing is Counterfeiting. Anyone who gets a hold of a blueprint will be able to counterfeit products easily. It will become more common and tracing the source of the counterfeited items will be nearly impossible. Many copyright holders will have a hard time protecting their rights and businesses producing unique products will suffer.
Production of Dangerous Items –With 3d printers, plastic knives, guns and any other hazardous objects can be created. It makes easier for terrorists and criminals bring a weapon without being detected.

Uniqueness of 3D printing

Uniqueness of 3D printing and why other manufacturing process are not capable to do which is done by 3D printing, In 3D printing process people can do some sort of manufacturing which is not possible before 3D printing invented.

1. Personalized car parts: For making any parts of car as according to the customize is possible to make it by 3D printing.3D printing can make car parts that are custom-built for the driver’s body and comfort: an ergonomic steering wheel, for example. Last month, Fortune reported Ford’s partnership with California-based 3D printing company Carbon3D. The automakers themselves can benefit from 3D printed parts, too. Instead of the ol’ Ford assembly line, engineers can make manufacturing and design more iterative with 3D printed materials, since prototyping suddenly becomes faster and cheaper and testing becomes more frequent and thorough.
2.Lighter airplanes: There have been lots of materials used to make planes lighter, and thus more fuel efficient and greener. But 3D-printed materials can cut weight by up to 55%, according to Airbus, which announced its involvement with 3D printing last year.
3. Human Body parts: Like, Molds of your Jaw: Possibly the arena 3D printing handedly dominates is personal health. Our bodies are unbelievably individualized, idiosyncratic flesh bags filled with biological items uniquely shaped to each person. Since customization is so critical, especially in surgical implants, 3D printing can really shine here.
4.Customized Surgical Stents: Stents are those little tubes surgeons stick in the hollow parts of your body—a blood vessel or artery, say—to hold it open and allow it to function properly. Usually, they’re mesh, but stents that are 3D-printed can have an edge, since they’re able to be customized more and are made with cheaper, flexible polymers that can dissolve safely into the bloodstream in a couple years.
At the Children’s Hospital of Michigan in the Detroit Medical Center, a 17-year-old girl was suffering from an aortic aneurysm, a potentially fatal heart condition that was discovered with a precautionary EKG. That’s when Dr. Daisuke Kobayashi and his team turned to 3D printing. A 3D printed model of her heart allowed the doctors to know exactly where to put stents in an otherwise delicate operation for a young patient.
5.Replacement Parts for Your Organs: 3D printing can be used to make surgically-implanted hardware that protects or supports damaged organs. This could lead the way to custom repairs for damaged tracheas or windpipes, for instance. Sometimes part of a windpipe needs to be removed, but the two remaining ends need to be joined together—if they can’t be joined together, the patient may die.
6.Organs and Bones: The most futuristic use of for these magical printers? They could, one day, create internal organs. That’s a literal lifesaver for folks who need an organ transplant. Also possibly available: eyes, blood vessels, noses, ears, skin, and bones. Even hearts.

Advantage and Disadvantage of 3D Scanning

Advantage

1. Small businesses are starting to benefit from low-cost versions of these scanners
2. Help fix defects on certain objects
3. Very Accurate
4. Almost all companies are benefiting from 3D scanners
5. Easy to use

Disadvantages

1. The size of a 3D scanner can be as big as a small refrigerator
2. The price of a 3D scanner is expensive. Some small businesses cannot afford them.
3. Non-contact 3D scanners can be very slow in scanning objects
4. The clarity of the image may not be the best
5. Cannot be bought from public department stores. Can only be bought from private corporate companies