6. 3D Scanning and printing

  • Design and 3D print an object (small, few cm3, limited by printer time) that could not be made subtractively
  • 3D scan an object (and optionally print it)

Visit Group website for more imformations. Click here.

What is 3D?

3D which means three Dimension object which we can fell.3D printing is any of various processes in which material is joined or solidified under computer control to create a three-dimensional object, with material being added together (such as liquid molecules or powder grains being fused together), typically layer by layer. In the 1990s, 3D printing techniques were considered suitable only for the production of functional or aesthetical prototypes and a more appropriate term was rapid prototyping.

3D Caterory

  • 3D printing
  • 3D Scanning

3D machine catagory :

  • 3D Printer
  • 3D pen

The Reasons for Several Types of 3D Printer

The reasons there are different types of 3D printers and printing processes are similar to that of the 2D printers we’re so familiar with. It all comes down to the following six considerations:

  1. Printer cost
  2. Print quality
  3. Print speed
  4. Printer capability
  5. Practicality
  6. User expectations

Type of 3D printer :

The nine 3D printer types you will learn about:

Stereolithography (SLA)

SLA is a fast prototyping process. Those who use this technology are serious about accuracy and precision. It can produce objects from 3D CAD data (computer-generated) files in just a few hours. This is a 3D printing process that’s popular for its fine details and exactness. Machines that use this technology produce unique models, patterns, prototypes, and various production parts. They do this by converting liquid photopolymers (a special type of plastic) into solid 3D objects, one layer at a time. The plastic is first heated to turn it into a semi-liquid form, and then it hardens on contact. The printer constructs each of these layers using an ultra violet laser, directed by X and Y scanning mirrors.

Digital Light Processing (DLP)

DLP is the oldest of the 3D printing technologies, created by a man called Larry Hornbeck back in 1987. It’s similar to SLA (see above), given that it also works with photopolymers. The liquid plastic resin used by the printer goes into a translucent resin container. There is, however, one major difference between the two, which is the source of light. While SLA uses ultra violet light, DLP uses a more traditional light source, usually arc lamps. This process results in pretty impressive printing speeds. When there’s plenty of light, the resin is quick to harden (we’re talking seconds). Compared to SLA 3D printing, DLP achieves quicker print times for most parts. The reason it’s faster is because it exposes entire layers at once. With SLA printing, a laser has to draw out each of these layers, and this takes time.

Fused deposition Modeling (FDM)

FDM is a 3D printing process developed by Scott Crump, and then implemented by Stratasys Ltd., in the 1980s. It uses production grade thermal plastic materials to print its 3D objects. It’s popular for producing functional prototypes, concept models, and manufacturing aids. It’s a technology that can create accurate details and boasts an exceptional strength to weight ratio.

Selective Laser Sintering (SLS)

An American businessman, inventor, and teacher named Dr. Carl Deckard developed and patented SLS technology in the mid-1980s. It’s a 3D printing technique that uses high power CO2 lasers to fuse particles together. The laser sinters powdered metal materials (though it can utilize other materials too, like white nylon powder, ceramics and even glass).

Selective Laser Melting (SLM)

SLM made its debut appearance back in 1995. It was part of a German research project at the Fraunhofer Institute ILT, located in the country’s most western city of Aachen. Like SLA (see above), SLM also uses a high-powered laser beam to form 3D parts. During the printing process, the laser beam melts and fuses various metallic powders together. The simple way to look at this is to break down the basic process like thus:

Powdered material + heat + precision + layered structure = a perfect 3D object.

Electronic Beam Melting (EBM)

A Swedish company called Arcam AB founded EBM® in 1997. This is a 3D printing technology similar to SLM (see above), in that it uses a powder bed fusion technique. The difference between the two is the power source. The SLM approach above uses high-powered laser in a chamber of noble, or inert gas. EBM, on the other hand, uses a powerful electron beam in a vacuum. Aside from the power source, the remaining processes between the two are quite similar. EBM’s main use is to 3D print metal parts. Its main characteristics are its ability to achieve complex geometries with freedom of design. EBM also produces parts that are incredibly strong and dense in their makeup.

Here are a few of EBM’s other impressive features:

Doesn’t need extra auxiliary equipment for the 3D printing process Has increased efficiency using raw materials Lessens lead times resulting in parts getting to market faster Can create fully functional, durable parts on demand for wide-ranging industries

Laminated Object Manufacturing (LOM)

A Californian company called Helisys Inc. (now Cubic Technologies), first developed LOM as an effective and affordable method of 3D printing. A US design engineer called Michael Feygin—a pioneer in 3D printed technologies—originally patented LOM.

Binder Jetting (BJ)

The Massachusetts Institute of Technology (MIT) first invented BJ 3D printing. You may also hear this technology referred to in other names, including:

Powder bed printing Inkjet 3D printing Drop-on-powder Binder jetting (BJ). This is the most popular name and the one we’ll use to refer to it. BJ is a 3D printing process that uses two types of materials to build objects: a powder-based material (usually gypsum) and a bonding agent.

Material Jetting (MJ)

You will also hear Material Jetting referred to as wax casting. Unlike other 3D printing technologies, there isn’t a single inventor for MJ. In fact, up until recent times it’s been more of a technique than an actual printing process. It’s something jewelers have used for centuries. Wax casting has been a traditional process where the user produces high-quality, customizable jewelry. The reason it gets a mention here is because of the introduction of 3D printing.

Which Printer I Used?

Steps to 3D print Object:

CAD/Design

  • Download or design object.
  • If Download object, there is many website like Thingverse.
  • If we Create Design, We used fusion, rhino, grasshopper, and various CAM software.

Save the file

  • Its an important part of the chain of printing.
  • Make sure save in this extension
    • .stl(recommoneded)
    • .obj(preferable)
    • .3mf
    • .ply
    • .3ds
    • .tsk

Part of slicer

  • It only read extension which are given upper.
  • Why Slicer?
  • Slicer which slice the img/obj.
  • Convert that img/obj to gcode.
  • GCODE?

– GCODE is code of that order which has to followup to that machine. - export it!

Software for Slice

  • Ultimaker = CURA+ =.gcode
  • Flashforge = Flashprint =.gx
  • CetusMKII = UPStudio =direct connect

Material for 3D printing

  • ABS (Recommeded)
  • PLA (Recommeded)
  • TPU
  • RESIN
  • Nylon
  • PVA Filament
  • Sandstone Filament
  • Wood Filament
  • Metal Filament
  • HIPS Filament
  • Magnetic Iron Filament
  • Conductive Filament
  • Carbon Fiber Filament
  • TPE Filament
  • Glow in the Dark Filament
  • Amphora Filament

For more detail Click Here

Properties while printing

  • Layer Height
    • 0.10
    • 0.15 - It provides us high speed and accuracy.
  • Infill Density
  • 0%
  • 10%
  • 15%
  • 30% - This gives us better results as the space inside material decreases as we go down the list, and 30% is most suitable as it has low space still gives high speed compared to higher percentage of materials.
  • 60%
  • 75%
  • 100%
  • Infill Pattern
  • Grid - As it matched the requirement of project as it gives medium strength and provides better speed and thus this self-explanatory 2-D pattern
  • Line
  • Triangle
  • cubic
  • Octet
  • Concentric Cubic
  • ZigZag - here i get little bit flexiblilty in my 3d model.
  • Cross
  • Gyroid
  • Support
  • Material
  • Speed
  • Support
  • Wall thickness

  • Switch On the power
  • Check Fillement
  • Clean Nossel
  • Clean Bed
  • Make little adhesive bed, it help to stick raft.
  • Heat/Pre heat bed (Cetus type of printer didn’t heat bed it heat only nossel)
  • load the file
  • Start print

Some Reference

Infill Time Matrerial
0 4 hr 32min 10 gm
1 4 hr 18min 7.5 gm
2 3 hr 55min 6.25 m
3 3 hr 38min 5.5 gm
4 3 hr 15min 4.75 m

Here are some reference practical done in different different settings . - with more details, there will be more material usage - as low speed, gives good quality - and at high speed, usage of material will less! - it also depends on infill, layerheight, etc - it also depends on material.

Output Model

  • Strength Check - It included checking thickness, infill and other likewise parameters.
  • Remove Useless material - In this step we have to remove the material that was used as support just for the sake of printing and which is not needed in actual product, by the use of cutters.
  • Clean it well - By the use of glass paper we cleaned it.
  • To make it an awesome object use acetone- By use of acetone there is possibility that plastic melts, so we have to use acetone in dilute and less proportion. We did this by using acetone dipped cotton to make object better.

Showcase your model

We tried different shapes using Rhino software, we placed different concentric spheres (sphere inside a sphere) and then we got this output.

There are also supportive portions through which we get help in printing, so that no extra supports are needed.

  • Put that object in open table.
  • Click at different angle.
  • Post on social Media. :p

STL File - STL file format is supported by many other software packages; it is widely used for rapid prototyping, 3D printing and computer-aided manufacturing.

GX File

3dm raw design file

Examined for errors.

There is possibility of errors in most of the CAD applications in output of STL files, errors are of following types: - holes; - faces normals; - self-intersections; - noise shells; - manifold errors.

Figure shows different types of errors encountered during working, like problem in angle setting, layer height setting and likewise.

These can also be improved by doing post processes after printing.

3D sharing

  • 3D scanning is the process of analyzing a real-world object or environment to collect data on its shape and possibly its appearance (e.g. colour). The collected data can then be used to construct digital 3D models.

The assignment was done in 2 techniques in the lab. The methods are: 1. Photogrammetry 2. Light Coding

Photogrammetry Steps

Step 1:

  • Select Model
  • Set Background
  • Make Origin for model
  • Click Minimun Picture of model
  • From Differnt angle
  • And different direction

Step 2:

  • Open Software -Autodesk ReCap
  • Select Images
  • Start

Step 3:(Software Side)

  • Regiester Model
  • Upload Model
  • Convert Model
  • Download It!
  • Get file with “.rcm” extension

All images for Photogrammetry Steps

Light Coding

The method ‘Light Coding’ uses Microsoft Kinect as the scanner and a software to process the data. In this case I have used Kinect Model 1414 with Kinect for Windows SDK 1.7 & KScan3D as the scanning software.

Kinect Windows SDK 1.7 can be found [here]

(https://www.microsoft.com/en-in/download/details.aspx?id=44561) and KScan3D is freely available here.

Step 1:

  • As we use XBox 360, first of all clean the lens and IR sensors which help to give clearity result.

  • We have to install XBOX 360 Driver.

  • Open “skanect” software.

  • Connect with XBOX 360, and we will see the image in various theme.

step 2:

  • Click On start.
  • Rotate 14.00fps - 21.50fps (recommended) for the best results.
  • We have to record it
  • afterwards Record complete it will start sync. framing.

Step 3:

  • Reconstruct the model
  • Connect all holes
  • We have to jump on next step.
  • SKANECT is paid version, but there is an another way to explore design.
  • We use “Sketchfab” to upload it.
  • That have feature to embed script for our design.

  • This figure shows the dialog box which allows us to select between cpu and gpu and select the quality. here we selected the medium quality.
  • Here i set camera and after centerizing the model I started scanning, I was rotatimg round with the speed of 15-18 fps.

  • Now scanning completed and I started the post process for the getting the stl file , and then filled all holes to give smoothness to the model, to give complete look.

  • Now to explore more we used colourize option to see the look of the model.

  • Now using watertight function for transforming model which give clearence to model that path finishing model.

  • Now using fusion function to cover the missing part and make model accurate that give us fine and fabulous result.

  • Now time to export in free version there was an option to save .stl, .obj. that file help me to print my scanned model which I print in ultimaker 2+ which is avalible at our fablab with material PLA.

New Skanect Model by maharshisolanki on Sketchfab

How to 3D Scan With Skanect

  • 3d Scanning at the Museum of Art and Design with Shapeways using a Microsoft Kinect and Skanect software.

Step 1: Setup

  • What you will need:

    • computer-

    • preferably a desktop as files are large

    • Skanect software

    • Microsoft Kinect This device reads color with its camera and reads depth with the infrared sensor.

    • Lights Lighting is very important in order to get an even colored scan

    • spinning platform (optional) This allows the subject to rotate making scanning much easier

Step 2: Software Settings

  • Picture of Software Settings
  • Open Skanect / Go to NEW / Make sure your settings match those in the picture

(for a child you may want to make the bounding box a bit smaller)

  • Press START

Step 3: Workspace Picture of Workspace A screen will come up showing the bounding box in the middle. The infrared and video images are on the right.

Step 4: Lovely Assistant - Have your lovely assistant step onto the platform. Be careful! It spins! Make sure the lighting is consistent on your subject.

Step 5: Record

  • Hold your Kinect up level with the subject’s waist a few steps feet back from the platform. Press RECORD. The Kinect will begin recorded the depth (red) and the color (green).

Step 6: Spin Around

  • Once you have done one full sweep of your subject head to toe, press the pedal to make the platform spin. As your subject is in motion slowly move the Kinect in an up and down motion making sure to get the top of the head all the way to the bottom of the platform as they rotate.

If you do not have a rotating platform have no fear. You can walk around your model or use any manual spinning base of your choice.

Step 7: Lining It Up

  • As you are scanning be sure that you are getting a high frame rate around 18-24 frames. If you get below 18 you have to move your Kinect faster. You can monitor this by looking at the white numbers at the bottom of the screen. These numbers can also aid as a way of keeping your subject in alignment. If you keep the numbers in the center of your subject as you scan head to toe you can be sure your scan will be straight.

Step 8: Cleaning Up Your Scan

  • Picture of Cleaning Up Your Scan 2 More Images

Once your subject has done a full rotation press the RECORD button in the top left corner again to stop the scan.

Now that you have a full body scan you have to do some post processing to get it ready to print. First is making it watertight. Go to the WATERTIGHT option. Choose smoothing LOW and press RUN.

Now your scan will have color. But it may not be straight or have a flat base. Now we have to use the MOVE & CROP tools. Use the SLIDE BARS to adjust the X, Y, and Z axis of your scan to make it flat and straight. Make sure your base is parallel with the X Y plane as cropping will cut off anything below it to make a flat base. Type in the name of your file in the TEXT BOX. Press CROP TO GROUND.

Step 9: Exporting Model - To export it to your computer go to SHARE and the export menu will open with a LOCAL option. Under LOCAL go to EXPORT MODEL and use the setting seen in the picture to export for printing. It is important to chooseVRML as the file type. This file type reads both shape and color. Click EXPORT and you are done! Now you can use that file to upload to a 3D printer of your choice.

Step 10: 3D Printed Selfie

Model file

Why Object(.obj) file file?

  • The big difference between STL and OBJ meshes is what’s displayed on the surface. STL files don’t display any data on the surface of the mesh. They indicate only the surface itself– the geometry of the object, how big it is and the shape of its sides, but that’s about it. That’s why STLs are greyscale by default, because there is no color or texture data.

Conclusion

This week is about another critical procedure. 3D printing and scanning. The address was about sorts of printers, materials, and procedures. At that point for filtering, we saw the diverse kinds of examining procedures and strategies alongside the post-handling of the equivalent. I state this week is an essential procedure since this is the initial phase in taking programming to genuine models. So far I’ve utilized the lowlife devices to record and for introduction, however, this time the model converts into the physical domain progressively like Architecture and that was energizing.