Fab Academy-2019 /Aaditi Kharade

Indivisual Assignment

Group Assignment

Highlights of the week

Highlight

Group assignment:

- test the design rules for our 3D printer

individual assignment:

-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)

For this assignment, we will learn how to use the 3D printers and 3d scanners. Our instructor Supriya gaves us details idea and demo related to this week's assignment for more detailing I refered This guide to know more about 3d printing.

So lets' start what I learnt ,about 3D printer & scanner and more.

What is 3D printing?

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.This where the alternative term Additive Manufacturing comes from.(source Wikipedia)

What is Additive & Subtractive Manufacturing?

*ADDITIVE - It is a process of build any object in layer by depositing any material.Eg.3D printing, here no special tools are required (for example, a cutting tool with certain geometry or a mold)

*SUBTRACTIVE - a process by which 3D objects are constructed by successively cutting material away from a solid block of material. e.g.(CNC machining)

3D printer works varies by process.

FDM printers(fused deposition modeling)-it melt plastic filaments and lay it down onto the print platform through a nozzle (like a high-precision, computer-controlled glue gun).

SLS (Selective laser sintering) - is an additive manufacturing (AM) technology that uses a laser to sinter powdered plastic material into a solid structure based on a 3D model.

SLA(Stereolithography)-SLA uses a laser to cure liquid resin into hardened plastic in a process called photopolymerization.

Group assignment:

In Vigyan Ashram We are using Julia & Accucraft but in this week our Accucraft machin has some maintaince issue we characterise our Julia by fracktel (software)3D printer for maintain and finishing our group assignment ,to study about designing rules, printing process and printing parameter and individual assignment

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.

Julia

Specifications of Julia for different versions downloaded from Fracktal Works's website are as below

Specification

As per above specification chart at vigyan Ashram we are using "Advanced"type of Julia 3D printer

For this we need only one software i.e frcaktory.

Test the design rules for our 3D printer

Material Used :Allen Key,Acetone,glue,spatula.

Material Used

for this assignment we worked in group.

Design file

For testing our printer we used default file suggested by Neil,and download it from Thingiversewe will test following parameters 3 D prinnting test

This test includes
Z-Height Check
Warp Check
Spike
Hole in wall
Raft Test
more Overhang Steps 50° - 70° (needs special care, like cooling)
2 different extrusion widths: 0.48mm & 0.4mm

Printing Process

Software setting

After completion of our designing ,

1.we have to save our file in .stl format,then will make it's Gcode for that we used "Fracktory" dowonloaded from Fracktal works website to know more about 3d printing. software it is simple and user friendly.Download the software and run the setup

2.so Load the file,then check the layer ,X-ray views of your print

3.set the quality then save the file as G-code in USB

Settings

Julia 3D Printer Setting

1.Switch on 3D printer

2.Calibrate printer by adjusting bed level ,for that we just followed instructions displayed on screen that are loose screw from left ,right and back side

3.Tight screw one by one right ,left & back respectively.

4.Place paper on bed and set the nozzle and bed level

Choose file from dropdown on display then give the print

Test parameter

Conclusion for indivisual test part

Comparision

We have to characteerise our 3D printer so for above test design ,we print it in fast and in normal quality mode.In fast print we remove the brim here we can see there is no max.difference in fast and normal print,but for finishing comparison we can say normal print is better

Test parameter

In above image overhang in normal print is better than fast print

Other test parts

Hole test: Here we want see how 3 d prints makes the holes,in this test part we gave different diameter holes and the result is 5 mm hole looks good while 0.5 mm hole seems disappear .

Fractory view

Hole Test

Resolution test: Here we want see how 3 d printer makes the thin lines,in this test part we gave keep length constant,so we found rigidity is directly propotional to thickness.

Resolution Test

Quality& thicknes test:In this test We keep our design same and we prints it just half part we changed mode in software as fast,hight,ulta ,normal .Ultra quality prints took more time than other but it prints more precisely than other

Quality Test

here we tried to keep our all prints in one image ,see how it looks,

Indivisual Assignment

In this task I used fusion 360 for design ,I decided to make any moving or rotating but useful object,here in Vigyan Ashram we oftenly required bulb cover(Lamp Shade)so I go through you tube I found this video tutorial

I refered this video and design my different shape ,steps are as follows

1.Draw freehand shape

Design1

2.Exit sketch

Design2

3.Revolve object by 360 degree

Revolve

Offset the plane

Offset

Split the upper covering portion

Split

Split2

Extrude cut the split body

Cut

Excrude cut

Shell the inner portion of in between body

Shell

Offset plane parallel to bottom surface

Offset

Split the body parallel to bottom surface

Split

Chose project option from sketch and draw strip on top surface

Model1

Model2

Model

Model4

Select circular pattern chose object and axis as shown

Circullar pattern

Circullar view1

Circullar view2

Now our final lamp file is ready,save it in .stl format

Final design view

Then load it in Fracktory software,make Gcode then via USB give to Julia and print it

Fractory view

After printing my object looks like this,it tooks lot of support

Lampshade

Project part

In this assignment I have to make some parts of my project to reduce latter effort,in Computer aided design assignment week I made Hinges for my door then in thid week I print it on 3D printer

Hinge

Moving hinge

Why this parts cannot made by Substractive modeling?

For Lampshade,substractive modeling is not possible because design of lampshade contains overhangs,meshes and small holes.substractive modeling machines like milling machine works only in 2D or we can say in only one plane,in additive modeling it is possible because layer is added one by one.

For hinge,the base rectangular part may be made by substractive modeling but inbetween part of shaft,where mates exists its not possible to make it flexible like additive modeling.

Advantages of 3 d Printer

1.3D printing allows easy fabrication of complex shapes, many of which cannot be produced by any other manufacturing method.

2.3D printing does not need any specialized tooling, there are essentially no start-up costs. The cost of a 3D printed part depends only on the amount of material used, the time it took the machine to print it and the post-processing - if any - required to achieve the desired finish.

3.The most common 3D printing materials used today are plastics. The 3D printing pallet also includes speciality materials with properties tailored for specific applications. Like metals

Limitations of 3 d Printer

1.Generally, 3D printed parts have physical properties that are not as good as the bulk material
2.The accuracy of 3D printed parts depends on the process and the calibration of the machine.
3.Printed parts are rarely ready to use off the printer. They usually require one or more post-processing steps.For example, support removal is needed in most 3D printing processes.

All prints

3 D Scanning

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.

A 3D scanner can be based on many different technologies, each with its own limitations, advantages and costs. Many limitations in the kind of objects that can be digitised are still present. for example, optical technology may encounter many difficulties with shiny, reflective or transparent objects.(source Wikipedia)

In Vigyan Ashram we have "Sense"3Dscanner

Sense scanner

Specifications

For operating this scanner we have to first download 3D system software,and install it then connect your scanner to Laptop/PC,then we will get activation code and then you will get acess to sense scanner

Scan setting

Here we can see system asks for 2 options i.e.object or person scanning,after seeing this I decided I will try both options

Scan setting2

So first I tried seating stool as a object

Set the scanner

Then I fixed my position and turn around the object,

Scaneed object

After scanning this object looks like

Scan before/After

After scanning the object ,I found object is not looking perfectly there some part were missed so I choose solidify option

Person

Scan before after

I followed same steps for scanning person,I asked one of Vigyan ashram DBRT student "shivaji"for help and to be model for my scanning section,here my batchmate Hemang Vellore helped me in whole process