Individual Assignment:

Design and 3D scan and print an object (small, few cm3, limited by printer time) that could not be made subtractive.

The 3D Modeling, Scanning & Casting prototypes for the social challenges is recurring worldwide competitions organized by multiple players in the ecosystem to foster innovation and empower young talents by combining Design, Engineering, and Software. Design the object in 3D, and make a prototype using 3D printing. You can also research open source hardware such as Arduino, WeIO, Raspberry Pi, or any similar electronic platform using them on a proprietary circuit board. The aim is to create a 3D model with at least 2 parts by imagining my creation, so that the final object is 3D-printable. The goal is to highlight the different possibilities of 3D printing.

Group Assignment:

3D printing is a type of additive manufacturing method, meaning objects are manufactured by adding material layers. 3D printing allows complex shapes to be created, as well as reducing the amount of material waste generated from the manufacturing process. There are different types of 3D printer technologies, but for the purpose of a Fab Lab (non-industrial level material quality needed, small batch production). We have used FDM (Fusing Deposition Modeling).
The 3D printer uses plastic filament from ABS, PLA, nylon and rubber. Extruding the plastic filament through a nozzle, the material arrives on the heated bed. The nozzle moves in X and Y axis. When one layer finishes printing, the nozzle continues to print the next material layer, building up the material in Z direction to create the object.

These are the two 3D Printers available in our Fab Lab. The Instructor gave us an introduction to the 3D Printers we have at Fab Lab O. First, we changed the previous plastic filament. The durability of the filament varies depending on the environment of the place.

Before printing, we have removed the print bed from the printer and cleaned its surface with a blade to remove the plastic filament and glue from the previous print (the printing bed can be also cleaned with a wet sponge). After putting the print bed back into the printer, we have applied a layer of paper glue lightly, which support the first printed material layer.
After the .stl file was loaded, the 3D Printer began to print.

The Testing Design Rules with a Testing Kit downloaded from thingiverse website -
I downloaded a simple test kit from Thingiverse to test the 3D Printer using a higher quality print setting.
Quality - layer height – 0.1mm
Fill Density – infill – 30%
Support – Yes
Raft - Yes
Some of the test findings (testing the design rules) :
- Wall Thickness:
0.1 mm (failed), 0.2 mm (failed), 0.3 mm (failed),
0.4 mm (ok), 0.5 mm (ok), 0.6 mm (ok), 0.7 mm (ok)
- Holes:
Size 3 mm, 4 mm, 5 mm
(shape is not so round, internal wall contain some residue)
- Bridge:
Print: 2 mm (ok), 4 mm (ok), 8 mm (ok),
16 mm (failed)
- Overhang of 25, 30, 35, 40, 45, 50, 55, 60, 65, 70 degrees all are ok.
The Testing Design Rules of a 3D Printer –

• Place object on the platform.
• Secure it in position as the platform will be rotated during the 3D scanning process.
• Click the "Scan" button at ScanStudio software.
• Ensure the object is in the position as shown on the screen.
• When the 3D scanning starts, the 3D Scanner shot out multiple light beams onto the object while the rotating platform will automatically rotate the object around. The 3D scanning process took about 50 minutes or longer.
• Use the "Trim" tool of ScanStudio to remove unnecessary portion like the platform and the overhung securing bar.
• Use the "Fill" tool of ScanStudio to fill up holes. The software will automatically detect and highlight the holes.
• Exported the 3D model from ScanStudio to a .stl file and imported into Fusion 360.
• However, I seem to miss out on "filling" all the holes. I might have to go back to the Fab Lab and use ScanStudio to fill the holes again, or I might use professional software like Blender or Autodesk MeshMixer to touch up the model.

Individual Assignment – 3D Scans – The 3D scanning technologies turn atoms into bits. There are many types of scanning technologies available on computer or on smart phones. The one that is used at Fab Lab O is an infrared depth map scanner. For 3D scanning or three-dimensional capture, what an expensive professional 3D scanning equipment and/or software used to do is now accessible to the consumer with the arrival of 3D scanner mobile app. Expensive 3D scanning equipment use to shot hundreds of depth-sensing beams on the object, while 3D scanning mobile apps are based on photogrammetry which is a technology whereby a 3D model is created out of multiple 2D photos.

Brief process to 3D Scanning:
When the 3D Design is ready, it is then exported in the .STL format for its impression.

Step 1: Gather data (acquisition sequence - data is captured by following a very specify sequence of movement)

Step2:Analyse captured data and processing 

Step3:Retouching (touch-up on small anomalies) 

Best practices :Avoid object with reflective areas will result images having lots of abnormalities that very hard to repair. The areas without textures are too smooth to scan.

3D Scanning - There are two ways to acquire the bits of an object, either the scanner remains stationary (mount it on a tripod when scanning a person) when the object rotates, or the object remains stationary when the scanner moves. Direct sunlight needs to be avoided, since it interferes with infrared light. The camera we use for scanning at Fab Lab O is Kinect (Microsoft Xbox). Once the device is connected to the computer,open Skanect, a free 3D scanning software (pro version comes with more high quality scan is also available).

A 3D scanner is a device that collects physical data of an object or environment in order to create a digital model. This data can include volume, texture and color. There are two main types of 3D scanners: contact or non-contact. The 3D scanning is the process of analyzing a real-world object or environment to collect data on its shape and possibly its appearance for example color. The collected data can then be used to construct digital 3D models. A 3D laser scanners create “point clouds” of data from the surface of an object, by capturing a physical object's exact size and shape into the computer world as a digital 3-dimensional representation. A 3D point cloud is a set of data points in space. The Point clouds are generally produced by 3D scanners, which measure a large number of points on the external surfaces of objects around them.
We have a ‘Sense’ 3D Scanner in our Fab Lab.

I have joined My Team Mate Pooja for this task.
http://fabacademy.org/2019/labs/vigyanashram/students/pooja-jadhav/Assignments/index%206.html
Later My Team Mate Aditi also requested me for help, so it was a good experience to experiment with the 3D scan for a second time.

http://fabacademy.org/2019/labs/vigyanashram/students/aaditi-kharade/assignment6.html
Issue – I tried experimenting with this, but the software got corrupted and there was an issue with the 3D scanner. Hence couldn’t do it.
The 3D scanning is Reverse Engineering Process and vital in Geo Spatial Analysis.

My experience at the Clark Planetarium, Salt Lake City, Utah – During my stopover at Salt Lake City for a night stay, while returning from the University Rover Challenge 2019 from Mars Research Desert Station, Hanksville, I visited The Clark Planetarium. Sharing my experience of the Infrared Waves, which is quite similar to the 3D Scanning procedure.





Photogrammetry – I wanted to explore on Photogrammetry. As I was Browsing, I understood the following concepts.
Photogrammetry is the art and science of extracting 3D information from photographs. The process involves taking overlapping photographs of an object, structure, or space, and converting them into 2D or 3D digital models. Photogrammetry is often used by surveyors, architects, engineers, and contractors to create topographic maps, meshes, point clouds, or drawings based on the real-world.

OpenMVG is a library target for photogrammetry, finding great use for the Multiple View Geometry (MVG) community. The emphasis appears to be on the structure from motion technique of photogrammetry, with a number of the integrated tools built around this. A photogrammetry pipeline that requires compiling to use, OpenMVG takes some computer savvy to get up and running on Windows or Linux.

Designed around the mantra of “Keep it simple, keep it maintainable“, the community-focused accessibility of OpenMVG makes it an accessible tool that fits into the workflows of other photogrammetry tools.

Applications of Photogrammetry Software –

1. Building Design and Renovation.

2. Digital Preservation.

Different Types of Photogrammetry - The way photogrammetry software usually works is the following. First, the program automatically registers the shared points between every image and then calculates the distances between them in 3D space. The result is a point cloud that you can transform into a 3D mesh. Photogrammetry is an ingenious technique for 3D scanning. You can capture large objects like buildings or even mountains that would be impossible to scan using other methods. Moreover, photogrammetry is also extremely affordable since you probably already own the most important piece of equipment: the camera of your smartphone. However, you also need photogrammetry software to create a 3D file of the object you have photographed.

Like many things, photogrammetry software comes in many shapes and sizes. Major software developers have published commercial solutions that are ideal for industrial and engineering applications. However, a number of programs are available for free download. To help you find the right photogrammetry software, we have assembled the following list of titles.

There are two primary types of photogrammetry: aerial and close-range. Like, BeMAGINE Photogrammetry, iWitnessPRO, Drone Deploy, Pix4D, Photomodeler, Autodesk Re Cap, Reality Capture, Agisoft Metashape, and 3DF Zephyr.

Free Photogrammetry Software – Colmap, Meshroom, MicMac, Regard3D, VisualSFM, and OpenMVG.

My Task for 3D Printing -
1. Exporting the model and prepare the mesh for 3D printing:
The scan quality should be good. Under Reconstruct/Remove Parts, these parts can be removed automatically.

2. Filament: The filament used is PLA 2.85mm diameter 750 gram. PLA is a sturdy yet biodegradable material. PLA stand for polylactic acid or polylactide and is derived from renewable resources.
Then I saved the file in .obj format under Share, and opened it in Mesh mixer, Autodesk software I used to edit and sculpt on my model. There are several areas in the model that were hollow, since these were the blind spots of the camera. This can be fixed under Edit/Make Solid.
With Edit/ Transform, the size and the position of the model can be determined.
With Edit/Plane Cut, the model can be cropped from different angles. Similar to clay sculpting, a range of tools are available under Sculpt for changing the form of the model.
Before exporting the file, make sure to select all the layers and click on Edit/Combine.

I understood that the 3D Printing process is

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file. The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object.
Since 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing”, developed a set of standards that classify the Additive Manufacturing processes into 7 categories according to Standard Terminology for Additive Manufacturing Technologies.
These seven processes are:

Subtractive Manufacturing –
Subtractive manufacturing is a process by which 3D objects are constructed by successively cutting material away from a solid block of material. Subtractive manufacturing can be done by manually cutting the material but is most typically done with a CNC Machine. It creates waste from the material that is removed. It has limited design capabilities.

The differences between Additive and Subtractive Manufacturing –


The Slicing Software –
The Slicing software is a necessary element of 3D printing, because 3D printers cannot translate a CAD drawing by themselves. It will create paths for a 3D printer to follow when printing. ideaMaker is a powerful user-friendly slicing software that prepares STL, OBJ and 3MF files for 3D printing in just 2 clicks. It generates the machine code that the printer will use for printing. Furthermore, the program defines a cross-platform program that takes 3D files (STL) and generates path information (G-code) for a 3D Printer.

SL.No	Software	Function	Level	System
1	Cura	Slicer, 3D Printer Host	Beginners	Windows, Mac, Linux
2	Matter Control 2.0	Slicer, 3D Printer Host	Beginners	Windows, Mac, Linux
3	3D PrinterOS	Slicer, 3D Printer Host	Beginner	Windows, Mac, Ubuntu, Raspberry Pi
4	Astroprint	Free	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
5	CraftWare	Free	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
6	IceSL	Free	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
7	ideaMaker	Free	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
8	KISSlicer	Free/$35	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
9	MakerBot Print	Free	Beginners	Windows, Mac, Ubuntu, Raspberry Pi
10	MatterControl	Free	Beginners, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi
11	Netfabb Standard	$1000 to $4300(annual Subscription)	Intermediate Users, Advanced Users	Windows
12	OctoPrint	Free	Intermediate Users, Advanced Users	Windows, Mac, Ubuntu, Raspberry Pi, Linux
13	Repetier	Free	Intermediate Users, Advanced Users	Windows, Mac, Linux
14	SelfCAD	Free trail, $9.99/month	Beginners, Advanced Users	Browser
15	Simplyfy3D	$150	Beginners, Advanced Users	Windows, Mac
16	Slic3r	Free	Advanced Users	Browser
17	Tinkerine suite	Free	Beginners	Windows, Mac
18	Zsuite	Free	Beginners	Windows, Mac

G-code is a language that humans use to tell a machine as to “how to perform a task”. With 3D printing, g-code contains commands to move parts within the printer. G-code consists of G- and M-commands that have an assigned movement or action. G-code is the programming language of your 3D printer. Using G-code, a computer tells a printer when, where, how to move and how much to extrude throughout the entire print process.
To import the file in Notepad++, go to Language > Define your language, click Import.
I have used Fractal Works 3D Printer to model my design in belief that My Design is My Creativity with a Purposeful Strategy.

You can check out more about the software at http://fractalarts.com/ASF/Fractal_Software_Programs.html
The 3D Printing Process I have followed – I have used Julia 3D Printer from https://fracktal.in/julia-series/

https://fracktal.in/how-to-succeed-with-printing-pva-soluable-support/
Step 1 – 3D model creation - I have made a 3D model of the object is created using CAD software.
Step 2 – STL file creation - Then I have converted the CAD model to a STL file to tessellate the 3D shape and slice it into digital layers.
Step 3 – STL file transfer - I have transferred the STL file to the printer using custom machine software.
Step 4 – Machine set up - The PLA Consumable was loaded by me and I had the printer set-up with the printing parameters.
Step 5 – Build - The Printer built the model by depositing the material layer by layer to print my design.
Step 6 – Part Removal - Lastly, I have removed the parts from the build platform and its support structure.
Step 7 – Post processing - Finally, post processing, cleaning was done by me to ensure that the next user finds it intact and ready for use.

Why it is not made by subtractive manufacturing? Subtractive manufacturing or subtractive fabrication involves cutting away from a solid block of material. It could be a block of, for example, metal, plastic, or wood. The manufacturing processes is based on controlled removal of undesired materials through cutting, drilling or milling to achieve the desired forms. Since this design contains small holes, overhang and mesh, the overhang and mesh of the Mobius geometry cannot be subtractive printed, hence I did not choose this method for 3D printing. The 3D printer can print better than any milling machine. While taking the curve parts into account the 3D printer can do a good job, and in some cases, support removal is needed in a few cases depending upon the design, which is not affordable with any other milling machine.
Software Used – Auto Desk Fusion 360. The 3D printed Temperature Holder was designed during the Computer Aided Design Assignment as shown below and was printed during this Assignment as shown below. http://fab.academany.org/2019/labs/vigyanashram/students/hemang-vellore/Assignment3/A3%20Computer%20Aided%20Design.htm
Design File - A3 Computer Aided Design_files\lm35 v2.f3d The Solar FAB Air Cooler Body design and 3D printing process is shown below.


Design File - A6 3D Modelling, Scanning and Printing_files\my air cooler.stl
Video link - https://youtu.be/ESNITVuf6QY
You can see the time taken for 3D printing this design. Now my prototype is 100% 3D printed.


After completing My Final Project, I have taken this picture to ensure that My Prototype stood good.

I have also made a Temperature Sensor Holder for my final Project here – Assignment 3 Computer Aided Design
http://fab.academany.org/2019/labs/vigyanashram/students/hemang-vellore/Assignment3/A3%20Computer%20Aided%20Design.htm

My visit to Imaginarium – India’s largest 3D Printing Company – https://www.imaginarium.io/
I have visited Imaginarium during my stint at the STEAM School, Bonjour India at Makers Asylum, Mumbai, India in December 2017.




Learning Outcome – I have learnt about 3D Design software using AUTODESK Fusion 360. The process is very engrossing. I understand that the 3D Scanner has to be held upright properly in order to get a perfect scan. I have experienced the effect of Infrared Sensors in real life. I have successfully 3D printed the Prototype for my Final Project and a Temperature Sensor Holder for my final project – Smart FAB Air Cooler.

Reference – FAB Academy Tutorials www.thingiverse.com
https://my3dtwin.com/how-3d-printed-figurines-are-made
https://all3dp.com/1/best-photogrammetry-software/
https://www.autodesk.com/solutions/photogrammetry-software
https://all3dp.com/1/best-3d-slicer-software-3d-printer/