The group assignment of this week is to characterize and test the 3D printers available in the lab. The individual assignment is to design and 3D print an object that can be printed additively, but cannot be made subtractively (i.e. using milling machine). The size of the design is limited by the printer size. The second individual assignment is to 3D scan an object.

Machines used:

  • 3D Printers: (Ultimaker 2+/ MakerBot 5th Generation / Prusa MK2)

Softwares used:

This week assignment content:

Design resources:

Final version of this week files:

6.1. Characterize the design rules for your 3D printer.

For this week group assignment, we did two different 3D printing tests on the three 3D printers we have in the lab. First test was the jolly 3D printing torture-test , which we had printed using three different filament materials PETG, ABS, and Nylon. We found that the print test using Prusa MK2 with PETG filament was the best. The second test was printed on MakerBot printer using PLA filament.

Link to this week group assignment

6.2. Design and 3D print an object.

Step 1: Design an object in Fusion 360

The first step of this assignment is to design an object that cannot be made subtractively (e.g. using the CNC machine). Therefore, I decided to design a juice box holder for kids to prevent them from squeezing their juice box and spraying drinks everywhere. I designed it using Fusion 360 with the help of our lab instructors. To meet this assignment requirements, I added a hollow cup handle.

My final design:

I have saved a copy of my design as .stl file to print it using a 3D printer. save_as_stl

Step 2: Slicing

For slicing, I used MakerBot Print software. I started by importing my design file. MakerBot_import

Then I rotated the object vertically to be able to print it without support. Also, I changed the printing settings as shown in the figure below: MakerBot_settings

Then I save it as a G-Code and export it to a usb flash memory.

Step 3: 3D Printing

I have printed my 3D design on the MakerBot 5th Generation printer with PLA filament. 3D_printer

To do that I did the following steps:

  • Add the filament you want.
  • Insert the usb flash memory and open the G-Code.
  • Heat the extruder.
  • Move into position.
  • Transferring print file.

steps

  • Here is my final result.

finalResult

  • The hollow handle:

hollow_handle

6.3. 3D scan an object.

Step 1: Using Qlone

At first, I used Qlone application. It can be installed on iPhone for free and you can scan the object you want without any complication. Once you open the application for the first time, you will be asked to download the scaling sheet that you should place your object on. To start scanning, move your phone around the object until you get all the mesh. Then the scanned file can be uploaded on some websites and applications for free. However, if you want to export the scanned file as stl, OBJ, FBX, or USDZ formats then you have to pay. For me I chose to download my scanned objects as GIF images.

I tried to scan two different objects. My first try was a small Bat Man, but it didn't scanned well and I think because it has small details, which cannot be detected.

The original object: object_batman

The scanning result: batman

Then, I tried another small object with less details and the result was better.

The original object: Object_2

The scanning result: Qlone

Step 2: Using XBOX 360 Kinect

My second try for the 3D scanning technology was using XBOX 360 Kinect sensor bar to scan a small brush. xbox

I have connected the XBOX 360 Kinect to the computer using USB wire and use the Kinect software to show the results.

Then I have started the scanning by moving the object to scan it from all sides. scanning

The scanned file was exported as stl file and opened in MeshLab software.

meshlab

Final scanned file:

I found 3D scanning using XBOX 360 Kinect is more efficient and produce more detailed results better than Qlone. However, Qlone can be used on smart phones, which make it portable.

6.4. Advantages and limitations of 3D printing.

Advantages

  • Capable of building more complex designs than traditional subtractive manufacturing techniques.
  • Ease of Access as its affordbale, small in size, and becomes available in most labs.
  • Minimize waste material as it prints only the required parts for the design with little support material.

limitations

  • Printing size is limited by the 3D printer size. Anything larger than the printing space need to be printed in seperate parts.
  • Printing materials types are few becuase not all plastics can be temperature controlled enough for 3D printing.
  • Printed parts with support need to be cleaned and smoothed to get the required finish.
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