5. 3D Scanning and Printing

Reflection

Group Assignment

Attached is the link to group assignment

Individual Assignment

I1. Enhanced Workflow: Tinkercad Design to 3D Printing with Ultimaker 3

i tried to detail the process of designing in Tinkercad, exporting the design, slicing with Cura for Ultimaker 3.

Step Activity Details and Adjusting Cura Settings
1. Tinkercad Design
Vector Tools Vector Tools 		Create your 3D model I Used Tinkercad to design my model, I considered printability and the final application. I used drag and drop to place in the 3D objects and merge them together to form the shapes.

Picture shows the 3D Design made in Tinkercad. The Link to the file is here.
2. Exporting Model Vector Tools Export as STL file I Exported my Tinkercad design as an STL file, ready for slicing in Cura.
3. Preparing in Cura Vector Tools Load STL file in Cura I Choose Ultimaker 3 as my printer in Cura and imported the STL file. Cura applies default settings optimized for Ultimaker 3.
4. Cura Default Settings and Adjustments Vector Tools Optimize settings for 3D Printing Layer Height:
Default is 0.16mm. Increase layer height (e.g., to 0.2mm) for faster prints with slightly reduced detail, or decrease (e.g., to 0.1mm) for higher detail in cosmetic parts.

Infill:
Default is 20%. Increase for parts requiring higher strength, decrease for less critical parts to save material and time.

Print Speed:
Default is 50 mm/s. Increase speed (e.g., to 70 mm/s) for less detailed parts to shorten print time, or decrease (e.g., to 40 mm/s) for intricate designs to enhance quality.

Temperature:
Adjust based on the filament. PLA typically uses 200°C nozzle/60°C bed. Higher temperatures may improve flow but risk stringing; lower temperatures improve detail at the cost of adhesion.

Supports:
Enabled by default for overhangs. Disable for simple geometries to save material and cleanup time, or adjust placement for complex models requiring support.

Build Plate Adhesion:
A brim is used by default. Use a raft for models with small footprints or remove it for large, flat models to reduce waste and post-processing time.
5. Slicing and Exporting G-code Vector Tools Generate G-code for Ultimaker 3 I Sliced my model with the adjusted settings and save the G-code to a USB drive for Ultimaker 3.
6. Printing on Ultimaker 3
Vector Tools
 Start your 3D print I Ensured the Ultimaker 3 is properly calibrated and the build plate is leveled before starting the print with your G-code.
7. Example of Use
Vector Tools 		For Clubs I want to use simple prints to entice youth to learn more.

I2. Workflow for Using Polycam on iPhone to Scan 3D Models

Step Description
1. Prepare the Object Vector Tools I Placed the object, I want to scan on a stable surface with good lighting. I ensure that the object is well-lit and evenly illuminated from all angles to capture details accurately.
2. Open Polycam App I Launched the Polycam app on your iPhone.
3. Start a New Scan I Tapped on the "New Scan" button within the Polycam app to begin a new scanning session. I Positioned my iPhone so that the object fits within the frame of the camera view.
4. Capture Reference Frame Vector Tools I tap the "Start Scan" button to begin the scanning process. I slowly move my iPhone around the object, keeping it within the camera's view.
6. Complete Scanning Vector Tools I continued scanning the object from various angles until I had captured all sides and details. Polycam automatically stitch together the individual scans to create a complete 3D model.
7. Review and Edit After scanning is complete, I reviewed the 3D model within the Polycam app.
8. Save or Share the Model Vector Tools I Save it to my iphone.

I3. Workflow for Using Onshape to make the print in place inner part

Step Description
1. Sketch Vector Tools I drawn a rectangle, I fillet two edges, I drawn a circle and a line to act as revolving axis. I placed the design which I am replicating from Tinkercad picture shown.
2. Extrude. Vector Tools I selected the extrude function on the rectangle and selected the desired parameters.
3. Revolve Vector Tools I sselected the circle and used revolve 360 about the chosen axis.
4. Export Vector Tools I parameterised the dimensions and selected the objects to export.

Useful Theory: Design Rules and Considerations for 3D Printing

When designing models for 3D printing, certain rules and considerations ensure the printability and integrity of the final product. This table outlines key design guidelines:

Design Rule/Consideration Description Why It's Important
Wall Thickness Minimum wall thickness must be adhered to, specific to the printing material and technology. Ensures structural integrity and prevents collapse or failure during and after printing.
Overhangs and Supports Designs with overhangs beyond a certain angle typically require support structures. Prevents deformation or drooping of unsupported features during the printing process.
Resolution and Tolerance Consider the printer's resolution and adjust tolerances for fit and function accordingly. Ensures components fit together as designed and function properly without excessive post-processing.
Orientation Positioning parts optimally in the printing volume can affect the strength and surface finish. Optimal orientation can reduce support usage, improve strength, and enhance appearance.
Escape Holes for Hollow Parts Hollow parts should have holes to allow excess material or support to be removed. Facilitates the removal of internal support material and prevents internal pressure buildup during processes like sintering.
Top and Bottom Layers Adjust the number of solid layers at the top and bottom of the print for optimal strength and surface quality. Improves the part's strength and ensures a smooth, finished surface on visible layers.
Infill Percentage The density of the print's internal structure, which can be adjusted to balance strength and material usage. Higher infill increases strength but also material usage and print time; lower infill saves material but reduces strength.

Issues and Rectification Methods for FDM 3D Printing

While FDM 3D printing is versatile and widely used, certain issues can arise during the printing process. This table outlines common problems and their solutions:

Issue Description Rectification Method
Warping The corners of the print lift off the build plate, leading to a warped bottom layer. Use a heated bed, apply adhesives (like glue or hairspray) to the build plate, or increase the bed temperature.
Stringing Thin strands of plastic are left between parts of the print, resembling strings. Adjust retraction settings in the slicer software, increase travel speed, or lower the printing temperature.
Layer Shifting Layers of the print are misaligned, leading to a shifted appearance in the Z-axis. Ensure the print bed and frame are stable, belts are tight, and stepper motors are functioning correctly.
Poor Surface Quality The surface of the print has imperfections, such as blobs, zits, or roughness. Calibrate the extruder, adjust layer height and print speed, and ensure filament quality.
Incomplete Fills The infill of the print is not fully formed, resulting in weak structures. Increase the infill percentage, ensure proper filament flow, and check for clogged extruders.
Nozzle Clogs The printer's nozzle becomes blocked, preventing filament from being extruded properly. Perform regular maintenance, clean or replace the nozzle as needed, and ensure filament quality.
First Layer Issues The first layer does not adhere well to the build plate, affecting the rest of the print. Level the build plate, adjust the nozzle height, use a raft or brim, and ensure the build plate is clean.