3D Scanning and printing

For this week, as an individual assignement, an Object should be designed and 3D-Printed, which could not be substractively made.

Research

There are many objects that can be made using additive 3D printing that would be difficult or impossible to create using subtractive methods like CNC machining or carving. Here is an example of an object that would be challenging to create subtractively, but could be easily designed and 3D printed.

Design: A small, intricate lattice structure

One advantage of 3D printing is the ability to create complex geometries that would be challenging to create using traditional subtractive methods. One such geometry is a lattice structure, which consists of a network of interconnected struts and voids. A lattice structure can be used for a variety of applications, including lightweight structural components, filters, and heat exchangers.

To design a lattice structure, a 3D modeling software like Autodesk Fusion 360 or SolidWorks could be used. At the begining a cube or sphere with the desired dimensions should be created, then could the lattice feature be used to create the structure. It's possible to experiment with different lattice patterns and densities to achieve the desired mechanical properties.

Workflow for Printing: Using an FDM 3D printer

Fused Deposition Modeling (FDM) 3D printers are a popular and affordable option for creating small objects. To print the lattice structure, a material that can create thin, strong struts and handle the small details of the design should be choosen. PLA (polylactic acid) or PETG (polyethylene terephthalate glycol) are good options for this.

Once the lattice structure is designed, it is now possible to export it as an STL file and import it into the slicing software. In the slicing software, the settings for layer height, infill density, and support structures could be adjusted. For a lattice structure, it's better to use a low infill density to maximize the open space in the design.

After slicing, the file is now ready to be sent to the 3D printer and start the print job. Depending on the size and complexity of the lattice structure, the print time may range from a few minutes to several hours. Once the print is complete, the support structures could be removed and the object cleaned to reveal the intricate lattice structure.

Lattice structure in 3D-Design

1. I begin by creating a sketch that shapes the form of my 3D object. This initial design serves as the foundation for the entire project.



2. Next, I extrude the outer part of the object. My intention is to use these pieces as LED covers, so this step ensures they have the necessary depth and structure.



3. Expanding on that, I also extrude both the outer and inner parts. This additional layering ensures that the top of the object is fully covered, providing a seamless surface.



4. With the basic form in place, I turn to the Volumetric Lattice tool. Using this feature, I create an intricate pattern that adds visual interest and complexity to the design. The lattice not only enhances aesthetics but also contributes to the overall strength of the object.



5. Once satisfied with the 3D model, I export it as a .3mf file. This format allows me to transfer the design seamlessly to the Prusa Slicer software for further processing.



6. Now, let’s dive into the specifics of the 3D printing process:

   • Material: I choose PLA (Polylactic Acid) for its ease of use and environmental friendliness.

   • Nozzle size: I opt for a 0.4 mm nozzle, which strikes a balance between fine details and efficient printing.

   • Supports: I configure supports to generate only on the build plate. This ensures stability during printing without unnecessary overhangs.

   • Infill: I set the infill percentage to 15%. This determines the internal structure of the object, balancing strength and material usage.

   

7. Finally, I slice the model using the Prusa Slicer, generating the G-code necessary for my Prusa 3D printer to bring the object to life layer by layer.



8. Here is the result after more tha 5 hours printing:

3D Scanning Process

iSense 3D Scanner for iPad

The iSense 3D Scanner is a compact device designed to work with the iPad, allowing for portable 3D scanning. It attaches to an iPad 2 case and uses structured light to capture depth, shape, and color data, creating detailed 3D models of objects and environments. The scanner processes information in real-time, displaying the 3D scan on the iPad as it captures data. This setup enables users to scan objects of varying sizes, from small items to large spaces. The iSense is commonly used in applications such as 3D modeling and printing, where a digital representation of physical objects is needed. It provides an accessible option for obtaining 3D scans directly on an iPad.

I found this object in our FabLab, i wanted a structure with versatile features to test the 3D-Scanner

1. Setup

   I positioned the target object on a rolling chair, ensuring it was well-lit and visible from various angles. Next, I prepared my camera or smartphone to capture photos of the object.

2. Rotation Scanning

   I meticulously rotated around the object, capturing photos at each position. By circling the object, I obtained different viewpoints, allowing me to capture its shape comprehensively.

3. Multiple Angles

   I took photographs from various perspectives—top, bottom, sides, and diagonals. The more angles I covered, the greater the number of data points collected for accurate reconstruction.

Results:

• X-Ray Image:

  This image likely reveals the internal structure of the object, highlighting any hidden features or defects.

  
• Shaded Image:

  Shaded images provide a visual representation of the object’s surface, emphasizing its contours and texture.

  
• Color Image:

  The color image might capture different details or features, complementing the first one. For example: Color

  

Fusion360 Project Volumetric Lattice Structure

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.3mf-File Volumetric Lattice Structure

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Link to the group assignement for this week