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- 3D printing (Process)

For individual assignment, I used VORON 2.4 R2 for FDM and Form 3 for SLA in Fab Lab West-harima. For the design, I incorporated the design rule limit in the group assignment.

1. What is VORON2.4 R2 ?

  • The VORON is the open-source FDM 3d printer, and user need to build up, so the user must have somewhat capability in fabrication, and calibration of the machine.
  • The VORON2.4 R2 in our Lab is build by the founder of Fab Lab West Harima, and operate it by responsive web user interface of Mainsail.

The Photo
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responsive web user interface alt text
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-Technical data

The Technical data of VORON 2.4 R2

Name Description
Build size 350(X) x 350(Y) x 350 (Z) mm
Printing technology FDM（Fused Deposition Modeling)
Extruder Single
Layer solution 0.1 - 0.4 mm
Travel Speed XY: 300 mm/s
Print Speed 100 mm/s for based speed
Nozzle 0.4 mm diameter
Supported print materials PLA, ABS, PETG, TPU, PC, Nylon
Build material price About 2000 USD
Firmware Klipper (default)
Official site https://vorondesign.com

2. PROCESS of VORON2.4 R2

2-1) Design & 3D Print (Test)

  • Open Fusion360 and make file with parametric design.
  • Sketch
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  • Create Pipe
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  • Create Circular pattern
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  • Sketch
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  • Extrude
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  • Sketch
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  • Create Pipe
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  • Create Circular pattern
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  • Combine alt text

  • Export the STL file (Utility > Make > 3D Print ) alt text

  • Test Print

    • 1st layer Z height change try: As the surface is rough, so I think the nozzle and bed surface is too close, so I did the Z height +0.05 through Mainsail, and it's success.
      alt text

    • Fail point!: The size is big!! Also, the output is even more unpleasant looking.
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    • The result and What I found:
      - In my desperation to create the design, I overlooked the size. - Took 3 hours to output because of the large size. Also the design The design has to keep moving before VORON can achieve its high-speed capabilities. Lost time and materials. - The above of pipe has little spaghetti.
      - During 3D print output, the angle of the top pipe hit the nozzle during output, which seemed to exceed the design of the overhang limit.

  • Correct the model with below point.

    • re-size: smaller
    • angle change gentle
    • less pipes alt text alt text
  • Output STL data (Go to Utilities > MAKE > 3dprint)

2-2) Slicer

Conversion to data format for output to 3D printer, using slicer software.
The Slicer setting is very important to reflect the output a lot.

  • Open SuperSlicer, and upload the STL data.

  • Do Slicer Setting, is suitable for Material "SUNLU PLA PLUS Filament 1.75mm white" And try unsupported.

    Print Settings

    Setting
    Perimeters 2
    Solid layers Top :4, Bottom:3
    Infill 15%, Gyroid
    Default speed 100 mm/s

    Filament Settings

    Setting
    Temperature Extruder 215 °C
    Temperature Bed 60 °C

  • Slicer execution
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  • Export G-code

2-3) Filament change

  • NOTE: Below Manual is When nozzle temperature is low.

  • In interface, Move the Toolhead to a position where it is easy to replace it.

    • click "ALL" of Toolhead
    • click "Z +25""" several time o move to the middle of the body
    • click "Y-100" several times to move it to the front.
  • In interface, Nozzle temperature input suitable temperature with each materials.
  • Once the specified temperature is reached, raise the lever (to unlock the filament).
  • Push the filament in slightly and then pull it out.
  • Push filament you use.
  • down the lever (to lock the filament)
  • In interface, press Cool Down.

2-4) 3D Printing

Machine Calibration and Filament Calibration are already done at FabLab West-Harima.
(If I have time, I'll do the Filament Calibration by myself later.)

  • NOTE: Below Manual *When nozzle temperature is low

  • In the interface, Preheat "Heater Bed' with suitable temperature for each materials.
    (as the base is thick, need pre-heat. And wait about 15 minutes. As official site, wait about 1 hour.)

  • Upload G-code files and start job. alt text
the Nozzle temperature the auto operation
reach 150 °C start Leveling automatically
reach target start output automatically

  • Output Check first layer status. Depends on the status move the Z height "+0.05" or "-0.05".

  • After finish printout, wait until the temperature become low around 30 °C, then remove the object. alt text

  • Done! It is unsupported, and the result is well.

2-5) Data file

3. What is Form3 ?

  • Form3 is produce functional level and high-quality prototypes, an affordable, industrial-quality resin 3D printer that reliably delivers.
  • The Features of Form3 is LFS（Low Force Stereolithography), galvano-style, Flexible tank with the bottom of the resin tank changed to a flexible material.
  • After 3D printing with Form3, a machine for curing (Form cure) and a machine for cleaning (ultrasonic cleaner) are required.　　
  • The Form3 in Fab Lab West harima is purchased second used in good condition with only a little use.
  • The model need cure with Form Cure

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-Technical data

Below Technical data is from Formlabs official site.

Name Description
Printing technology SLA, LFS（Low Force Stereolithography)
Supported print materials 30+ Functional Resins:
Layer pitch 25- 300 micron
Support material Automatic Generation
Build material price About 2000 USD
Software Preform
Work size 145 x 145 x 185 mm
Cartridge 1 　　　　　　　　　　　
Printer dimensions 405(W) x 375(D) x 530 (H) mm
Official site formlabs

4. PROCESS of Form3

4-1) Make STL data

In this time, The STL Data create with 3D scanning by CREAFROM.
process -> link.

4-2) Slicer

  • Download Preform (only first time)
  • Open Preform for slice, and upload the STL file.
    In the slice setting, I just change below 2 points, and click 1 button　”Auto-Generate Selected”
    • Support: Full Raft → Mini-Raft
    • From Printer Setup → Material: Grey v4 alt text alt text

4-3) 3D printing

  • Output Process is Just follow Quick start guide of Folmlabs.

    • When the resin is heat with enough temperature, automatically start 3D print. In case of the start temperature is 31°C. The resin was 11°C, so it takes 1 hour to heat.

  • Output is Done! (Time: About 4 hour 10 mins, Lamination Pitch：0.100 mm ) alt text

  • Remove the Bed
  • Remove the output from the Bed with Dedicated spatula. alt text
  • The plan was to take the support after curing, but the support was also removed during peeling from the bed. alt text
  • Clean output, with he ultrasonic cleaner and IPA
  • After clean. (The resin status: soft)
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4-4) Cure

For the Cure, I use Form Cure - Turn on. - Set Cure time and temperature, and start. Cure time and temperature are different depends on material. alt text - After clean. (The resin status: soft)
alt text - Done! It is good status!

NOTE
- The effective temperature and time required for curing vary depending on the type of resin. - I refer the below site, as I can see the recommended settings for Form Cure time and temperature are displayed.
- Useful link :Support.formlabs.com (Japanese)

4-5) Data file