3D printing. Group 2 Work.

Group work for week 5

This week we tried out different 3D printers.

We used three different test files provided to us by our instructor to compare the four different printers' qualities.

• Test 1 was printed beforehand by our instructor
• Test 2 was printed by the other group
• Test 3 was our group's responsibility

The printers we used were:

• Ender-3 pro
• Raise 3D Pro2
• Formlabs Form2 (resin printer)
• Fortus 380 mc

Specifications

So with each printer we printed the Test 3 which included two different models (as seen in the pictures)

Please find our documented observations in the last section.

Test 1

Figure: There was some "spaghetti" like structure below the overhang in the test piece printed by Fortus 380 mc, when the overhang was nearly horizontal.

Figure: There were some strings between structures in the test piece printed by Fortus 380 mc.

Figure: In the test piece printed by the Raise 3d pro2 ther was roughness below the overhang when the angle was nearly horizontal.

Figure: The test pieces printed by Ender 3 pro and Formlabs Form.

Printers' Settings for TEST1
	Ender-3 pro	Raise 3D pro2	Formlabs form2	Fortus 380 mc
Layer height	0.2mm	0.2mm	0.16mm	0.254mm
Material	PLA	ABS	Resin:Grey V4	ABS
Bed Temp	60℃	100℃	Operating temp: auto-heats to 35℃	(Oven temp)315℃
Material Extruder Temp	200℃	240℃	Resin melting point: 250℃. Post Cure: 60℃	130℃
PrintTime	2h 56m	3h 34m	2h 1m	1h 14m

Test 2

Figure: The test pieces printed by Raise 3D, Ender 3 pro´, Formlabs Form, and Fortus 380 mc under TEST2 by another team.

Printers' Settings for TEST2
	Ender-3 pro	Raise 3D pro2	Formlabs form2	Fortus 380 mc
Layer height	0.3 mm	0.2 mm	0.16 mm	0.254 mm
Material	PLA	ABS	Resin: Grey V4	ABS
Bed Temp	60 C	100 C	Operating temp	(Oven temp)
Material Extruder Temp	200 C	240 C	Melt point 250	130 C
PrintTime	36 min	1h 30 min	1h 30min	27 min

Test 3

Figure: Testprints for clearance and overhang

Figure: Testprint for clearance and overhang for Raise 3d pro 2, printed with supports

Printers' Settings for TEST3
	Ender-3 pro	Raise 3D pro2	Formlabs form2	Fortus 380 mc
Layer height	0.2 mm	0.2 mm	1.6 mm	0.254 0mm
Material	PLA	ABS (hips support)	Resin	ABS
Support	Zig Zag	None	No internal support	SR3
Bed Temp	60	100	-	92
Material Extruder Temp	200	240	-	230
Support Extruder Temp	200	250	-	230
PrintTime	2h 55min	1h 56 min	1h 30 min	1h 27 min

Evaluation

Observations from the tests
First, we use this 3D printer test, TEST1, to test: angle, bridging, overhang, hole, scale, stringing, diameter, and support.
"Angle
An overhang angle is the angle the overhang sticks out from horizontal."	In the test part printed by the Fortus 380, there appeared “spaghetti” like structure below the printed part when the angle from the vertical direction exceeded about 60 degrees (overhang angle less than =90-60=30). Also, in the test part printed by the Raise 3D-pro2 there was clear roughness below the structure when the angle from the vertical direction was 70 degrees ore more (overhang angle less or equal to 20). Ender Pro printed the overhang angle test well, only few strands of printing filament were found on the very edge of the overhang test part.
"Bridging
The bridge refers to the distance between two intermediate supports of a structure. Although horizontal spans are discouraged, certain geometries can be printed."	In the test piece printed by the Fortus 380, there was problems with the bridged structures (for all distances? - let’s check). Otherwise the test pieces printed by the other printers seemed ok.
"Overhang
An overhang is a part of the model that sticks out horizontally parallel to the build platform. This can cause the layers to lose their structure when printed without support.	As mentioned at the angle section, the test piece printed by the Fortus showed problems when the overhang angle (the angle the overhang sticks out from horizontal direction) was less or equal to 30 degrees. Also in the test part printed by the Raise 3D-pro2 there was clear roughness below the structure when the overhang angle was less or equal to 20.Ender Pro printed the overhang test without problems.
Hole	The holes appeared to be printed reasonably well (judging from visual inspection) on all the other printers, except the Fortus 380c, where the hole shape deviated from the designed circular shape
Scale
"Stringing
Stringing is caused when small strings of plastic are left behind on a 3D printed model (also called ""oozing,"" ""whisky,"" or ""hairy"" prints). Plastic usually oozes from the nozzle while the extruder is moving to a new position.	As mentioned in the Angle and Overhang sections, the Fortus 380 had lot of problems with stringing, when the overhang angle was less or equal to 30 degrees. Also Ender 3-pro had little stringing. Formlabs 2, Raise 3D produced pretty good and smooth result with no problems with stringing.
Diameter	Measured diameters: We measured two outer diameters from the test print, larger and smaller. Raise 3D: 8mm, 6mm; Formlabs: 8mm, 6mm; Ender 3D pro2: 7.5 mm, 6.5 mm; Fortus 8mm, 6.1mmm
Then we test wall thickness, again without support, using this file, TEST2.
"Wall Thickness
Supported walls are those that are connected to other walls on two or more sides."	1) Raise 3D: Skipped one wall. Walls were connected 2) Ender: skipped two wall, rest of the walls were moving. 3) Formlabs: All walls were printed sucessfully. 4) Fortus: Skipped four walls.
Then, we do tests for overhand and clearance with support using these files, TEST3.
Overhang
"Clearance
In a model, clearance is the distance needed between two moving parts (e.g., the gap between a gear and a joint)."	We used clearance of range from 01. mm to 1 mm, with step size of 0.1 mm. 1) Raise 3D: We earlier forgot to print support for Raise 3D. Then, we printed one with support. Clearance of 0.2mm or higher allowed free movement between gear and joint. 2) Ender: Clearance of 0.2 mm or higher allowed free movement. 3) Formlabs: Clearance of 0.2 mm or higher allowed free movement. 4) Fortus: Clearance of 0.7 mm or higher allowed free movement.

General specifications

Specifications for each printer used
	Ender-3 pro	Raise 3D Pro2	Formlabs Form2	Fortus 380 mc
Nozzle Diameter	0.4 mm	0.4 mm	-	0.4 mm
Build Volume	220x220x250mm	305x305x300mm	145x145x175mm	356x305x305mm
Printing Precision	+-0.1mm	0.01-0.25 mm	0.1-0.05mm	+-0.127mm