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Week 5. 3D Scanning and Printing

Group Assignment:

  • Test the design rules for your 3D printer(s)

Technical Parameters of Prusa i3 MK3S

We went through this page to learn about specs.

  • Build Volume: 25×21×21 cm (9.84”×8.3”×8.3”)
  • Layer height 0.05 - 0.35 mm
  • Nozzle: 0.4mm default, wide range of other diameters/nozzles supported
  • Type: Fused Depositon Modeling (FDM)
  • Filament diameter: 1.75 mm
  • Supported materials: Wide range of thermoplastics, including PLA, PETG, ASA, ABS, PC (Polycarbonate), CPE, PVA/BVOH, PVB, HIPS, PP (Polypropylene), Flex, nGen, Nylon, Carbon filled, Woodfill and other filled materials.
  • Max travel speed: 200+ mm/s
  • Max nozzle temperature: 300 °C / 572 °F
  • Max heatbed temperature: 120 °C / 248 °F
  • Slicer: PrusaSlicer

Design rules for the Prusa i3 MK3S printer

We downloaded the testing model from the link Design Rules Test Model to check on parameters like:

  • Overhang test- What could be the highest degree that printer can print hanging parts
  • Bridging test-What could be the maximum length machine can print good.
  • Support test
  • Stringing test
  • Hole test

  • Diameter test (1mm wall)

  • We used Prusa slicer to generate the G-code.

  • Print Settings: BE SURE TO PRINT THIS WITHOUT SUPPORTS AND WITH 100% INFILL.
  • Enter the SD card and begin the print by going to the gcode file.
  • Printing is finished, and here’s how it turned out.
    • Overhang test:
    • Other tests:

Conclusion

  • Overhang test- From this test support is required after an angle 60 degree.
  • Bridging test- Bridging was not that good after distance of 2cm.
  • Micro-engraving- Texts weren’t printed good, therefore, it is advisable to avoid using letter size below 5mm.
  • Stringing or oozing- also known as “hairy prints”, is the name given for when small strings of filament are left on a printed model. This usually happens when the filament keeps flowing from the nozzle while the extruder is moving to another object. This issue is caused by very high printing temperatures and/or using incorrect retraction settings.

Tech Specs of Formlabs Stereolithography 3D Printer

  • Technology: Low Force Stereolithography
  • Resin Cartridges: 1
  • Supports: Auto-Generated/Light-Touch Removal
  • Minimum Access Dimensions (W × D × H): 40.5 × 53 × 78 cm
  • Internal Temperature: Auto-heats to 35 °C
  • Power Requirements: 100–240 VAC, 2.5 A, 50/60 Hz, 220 W
  • Printer Control: 5.5” interactive touchscreen 1280 × 720 resolution
  • File Types: STL, OBJ, and 3MF file input FORM file output
  • Weight: 17.5 kg

Design rules for the Formlab printer

  • Open PreForm (which prepare models automatically in minutes, upload them to printer to build model) and go to file > open > design test model.
  • Choose printer, material and material thickness(0.1, which is fastest)
  • To initiate printing, simply click on “Upload Print”. This action will prompt the printer to begin the printing process automatically.

  • Note: In this print, I didn’t include support structures to assess the printer’s capabilities accurately. However, for actual printing, it’s advisable to enable automatic support generation to ensure that intricate or overhanging parts are adequately supported during the printing process.

  • This is how it looks after printing:

Conclusion and Observations

After printing design rule model on Formlab printer, following observations were made:

  • Maximum Unsupported Overhang Length: At an angle 90 degree, recommended: 5.0 mm.
  • Minimum Unsupported Overhang Angle: Recommended 10° from level. Printing at an angle less than 10° could cause the overhang to break off the model during the peel process.
  • Maximum Horixontal Support Span/Bridge: Recommended: 29 mm
  • Minimum Engraved Detail: Recommended: 0.15 mm
  • Minimum Hole Diameter: Recommended: 0.5 mm