3D SCANNING AND PRINTING
Exploring additive manufacturing and 3D digitization techniques
Group Assignments
The main objective of this week is to be able to recognize the codes in the basic operation that will be carried out. What is the heat-based layer adhesion process? The machines will be used to print in 3D and we will use a PLA type filament.
3D Printing Fundamentals
3D printing operates on the fundamental principle of transforming a digital model into a tangible three-dimensional object by progressively depositing material layer by layer.
This method of manufacturing differs significantly from traditional subtractive techniques such as CNC machining or formative methods like injection molding.
In contrast to these methods, 3D printing does not require additional tools for cutting or shaping. Instead, the piece is built directly onto a platform, gradually constructed layer by layer. This characteristic grants us the ability to produce intricately complex parts efficiently and flexibly.
Printing Process
In order to 3D print a part, it's crucial to first design the 3D model using CAD software. After that, the file is uploaded to the printer software, which slices the model into thin two-dimensional layers. These layers are then converted into a set of machine-readable instructions (G-code) for the printer to execute. This process ensures the accurate reproduction of the model in physical form.
Technical Specifications
Ender 3 S1 Pro Printer
| Parameter | Specification |
|---|---|
| Build Volume | 220 × 220 × 270 mm |
| Printing Technology | Fused Deposition Modeling (FDM) |
| Layer Resolution | 0.05 - 0.4 mm |
| Nozzle Diameter | 0.4 mm (standard) |
| Max Nozzle Temperature | 300°C |
| Max Bed Temperature | 110°C |
| Print Speed | Up to 150 mm/s |
| Supported Materials | PLA, ABS, PETG, TPU, PA, Wood |
Materials Comparison
| Material | Properties |
|---|---|
| PLA | Biodegradable, easy to print, low warping |
| ABS | Durable, heat resistant, requires heated bed |
| PETG | Strong, flexible, chemical resistant |
| TPU | Flexible, rubber-like, impact absorption |
3D Scanning Process
Scanning Setup
Proper configuration of the Einscan-SE scanner with optimal lighting conditions
Scanning in Progress
Capturing multiple angles for complete object reconstruction
Point Cloud Data
Initial scan results showing captured points from the object surface
Mesh Reconstruction
Processed scan data converted into a 3D mesh model
Final Model
Completed 3D model ready for export and printing
Design Process
I started to think what would be the most useful for me, I remembered that I have nowhere to put my caps so I decided to make an aerial cap holder.
Step-by-Step Creation
- Opened CATIA V5 and created a new part design
- Selected the YX plane to begin the sketch
- Created a square with dimensional constraints
- Extruded the sketch with a 1cm pad operation
- Added smaller squares for the support structure
- Applied chamfers and fillets for better aesthetics
- Exported the final design as STL file
Printing Parameters
| Parameter | Value |
|---|---|
| Layer Height | 0.2mm |
| Infill Density | 20% |
| Print Speed | 60mm/s |
| Support Type | Tree Supports |
| Material | PLA |
| Nozzle Temperature | 200°C |
| Bed Temperature | 60°C |
3D Printing Technologies Deep Dive
Understanding the different additive manufacturing technologies and their applications in modern fabrication processes.
Scanning Setup
Proper configuration of the Einscan-SE scanner with optimal lighting conditions
Scanning in Progress
Capturing multiple angles for complete object reconstruction
Point Cloud Data
Initial scan results showing captured points from the object surface
Mesh Reconstruction
Processed scan data converted into a 3D mesh model
Final Model
Completed 3D model ready for export and printing
Fused Deposition Modeling (FDM)
The most common and affordable 3D printing technology that works by extruding thermoplastic filaments through a heated nozzle.
- Materials: PLA, ABS, PETG, TPU
- Accuracy: ±0.5% (lower limit ±0.5 mm)
- Best for: Prototyping, functional parts, education
Stereolithography (SLA)
Uses a laser to cure liquid resin into hardened plastic in a layer-by-layer fashion, offering high precision.
- Materials: Photopolymer resins
- Accuracy: ±0.5% (lower limit ±0.15 mm)
- Best for: Detailed prototypes, jewelry, dental
Selective Laser Sintering (SLS)
Uses a laser to sinter powdered material, binding it together to create a solid structure without supports.
- Materials: Nylon, TPU, metal powders
- Accuracy: ±0.3% (lower limit ±0.3 mm)
- Best for: Functional prototypes, complex geometries
Digital Light Processing (DLP)
Similar to SLA but uses a digital light projector screen to flash a single image of each layer all at once.
- Materials: Photopolymer resins
- Accuracy: ±0.1% (lower limit ±0.05 mm)
- Best for: High-detail models, rapid production
Multi Jet Fusion (MJF)
Spreads a thin layer of powder and then applies a fusing agent with inkjet nozzles, followed by heating.
- Materials: Nylon, elastomers
- Accuracy: ±0.2% (lower limit ±0.2 mm)
- Best for: Functional end-use parts
Binder Jetting
Deposits a binding agent onto thin layers of powdered material to build parts layer by layer.
- Materials: Sandstone, metal, ceramics
- Accuracy: ±0.2 mm
- Best for: Full-color models, metal parts
Technology Comparison
| Technology | Resolution | Speed | Cost |
|---|---|---|---|
| FDM | 100-400 microns | Medium | Low |
| SLA | 25-100 microns | Slow | Medium |
| SLS | 80-120 microns | Fast | High |
| DLP | 35-100 microns | Fast | Medium |
| MJF | 80 microns | Very Fast | High |
Material Properties
| Material | Tensile Strength | Flexural Modulus | Heat Deflection |
|---|---|---|---|
| PLA | 50-70 MPa | 3.5 GPa | 50-60°C |
| ABS | 30-50 MPa | 2.1-2.8 GPa | 90-110°C |
| PETG | 50-55 MPa | 2.1 GPa | 70-80°C |
| Nylon | 45-90 MPa | 1.4-3.5 GPa | 120-150°C |
| Resin | 30-60 MPa | 1.5-3.0 GPa | 50-80°C |
3D Scanning Process
Scanning Setup
Proper configuration of the Einscan-SE scanner with optimal lighting conditions
Scanning in Progress
Capturing multiple angles for complete object reconstruction
Point Cloud Data
Initial scan results showing captured points from the object surface
Mesh Reconstruction
Processed scan data converted into a 3D mesh model
Final Model
Completed 3D model ready for export and printing
Scanning Methodology
3D scanning is the process of analyzing a real-world object or environment to collect data on its shape and possibly its appearance. The collected data can then be used to construct digital 3D models.
For this project, I used the Einscan-SE structured light 3D scanner, which projects a pattern of light onto the object and uses cameras to record the deformation of this pattern. This method is particularly effective for capturing fine details and complex geometries.
Scanning Workflow
- Prepare the object (cleaning and optional matte spray)
- Calibrate the scanner for optimal accuracy
- Perform multiple scans from different angles (36 in total)
- Align and merge scans in EXScan software
- Apply global optimization to reduce errors
- Create a watertight mesh model
- Reduce polygon count for 3D printing
- Export as STL for printing
Scanning Parameters
| Parameter | Value |
|---|---|
| Scanner Type | Structured Light (Einscan-SE) |
| Resolution | 0.1mm (high detail mode) |
| Accuracy | ±0.05mm (with proper calibration) |
| Scanning Speed | 10 frames/second (8Hz in high accuracy mode) |
| Scanning Distance | Optimal range: 300-700mm (varies with lens) |
| Light Source | White LED structured light (460nm wavelength) |
| Camera Resolution | Dual 1.3MP industrial cameras |
| Software | EXScan S_V3.1.0.1 with automatic alignment |
| Output Formats | STL, OBJ, PLY, ASC, 3MF |
| Scanning Modes | Fixed scan, handheld scan, turntable scan |