This is week #5 of Fablab Academy and this week is about 3D scanning and printing totally different from last week. During the assignments of this week I'm using a 3D printer, solidowrks and several new assignments. So lets start with this week journey. As I did last week, I will
start by sharing some important information about the machine were using.
This week assignmets are:
Test design rules for the 3D printer.
Design and 3D print an object (small, few cm3, limited by printer time) that could not be made subtractively
3D scan an object (and optionally print it)
Equipment, material and software I will be using:
3D printer
PLA filament
3D scanner
Solidworks
PrusaSlicer (for 3D printer)
ExScan Pro (for 3d scanner)
3D printer
What is a 3D printer?
3D printers use CAD to create 3D objects from a variety of materials, like molten plastic or powders. 3D printers can come in a variety of shapes and sizes ranging from equipment that can fit on a
desk to large construction models used in the making of 3D-printed houses. There are three main types of 3D printers and each uses a slightly different method.
Is a process of making three dimensional objects from a digital file. The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying
down successive layers of material until the object is created. Is a process in which a digital model is turned into a tangible, solid, three-dimensional object,
usually by laying down many successive, thin layers of a material. 3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a block of material with for instance a
milling machine.
Polylactic acid, PLA, is a thermoplastic monomer derived from renewable, organic sources such as corn starch or sugar cane. Using biomass resources makes PLA production different from most plastics, which are produced
using fossil fuels through the distillation and polymerization of petroleum. Is a type of polyester made from fermented plant starch from corn, cassava, maize, sugarcane or sugar beet pulp. The sugar
in these renewable materials are fermented and turned into lactic acid, when is then made into polylactic acid. The material properties makes it suitable for the manufacture of plastic film, bottles and biodegradable
medical devices, like screws, pins, plates and rods. These are some properties:
A 3D scanner generates 3D scans. A scanner works like a video camera, meaning it takes shots of an object. A camera, however, makes two-dimensional
stills, while the scanner captures the geometry of the object’s surface, and the shots it has made are worked into a 3D model rather than a video. Is
a process of analyzing an object from the real world, to collect all the data in order to recreate its shape and appearance, digitally.
How does it works?
Laser 3D scanning is certainly the most common and used 3D scanning technique. Digitally capturing the shape of the object using laser light to get a
digital representation of the real object. 3D scanners are able to measure really fine details and capture free-form shapes to generate highly accurate
point clouds. This laser scanning technique is perfect for measurement and inspection of complex geometries. It allows getting measurements and data
from where it is impractical with traditional methods! A scanner using laser light is a little bit like a camera: it can only capture what is in its
field of view.
As I did last week, it's important to have a practice time. here are the results of this time. This results will help me know how well the printer works. All the files im using I download it from the Fab Academy site.
Before I start the 3D-printing of the space shuttle, I will print some parts that will help me know about the capabilities of the 3D-printer. So lets begin:
Design rules for my printer: What will I use?
Printer Prusa MK3s+
Nozzle - 0.4mm
Flash memory card
PLA of 1.72 mm for my printing material.
Results:
1.1. Overhang:
This is my first 3D print, as you can see the top part did look good.
This happens because the printer didn't have a support material to print that part.
When this happens it means that we have to add a support, the printer has this option.
The printer took 17 / 22 minutes to print the parts.
In the images you can see both results.
1.2. Angle:
The second printing went much better.
You can see that there was no support need it for most of the printing.
The results shows that at angles 0° - 20° angle needs support material for better results.
This part took 1 hour and 13 minutes.
1.3. Overhang:
Third printing test had some details.
For this print there was no support material.
In this printing, I would determine that from structure 2 through 10 there is the need for support material.
This took 47 minutes to print.
1.4. Bridging:
Fourth printing test looks very good.
For this print there was no support material.
This is a good example when the print has support material, much better quality.
This took 1 hour and 17 minutes to print.
1.5. Thickness:
Forth printing test looks very nice.
In this printing test there is no need for support material and thickness looks very detail.
You can see a little material between slide 7 through 11 (left to right).
It took 35 minutes to print.
1.6. Dimensions:
Sixth printing test looks very good.
In this printing we are considering size.
There's no extra material as in the thickness test.
You can see the dimensions of exterior ant interior rectangle.
It took 27 minutes to print.
1.7. Anisotropy:
Sixth printing test looks very good.
In this test I printed a very simple part.
There's no need to add support material.
There's no extra material in the walls.
This was the fastest printing test, just 8 minutes.
1.8. Surface finish:
Seventh printing test, I like this one the best but theres some details.
If look at the walls aren't smooth.
The dome looks good, no extra material as well as the gap.
The time to print was 36 minutes.
More results from a few more test:
I tested the surface of the printed part.
You can see in the image the result of 4 different infill test:
Upper left - 0.15
down left - 0.05
Upper right - 0.3
down right - 0.1
As I increase the thickness the walls are smoother.
The one that has 0.1 (upper left) looks brighter.
The 4 printed parts printed correctly.
1.9. Infill:
Eigth and last printing test, this result looks very good.
unlike the past result walls are smooth.
In the front part the result has no extra material.
The back part of the part has a little extra material, but it can be easily remove.
More results from a few more test:
Now, in this one I tested the infill and see the printer results at certain point.
You can see the the filling it does inside the printed part.
In the images you'll see a printed number indicating the infill.
You can see the amount of material the printer uses in each part.
0 infill material:
15 infill material:
50 infill material:
100 infill material:
It's nicely printed.
It's nicely printed
Support material doesn't fill all the printed part, theres some spaces with no material.
Support material fills all the printed part, spaces with no material aren't visible.
The walls feel strong, not as the other parts
The walls feel stronger than the 0 one
It definetely much resistant than the other 2 and the walls feel stronger
This fells the strongest of the 4 printer parts
It looks detailed
It looks detailed
It looks detailed
The number looks detail
Walls look and feel smooth
Walls look and feel smooth
Walls look and are smooth
Walls are smooth
Individual assignments:
1. Designing in Solidworks
For my first assignment I begin with a design in Solidworks. I decided to design a space shuttle. This are the steps of my design.
First part of the design:
I started with one of the rockets.
Define some dimensions and revolve.
Design 1 ring, replicate it 5 times using linear pattern and setting a distance between rings.
Now I mirror the rocket and the supports. With this i'll have two rockets join by the supports.
Second part of the design:
Now I begin with the cabin and for this part I:
Draw half of the cabin, define dimensions and mirror the results.
Once I mirror, I revolve the cabin 360°.
After mirroring I clic on Insert, Operations and then Dome
I define the dimensions for the dome.
Third part of the design:
In this part I started to desgin the space shuttle cabin.
Define some dimensions and revolve.
Desing some parts like the supports, created some planes, the wings, propellants and windows.
In this process I use some commands like revolved, revolved cut, extrude, mirror, circular edges, lofted boss, linnear pattern and fillet
2. Setting the 3D printer
Before printing I have to setup the printer so it can work properly.
I define the printer configuration to 0.20 mm Speed.
Set the type of filament that we are going to use, in this case PLA.
Set the type of printer: Prusa i3 MK3S & MKS3+.
Now it's ready to print.
3. G-code 3D printer
Before I begin with the practice time and document the results I learn how to prepare the file so it can be read by the 3D printer. The files extension files for the printers and the Prusa software are .stl.
But this isn't enough, as well as the CNC router from last week, I have to generate the G code and this is how:
First you must open Prusa software.
Upload the .stl file.
Click on slicing now.
Finally export G-code.
The file generate is the one were using in the 3D printer.
The result shows if theres the need for support material.
How to add support material:
After clicking on the slicing button, Prusa software shows an alert that theres the need for support material.
Click on editor view.
Then click on paint supports.
I chose Smart Fill as the support type.
Select the blue parts, where I want the supports to be included.
Then on the support options, at the right side of the screen, select the type of support need it.
In my case I chose only for forcing supports, third option.
Then clic on slicing again.
This is going to show a preview of the support material and the time it will take to print.
Finally generate the G-code.
An important thing to know is that the support material is thinner which make it easy to remove.
4. Printing my space shuttle
So, after practicing, making some test, generating G-code i'm going to begin printing my desing. I hope everything goes well
Lets begin by practing the steps:
Make your design.
Save it as a .STL file
Use PrusaSlicer to generate the G-code
Save the file and make sure to verify if there is the need to add support material. In my case I need it.
First result:
A completely mess.
It wasn't enough support material.
I think it moved.
Second result:
It wasn't a mess but this time a part of the space shuttle move.
I think I need more support material.
I'm trying to put more support material.
Third result:
It was looking very good but.................
This is the time to laugh (being sarcastic)
At least this time it didn't move.
Fourth and fifth:
Im trying a few things:
First making the central part that got ruin a little bit it thicker.
Printing a another version but from a diferent position.
By printing it in another angle I have to consider support material.
The black one is a little bit smaller.
This are the results......FINALLY!!!!!
5. Scanning
This is my last assignment for the week. It has been a lot of work:
So before I start scanning, I have to install the ExScan Pro software so I can use de scannning machine I describe at the beggining. Once I scan my figure, I have to printed.
Lets start:
First thing is to install the ExScan Pro software. I didn't download it, I use the USB that the scanner brings.
I install the ExScan Pro and connect the scanner to the computer.
Once its connect I have to calibrate it. ExScan Pro guides you on what to do.
FYI: This is the figure i'm scanning, it's a Pokemon: Charizard.
Considerations before scanning:
It´s better to scan in a place that has low lighting.
Set your figure in a flat base. I used a black office chair. It help a lot because I can rotate it.
Try to keep the scanner in an angle it can scan as much as posible.
The figure should be set in different angles for a better scan.
Something that help me a lot was conecting the computer to a bigger screen while scanning.
Once you scan the figure, you can pause the scan ansd set the figure in another angle.
Scanning time:
It took me about 2 hours, just to scan.
I started scanning Charizard and watching the progress in the screen.
I took several pauses and change Charizard angle.
Sometimes ExScan Pro indicated me I was to far so I need it to get closer to the figure.
If necessary scan several times the same angle of the figure.
After scanning, it's time to print. I hope a no mess moment!
I have to save the file as a .STL file and use PrusaSlicer to make sure the printing doesn't need support material.
But Charizard need it, I use smart fill and PrusaSlicer just add it supoorting material.
Had to change the scale to 24%, the printing time that showed was 1 hour 44 minutes.
In the video you can see the final printing with the support material.
In this part I got to be carefull and remove the support material with tweezers.
Final part
Files
In this part you can download the files that I use for this 5th week assignments.
