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3D Printer Design Rule Testing - My Take!

Introduction

So, for our group assignment, we decided to put our Bambu Lab X1 Carbon through its paces to see what it can really do. The goal was to figure out its strengths and weaknesses regarding overhangs, holes, bridging, and how accurate it is with dimensions. This whole thing is about getting a better handle on what 3D printing can and can’t do, which is pretty crucial for the Fab Academy. We also printed a “clockspring3D” model to further explore the printer’s capabilities with more complex geometries.

The Gear We Used

  • Printer: The trusty Bambu Lab X1 Carbon
  • Filament: Just some generic PLA in grey (nothing fancy!)
  • Slicer Settings:
    • Quality: 0.20mm Standard @BBL X1C (the default setting)
    • Sparse Infill Density: 15%
    • Sparse Infill Pattern: Grid
    • Support: Nope, we wanted to see how far we could push it without supports! (For the test design. The clockspring3D model probably used supports)

The Test Designs - What We Were Trying to Break (or Not)

We used a test design that had a bunch of different features to stress-test the printer, and the clockspring3D model to see how it handles more intricate shapes and details.

  • Test Design Features:

    • Overhangs: Angled bits from 15° all the way to 80° to see when things start to droop.
    • Holes: Different sized holes (4mm, 8mm, 12mm, 16mm) to check if the printer makes circles the right size.
    • Bridges: Horizontal spans of increasing length to see how well it can print across gaps.
    • Vertical Pins: Skinny little towers to see if it can handle tiny, unsupported stuff.

  • Clockspring3D Model Features:

    • Intricate gear designs on the sides.
    • Overhanging “spring” structures.
    • Text and logos (“clockspring3D” and “HOT WOKS”).
    • Internal channels/vents.

What Happened - The Results

Okay, so here’s what we found after the prints finished:

Test Design Results

  1. Overhangs:

    The overhangs were interesting. The shallow angles (15° to 45°) looked pretty good, to be honest. But once we got past 50°, things started to get a bit messy. The 70° and 80° overhangs were a hot mess – definitely needed support there.

    Basically, if you want to print without supports, keep those overhangs under 45°.

  2. Hole Test:

    The holes seemed okay at first glance, but we’d need to measure them to be sure they’re the right size. There might be a bit of an “elephant’s foot” effect on the bottom layers, which isn’t ideal.

    We need to grab some calipers and check those diameters. If they’re off, we might need to tweak the horizontal expansion setting in the slicer.

  3. Bridging Test:

    The bridges had some sag, especially the longer ones. The top surface wasn’t super smooth either.

    To fix this, we could try slowing down the bridging speed and cranking up the cooling fan. Also, maybe try a different infill pattern for bridging.

  4. Vertical Pins:

    Some of the pins didn’t even make it – they were either missing or all bent out of shape.

    These are just too fragile without support. We’ll definitely need to use supports for anything like this in the future.

  5. Surface Finish:

    The top surface had some visible lines, which means we could probably get a smoother finish.

    Maybe playing with the printing speed, flow rate, or layer height could help. I’ve also heard good things about the “ironing” setting in the slicer.

Clockspring3D Model Results

  • Gears: The gear details seem pretty well-defined, although there might be some slight imperfections depending on the resolution.
  • Overhanging Springs: These look like they printed decently, suggesting that supports were used effectively. There might be some minor support scarring.
  • Text/Logos: The text and logos are generally legible, indicating good resolution and detail reproduction.
  • Overall Surface: The surface finish appears consistent with the test design, showing some layer lines.

Why Did It Turn Out Like This?

  • Overhangs (Test Design): No support = gravity wins. The filament sags before it cools.
  • Bridging (Test Design): Not enough cooling or printing too fast can cause bridges to droop.
  • Vertical Pins (Test Design): Too tiny and unsupported, so they warp or fall over.
  • Infill Density (Test Design): 15% is pretty low, which might make overhangs and bridges weaker.
  • Generic PLA (Both Designs): It’s not the best filament out there, so that could affect the print quality.
  • Clockspring3D Model Complexity: The intricate details and overhangs in this model require careful support placement and potentially finer resolution settings.

How We Could Make It Better

Test Design Improvements

  1. Use Supports: For anything over 45°, just use supports. Trust me.
  2. Tweak Bridging Settings: Slow down and cool it down.
  3. Up the Infill: 20-30% infill for parts that need to be strong.
  4. Calibrate: Fine-tune the temperature and flow for the filament.
  5. Measure and Adjust: Check the dimensions and adjust the horizontal expansion.
  6. Bed Adhesion: Make sure the first layer sticks well, especially for small parts.

Clockspring3D Model Improvements

  1. Optimize Support Placement: Ensure supports are placed strategically to minimize scarring and provide adequate support for overhangs.
  2. Fine-Tune Resolution: Consider using a smaller layer height for even finer details, especially for the gears and text.
  3. Post-Processing: Clean up any support remnants and consider sanding or other post-processing techniques to improve the surface finish.

What We Learned (The Important Stuff)

  • What we learned about the printer:

    • The Bambu Lab X1 Carbon can print pretty accurately.
    • Overhangs need support if they’re too steep.
    • Bridging needs some tweaking to get right.
    • Tiny, unsupported things are a pain.
    • The filament and how you set it up really matter.
    • Complex models like the clockspring3D require careful attention to support placement and resolution settings.

Advantages and Limitations of 3D Printing - The Big Picture

  • Advantages:
    • Super quick for making prototypes.
    • You can make crazy shapes.
    • Easy to customize stuff.
  • Limitations:
    • Not as many materials as regular manufacturing.
    • Dimensions can be a bit off sometimes.
    • The strength can change depending on which way you print it.
    • You might need to clean it up afterward.
    • It’s not super fast for making lots of things.
    • Complex geometries require careful planning and may need post-processing.

Conclusion

Testing the Bambu Lab X1 Carbon with both the design rule test and the clockspring3D model was a good learning experience. We now have a much better idea of what it can do and what it struggles with. Knowing this will help us design better parts and get better prints in the future. It’s all part of the Fab Academy journey!