5. 3D Printing and Scanning

Group assignment for week 5: - Test the design rules for your 3D Printer(s).

1.Design Rule test with PRUSA MK3S 3D Printer

This printer is available in our lab. This printer was released in 2017.It is one of the most popular medium sized 3D printer on the market. It is well known for their ease of use, good print quality, and enornous community support.

Technical Specification for PRUSA MK3S 3D printer

- Build Volume : 250mm(l) X 210mm(w) X 210mm(h)
- printer size : 520mmX540mmX480mm(lxwxh)
- weight 7kg
- Display: Monochrome LCD
- Drive type : FDM Direct(all metal)
- Fiament capacity: PLA,ABS,PETG,Nylon
- connectivity: SD card
- Drivers: TMC2130
- Build surface: Sprint steel PEI sheet
- Heating bed : YES
- nozzle diameter : 0.4m
- Maximum movement speed: 200mm/Sec.
- number of extruders: 1
- filament diameter : 1.75mm
- supported file types: STL, OBJ, M3F

For more details, go to our reference link here

Procedures for Design rule test using PRUSA MK3S

To test Design rule using PRUSA MK3S 3D Printer, we have choosed to download the ready made STL file from Thingiverse, one of the popular free design library site.The file choosen was All in one 3D print test from its link here.

download source

This test includee support test, scale test, overhang test, hole test, diameter test and bridging test.And we have used PrusaSlicer-2.9.0 version for slicing.

Firstly, we have opened our downloaded STL file into PrusaSlicer.

Under Plater, did the following settings, with no supports and Infill as 15%.

Then, we clicked on Slice now and followed by clicked to Export G-code.And saved it and tranfer to SD card as the printer supports SD card and took to the printer.

Parts of PRUSA MK3S

*image source link from here

We have inserted SD card to its slot and from Home screen go to Select from SD card and choosed file and gave print command.

Test output and Conclusion with PRUSA MK3S

Nozzle Size Impact on Text Quality:

The text printed on the test piece was not much clear, especially for smaller words as the PRUSA MK3S printer has nozzle diametr of 0.4mm. For finer details, such as small text, a smaller nozzle size ( 0.2 mm or 0.25 mm) would likely yield better results.

Bridging importTest:

Bridging performance was solid, with clean results up to 20 mm. This suggests that the printer handles bridging well within this range, though longer spans may require tuning or supports.

Hole Test and Diameter Test:

The printer was able to accurately print holes of any depth,which determines its consistency in vertical dimensions. However, for smaller diameters, the results were less precise, requiring adjustments to settings (like flow rate, speed, or cooling) or the use of a smaller nozzle for better accuracy.

Overhang Test:

The printer demonstrated strong overhang performance, successfully printing without supports up to a 50-degree angle. This indicates good cooling and extrusion control for overhangs. However, it requires the support from 60 degree.

2.Design Rule test with Bambu Lab X1 Series

The Bambu Lab X1 Carbon is a high-performance 3D printer designed for both professional and advanced hobbyist use. It is part of Bambu Lab's lineup of innovative 3D printers, known for their speed, precision, and advanced features. The "Carbon" in its name refers to the carbon fiber-reinforced components used in its construction, which enhance durability and rigidity while keeping the printer lightweight.

Technical parameters (specifications)

- Build Volume: 256 × 256 × 256 mm (10.1 × 10.1 × 10.1 inches)
- Nozzle Diameter: 0.4 mm (standard), swappable nozzles available.
- Extruder Type: Direct Drive Extruder (high torque, geared design).
- Build Plate Material: Double-sided textured PEI plate (flexible and removable).
- Build Plate Temperature: Up to 120°C (248°F).
- Bed Leveling: Automatic bed leveling using LiDAR technology.
- Material Compatibility: PLA, ABS, PETG, TPU, PA, PC, and more.
- Slicing Software: Bambu Studio (based on PrusaSlicer, optimized for Bambu Lab printers).
- Wi-Fi: Yes (supports remote printing and monitoring).
- Layer Height: 0.05 mm to 0.3 mm (adjustable in slicing software).
- Maximum Print Speed: Up to 500 mm/s (depending on material and settings).

Procedures for Design rules Test with Bambu Lab X-1 printer

Opened bambu studio (which prepare models automatically in minutes, upload them to printer to build model) and go to file > open > design test model.

Result and conclusion for Bambu Lab X-1 Carbon Printer

Nozzle Size Impact on Text Quality:

Since the Bambu printer used a 0.4 mm nozzle diameter, the text was not printed with optimal clarity. For finer details, such as small text, a smaller nozzle size (e.g., 0.2 mm or 0.25 mm) would likely yield better results.

Overhang Performance:

The printer demonstrated strong overhang performance, successfully printing without supports up to a 75-degree angle. This indicates good cooling and extrusion control for overhangs.

Bridging Capability:

Bridging performance was solid, with clean results up to 5 mm. This suggests that the printer handles bridging well within this range, though longer spans may require tuning or supports.

Hole Depth and Diameter:

The printer was able to accurately print holes of any depth, showcasing its consistency in vertical dimensions. However, for smaller diameters, the results were less precise. Larger diameters printed well, but smaller holes may require adjustments to settings (e.g., flow rate, speed, or cooling) or the use of a smaller nozzle for better accuracy.

Formlabs

For this week for the group assignment, we were assigned to explore as many 3D printers as we can and especially which are available in the lab so for that purpose, we tried exploring on Formlabs.

Formlabs is a company that specializes in high-quality resin-based 3D printers and materials. They are best known for their SLA (Stereolithography) and SLS (Selective Laser Sintering) 3D printers, which are widely used in industries like engineering, dentistry, jewelry, and manufacturing.

General Specifications:

• 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

Since for the group this week, we did design test rule using bambu printers and Prusa Mk3S printers and for FormLabs, we just explored and printed one simple model.

Steps to follow while the operating FormLabs

1. Prepare the Model: Design in 3D software, export as .STL/.OBJ, and use PreForm to import, position, and adjust settings (resin type, orientation, supports) before saving as a .form file.

2. Prepare the Printer: Power on, connect to the network, install the resin tank and cartridge, and ensure the printer is clean.

3. Start the Print: Load the .form file into the printer, initiate printing, and monitor progress.

4. Post-Processing: After printing, remove the model, clean it in isopropyl alcohol, and cure it in a UV station.

5. Final Checks: Inspect the print, and clean the build platform and resin tank for future prints.

Disclaimer: The content above has been abstracted from ChatGPT for the reference purpose

*PreForm is the 3D printing software that prepares your models for printing on Formlabs 3D printers in just a few minutes.

Steps to follow while using Preform

• First download the Preform

• After downloading, open the preform software and import your design.

• Orient the model and generate supports.

• Select the printer and resin colour and click on apply.

• Model reprocessing will start to take place and printer will start printing the model.

• After printing gets completed our model will be formed and will be attached on build platform and then we should remove it and post process.

Post process: It is the process of removing supports and excess liquid resin from the model after printing gets completed. So for removing excess liquid resin we wash the model in IsoPropyl Alcohol (IPA) using form wash station.

• We removed the model and dipped inside the form wash station for the initial post process.

• We did final rinsing of our model by setting the time limit in form wash and then placed the model inside the formlab form cure unit. Formlab form cure unit uses uv light and controlled heat to complete the curing process and then we can remove our model.

Thank you have a nice day!