5. 3D Scanning and Printing

Hero Shot

Task for the week04
Group Assignment:

• Test the design rules for your 3D printer(s)
• Document your work on the group work page and reflect on your individual page what you learned about characteristics of your printer(s)

Individual Assignment:

• Design and 3D print an object (small, limited by printer time) that could not be easily made subtractively
• 3D scan an object (and optionally print it)

Link to group assignment is here

Note: Some Key takeaways from group assignment
- for prusa support is required after 60 degree where as Bmabu prints well without support till 75 degree.
- Prusa can print small text details however bambu cannot print the small text details.
- Both Bambu and prusa can print the hole of any diameter.

Individual Assignment

3D Scanning

3d scanning is the process of capturing shapes and texture of the physical object to create a 3d model. We have Arteac Eva in our lab, however the scanner is malfunctioning so I am using my phone scanner as susggested by our instructors. Followings are the two scanners that was suggested by our instructor, however I am going to use Kiri engine

1. Kiri Engine
2. Scaniverse

Kiri Engine

Kiri Engine is 3d scanning app that allows the user to do the high quality scanning without having to go the expensive hardware. This app is available both for ios and android.

Before gettig started with scanner make sure the environment is consitent with lighting to ensure the light quality scan. Also make sure that the object you are scanning is clean free of any obstructions.

Workflow

Download the Kiri engine and sign up with your email account.

Open the app on your device. As soon as you open your app, it will appear as shown in the first image below. Click on the + icon, and then Click on photo scan as shown in second image.

After clicking on the photo scan, an option will display for scanning. there is three options to do the 3d scan:
1. Photo scaning
2. video recording
3. photo from local.

I used the first option to do the 3d scan.

Slowly move around the object or scene you want to scan. The app will guide you to capture images from multiple angles. Ensure you cover all sides of the object for a complete 3D model.Once you’ve captured all the necessary images, the app will upload them to the cloud for processing. This step may take some time depending on the complexity of the scan and your internet connection.

It will notifies once the upload is successful. Click ok to proceed and it starts automatically. It takes few minutes for processing which can be seen as Queuing. Once it is done is is narked as Succeeded.

After processing, you can review the 3D model within the app. Check for any missing details or imperfections.Next I m using the crop tool to remove the unwanted portion.

Once you’re satisfied with the model, you can export it in various formats (e.g., OBJ, STL) compatible with 3D printing, AR/VR applications, or other 3D modeling software. When you click on export

After clicking on export, it will notifies as the 3d model will be sent to user email. After few minutes you can checked your email.

You can download the file and it will get downloaded in zip files.You can extract the file and the file is ready to print :rocket:

Tips for the best results

• Stability: Keep your device as stable as possible during scanning to avoid blurry images.
• Overlap: Ensure there is sufficient overlap between images to help the software accurately stitch them together.
• Patience: Take your time during the scanning process to capture all necessary details.

3D Printing

3D Pritning is the process of creating three dimensional object by adding layers of materials. It is also called additive manufacturing.

The types of 3d printing:

1. Fused Deposition Modeling (FDM) – A filament is melted and layered to build the object.
   Examples: Ender, Prusa

2. Stereolithography (SLA) – Liquid resin is hardened with a UV laser to form the object.
   Examples: Formlab, StratysysJ55

3. Polyjet- PolyJet 3D printers utilizes photopolymer materials cured by UV light to build objects layer by layer.

Examples: StratysysJ55,Stratasys J850™ Prime

1. Powder Bed Fusion (3DP) – Powder is fused using a binder or laser to create the object.

Additive Vs Subtractive Manufacturing

Key Differences Between Additive and Subtractive Manufacturing

Aspect	Additive Manufacturing	Subtractive Manufacturing
Process	Adds material layer by layer.	Removes material from a solid block.
Material Usage	Minimal waste (uses only what’s needed).	Generates waste (material is removed).
Complexity	Excels at complex, intricate designs.	Limited by tool access and geometry.
Speed	Slower for large objects.	Faster for simple, high-volume parts.
Cost	Cost-effective for prototyping and small runs.	Cost-effective for mass production.
Materials	Limited to compatible materials (e.g., plastics, resins, some metals).	Works with a wide range of materials.

Advantages of additive manufacturing - Enables the creation of complex geometries and intricate designs that are difficult or impossible to achieve with traditional manufacturing methods.
- Speeds up the product development cycle by allowing quick iteration and testing of designs.
- Supports the use of recycled materials in some cases.
- Eliminates the need for expensive molds, dies, or tooling, especially for low-volume production.

Disadvantages of Additive manufacturing - The materials are costly
- Its is generally slower than the traditional mass production.
- May result in rougher surfaces requiring post-processing. - The build volume of most 3D printers limits the size of parts that can be produced in a single print.

Types of FDM filament

• PLA: is the most commonly used material
• ABS: we no longer use it, there are other materials that are easier to print
• Nylon: is difficult to print, but offers high flexibility
• PETG: is often made from recycled plastic bottles
• TPU: is a flexible material
• HIPS and PETG: are food-safe materials

Types of 3D printer in our lab

We have 5 different types of 3d printer in our lab.

1. Stratysys JSS
2. Formlab 3
3. Bambu X1 carbon
4. Bambu A1
5. Prusa ikm3

Most busy 3D printer in JNWSFL are:

• Bambu X1 Carbon and Bambu A1
• Prusa ikmk3

Advantages of BambuA1 over Prusa ikMk3

Feature	Bambu Lab A1	Prusa (e.g., MK4)
Speed	Up to 500 mm/s	~100-200 mm/s
Multi-Color Printing	AMS Lite (4 colors, easy to use)	MMU (less reliable, more complex)
Ease of Use	Auto-calibration, touchscreen	Manual calibration required
Cloud Connectivity	Built-in cloud printing & monitoring	Requires additional setup
Design	Core XY, enclosed	Cartesian, open-frame
Price	More affordable	Higher cost
Innovation	LiDAR, AI monitoring, vibration comp	Reliable but fewer advanced features

Advantages of Prusa Printers over Bambu A1

Advantage	Prusa Printers	Bambu Lab A1
Open-Source Ecosystem	Fully open-source hardware & software	Proprietary system, limited customization
Proven Reliability	Long track record of dependable performance	Newer brand, less long-term testing
Material Compatibility	Supports exotic & specialized filaments	Limited by proprietary nozzles/firmware
Upgradeable & Repairable	Modular design, easy upgrades & repairs	Limited upgrade options, harder to repair
Community & Support	Large active community, long-term updates	Smaller community, unproven long-term support
Transparency	Open documentation, transparent about tech	Proprietary, less transparency
Sustainability	Focus on eco-friendly practices & recycling	Less emphasis on sustainability

Designing 3D object

Since I am newbie to blender and started exploring the blender from the CAD week. This week I wanted to use blender for my 3d design, because this will help me explore its different features. I made vase using a Blender. I refer this turorial to design a vase.

Design 1

Open a new file and remove the default cube with key x. Press SHFT+A and from mesh select vert. I started by creating a mesh using a single vert.Add> Mesh> single vert > add vert

I changed the view to x by using numpad 1. I went by extruding by single vertex using key E. Press key E and drag along the Y axis.Got the shapes as shown in the image below.

Enter tab, when you are done with the editing it will take you to the Object mode. In the Modifier (blur wrench tool) I am going to add the screw. The vsae will be formed as shown in the second image.Turn Off the smooth shading and click on flip. Also add the Sub division modifier and increase the level.
Next fill the top, In edit mode > click the vertex on top and click merge on screw modifier.Grab the top vertex and extrude it to Yaxis.
Tab out edit mode> object mode > select new modifier and select wire frame and subdivison. You can play with the wireframe thickness and subdivision level and render and click apply*.
Then I add the sphere to my vase so the ball will moves around in the vase. For that I add the sphere by shift + A> choose the sphere. I drag the sphere by pressing key g and put inside my vase. Next I went by rendering the object and this is how my object looks.
I export my file and kept it ready for the 3d printing. I did the printing however I was not able to remove the support. I also tired printing without using support, the print was all failure, so I did another new design.

Design 2

I refer this tutorial to design the wireframe torus.

Open the blender and delete the default cube. PressShift+A and from a mesh select math function xyz as shown in the image below.

Now click on the xyz function which is at the left botton of the working space. Select the twisted torus and as you click on the twised torus the shape will change it shapes. I export the this ans wanted to print and look how it comes. I exported the file in stl and kept it ready for the print.

Adding a wireframe In edit mode I changed the value of U wrap and V wrap.This will allow to apply the texture and also controls how the texture repeats or stretches along the U (horizontal) axis and V (vertical axis). As I change the value it change its shape.

Tap out the edit mode and hit tap to go in object mode ,Select the bevel by going to the Modifier Properties tab (the blue wrench icon) in the right Properties panel,and adjust the setting and click apply.

Now Hit tap to go in edit mode, select the face and press key alt+shift and select the face of the torus and click on select and choose checker deselect set the value of deselect to 2 and hit key x and deleted the faces.

Repeat the same step till you get the shape as shown in the picture below.

In modifier select wireframe ans adjust the thickness. Again in modifier select surface sub division and adjust the level value and render and click apply.

Now my design is ready to print and I export the file in stl.

Design 3 Impromtpu torous

Open the blender. Delete the default cube and Press SHFT+a and from Mesh select a Cylinder.

Select the cylinder, hit tab to go into edit mode, make sure you are in vertex select and select the middle 6 vertices (multi-select with SHFT). With all 6 selected press J to create two new edges between them.Repeat the same step for the bottom.

Switch from vertex select to face select in the top-left of the window and select the faces in the ring around the cylinder.Right-click on the selected faces, and choose Delete Faces. This will create hole in the center.

Switch to edge select.While holding ⌥ select one of the edges next to the hole, this will select the entire loop around the hole. Press F to add a face.Repeat on the other side. Since we are going to spin the cylinder, now we need to remove bottom and top faces.Like before, go into face select and select the two top and two bottom slices that remain of the circle. Right-click and select Delete Faces. This will leave you with two tube like shapes.

Next, we need to add more facets along the height of the cylinder using a loop cut. Press CTRL+R to start the loop cut. As you move your mouse over the cylinder, Blender will show possible loops. When you see the horizontal loop, click to select it, then click again without moving the mouse to center it. In the Loop Cut and Slide window, set the Number of loop Cuts and ensure the Factor is set to 0. Repeat this process on the other side of the cylinder.

Twist and bend

Select the Simple Deform modifier by going to the Modifier Properties tab (the blue wrench icon) in the right Properties panel, adding a Simple Deform modifier. set the values as shwon in the image below.

Again add the simple deform modifier and set the values as shown in the image below.

Deselect the cylinder SHIFT+A to add an Empty -> Plain Axes, press G+Y to move it 1 unit to the left, then select the cylinder again and in the Modifiers tab, choose the new Empty as the Origin.

Next I add the tissue to add the heagonal grid on the top.I downloaded the tissue ad tool and installed it as shown in the image below.

I tired to add the polyhdreal wireframe however it gives the error shown in the image below.I simply added smooth edges by right-clicking. I’m keeping this as an impromptu design and want to see how it turns out.”

Next I render the object and ctrl s to save my design.Then I exported my design in stl files. The 3d design came out really nice.

Design 3

Using the blender, I also design the the rose and then printed using the bambu A1. I printed the rose without giving the support and it came out really nice.

Printing 3D object

For 3D printing I am going to use Bambu A1 and Prusa IKM3

Setting up your BambuA1

1. Power ON the printer. The power cord is at the back side of the printer.

2. Log in your account

1. Load the filament

After loading the filament. Open your bambu studio.

Printing with Bambu studio

Bambu Studio is a slicer software that converts file formats such as STL or OBJ into G-code for 3D printing. It is specifically designed for use with Bambu Lab 3D printers, offering optimized performance and advanced features tailored to these devices.

Download and install the bambustudio

Connect your Bambu printer
- USB Connection: Connect your Bambu Lab printer to your computer using a USB cable.
- Wi-Fi Connection: Ensure your printer is connected to the same Wi-Fi network as your computer. Bambu Studio supports wireless printing and monitoring.
- Cloud Connection: Log in to your Bambu Lab account in Bambu Studio to enable cloud-based features like remote printing and firmware updates.
- Use bambu handy to connect the printer using phone

Open the bambu studio software and import the file you want to do the printing or you can aslo drag and drop the file directly into your workspace.

Now you can adjust the print setting by: - Select Printer:select the printer that you are using - Select the printer plate(Texture PEI plate)
- Select Filament:select the types pf filament that you are using
- Adjust Settings: adjust the layers,Layer height, Infill density, Print speed,Support structures (you can give the types of the support) and qualit

You can also make the object lay on the face, scale up and down, and rotate the object.

Next once satisfied with the setting you can go by slicing the object.This will convert my object into g-code that my machine understands.

Next you can preview your see the layers

I clicked on print plate to the 3d printing.

As soon as you hit the send button, it

When you clicked on the device taskbar, it will show the following as shown in the image below:

3D Printing my second design
The vase printing was a failure, so I printed my torus design. I follow the same step as above to do the printin gusing Bambu A1.Fisrt I printed torus without giving support however it printed my torus in air and then I stop the print and reprinted giving tree support as shown in the image below.

Again the print was failure

I reprint again and it work

I also printed my impromtpu torus design and it printed pretty well.

Printing with Prusa ikMK3

Prusa slicer is the software that conver your 3d model into g-code. It is develop by prusa research. This software is compatible with any other 3d printers.

Download and install the prusa slicer

Turn on the printer

Load the filament and extrude it

Open the prusa slicer,import the file you want to do the printing. Since my vase printing in bambuA1 was a failure. I wan to try by printing in the prusa. After you are satisfied with the setting, slice the model to gcode. Here I kept the infill of 20% and gave support on build only.

I export my g code by selecting the esport G-code which is located at the bottom of prusa slicer.Its ready for 3d printing :rocket:

Insert the sd card into your prusa and select your file. to select your file > info>print from sdcard> select your file.

the screen will shows the status of your printing.

Failure

Since my design has many holes, I had to adjust the support settings. Initially, I tried adding supports to the build plate, but the results were not as expected. Next, I attempted using enforced supports, but that also did not work.Finally, I scaled up my design, added a brim, and used enforced supports, Again it didnt print well

3D Printing my second design
The vase printing in prusa was a failure, so I had another design (torus). I follow the same step as above for 3d printing using the prusa.I import stl file and slice it without giving any support. However the print was failure as it was noable to print from its first layer. This image was a failure

Then I reprint using the enforce support.

The print was really success :rocket:

I also printed my wireframe torus using prusa. Here I just gave the brim and printed without support. I export my g-code file and save it.

The printing came out nice however there is some string or hairy in the 3d print, this was caused due to the old filament.

Files

Download the 3D printing ZIP packages:
1. rose
2. torus
3. torus gcode
4. torus wireframe

Discalaimer:I have copied the differences between additive and subtractive manufacturing, pros and cons of additive manufacturing as well as the advantages of Prusa over Bambu, based on my understanding after researching on DeepSeek.