Week 05 - 3D Scanning and Printing

3D Printing

3D printing, also known as additive manufacturing, is a revolutionary fabrication process that creates three-dimensional objects by depositing materials layer by layer. This technology has transformed various industries, from manufacturing and healthcare to architecture and education. The ability to rapidly prototype and produce complex geometries makes it an invaluable tool for designers and engineers.

Different Types of 3D printers

There are several main types of 3D printers, each suited for different applications:

1. Fused Deposition Modeling (FDM): The most common and affordable type, which works by extruding thermoplastic filaments layer by layer.
2. Stereolithography (SLA): Uses liquid resin that is cured by UV light, producing highly detailed and smooth parts.
3. Selective Laser Sintering (SLS): Employs a laser to fuse powder materials, ideal for complex functional parts.
4. Digital Light Processing (DLP): Similar to SLA but uses a digital light projector screen, offering faster print times.

DIFFERENT TYPES OF 3D PRINTERS

Printer Type	Technology Used	Materials	Advantages	Disadvantages	Applications	Examples of Manufacturers
FDM/FFF	Extrusion: Heated filament extruded through a nozzle, layered with heat as energy source.	PLA, ABS, PETG, TPU, Nylon, Polycarbonate, Composites	Low cost, easy to use, large build volumes, flexible parts	Lower resolution, weak Z-axis strength, thermoplastic only	Prototyping, hobbyist, functional parts, education	Prusa, Ultimaker, Creality, MakerBot, Stratasys
SLA	Resin-based: Laser cures liquid photopolymer resin layer by layer; laser as energy source.	Photopolymer resins (standard, tough, flexible, etc.)	High resolution, smooth finish	Messy resin, brittle parts, small build volume	Jewelry, dental, miniatures, detailed prototypes	Formlabs, Peopoly, Elegoo, Anycubic
DLP	Resin-based: UV light projector/LCD cures entire resin layers; UV light as energy source.	Photopolymer resins (similar to SLA)	Faster than SLA, high resolution, smooth finish	Messy resin, limited properties, post-processing	Dental, jewelry, miniatures, prototypes	Anycubic, Elegoo, Phrozen
SLS	Powder-based: Laser sinters powdered material; laser as energy source; unsintered powder supports.	Nylon (PA11, PA12), TPU, Polypropylene, Glass-filled	No supports, strong parts, complex geometries	Expensive, rough finish, post-processing required	Functional prototypes, end-use parts, aerospace	EOS, 3D Systems, Formlabs (Fuse 1)
MJF	Powder-based: Inkjet applies fusing/detailing agents, fused with heat; heat as energy source.	Nylon (PA11, PA12), TPU	Fast, consistent quality, strong parts	Expensive, limited materials, post-processing	Functional prototypes, end-use parts, small runs	HP
Binder Jetting	Powder-based: Inkjet deposits binding agent on powder, often sintered post-process; heat for sintering.	Metals (steel, bronze), Sand, Ceramics	Fast, lower-cost metals, full-color capable	Lower density, rough finish, post-processing needed	Sand molds, architectural models, metal parts	ExOne, Desktop Metal, voxeljet
DMLS/SLM	Powder-based: High-powered laser fuses metal powder; laser as energy source.	Stainless Steel, Titanium, Aluminum, Inconel, Co-Cr	High-strength metal parts, complex geometries	Very expensive, post-processing, small build size	Aerospace, medical implants, tooling	EOS, Renishaw, SLM Solutions, GE Additive
EBM	Powder-based: Electron beam melts metal powder in a vacuum; electron beam as energy source.	Titanium, Cobalt-Chrome, Inconel	Excellent properties, less stress than laser	Expensive, limited materials, slow, vacuum needed	Aerospace, medical implants, high-performance	Arcam (GE Additive)
PolyJet	Inkjet-like: Photopolymer droplets jetted and cured with UV light; UV light as energy source.	Photopolymers (rigid, flexible, transparent, colors)	High resolution, multi-material, multi-color	Expensive materials, brittle parts	Detailed prototypes, medical models, art	Stratasys, 3D Systems (MultiJet)

the prompt used is .

explain all different types of 3d printer types with the below details and make a table . Details to Add to Each Printer Type: Technology Used: Explain how the printer works, the type of energy used (laser, heat, etc.), and the materials it can process.

Materials: List the common materials used by each printer type (PLA, ABS, resin, nylon, metals, etc.).

Advantages: What are the key benefits of this technology? (High resolution, strong parts, multi-material, low cost, etc.)

Disadvantages: What are the limitations? (Material cost, print speed, part size, material properties, etc.)

Applications: What are the typical uses for parts made with this technology? (Prototyping, tooling, end-use parts, medical, aerospace, etc.)

Examples of Manufacturers: List companies that produce printers of this type (Stratasys, 3D Systems, Prusa, Formlabs, etc.).

Each type of 3D printer has its own advantages and limitations in terms of material compatibility, print quality, speed, and cost. The choice of printer depends heavily on the specific application requirements, budget constraints, and desired end product characteristics. Understanding these different technologies is crucial for selecting the right printer for your needs.

Safety Measures While Using a 3D Printer

Read the Manual – Familiarize yourself with the printer’s user manual and safety guidelines before operation.

Use in a Well-Ventilated Area – 3D printing, especially with ABS and resins, can release harmful fumes. Ensure proper ventilation or use an air filtration system.

Avoid Direct Contact with Heated Parts – Components like the nozzle and heated bed can reach high temperatures. Wait for them to cool before touching.

Wear Protective Gear – Use safety gloves when handling resin and safety glasses to protect against debris or splashes.

Monitor the Print Process – Never leave a 3D printer unattended for long periods to prevent fire hazards.

Keep Flammable Materials Away – Ensure the printing area is free from flammable objects like paper, plastic, and liquids.

Use the Right Filament for Your Printer – Incorrect or poor-quality filament can cause clogs, failures, or harmful emissions.

Handle Resin with Care – If using an SLA printer, wear nitrile gloves and avoid skin contact with liquid resin.

Properly Dispose of Waste – Used resin, failed prints, and support materials should be disposed of according to environmental and safety regulations.

Ensure Electrical Safety – Plug the printer into a surge protector and inspect wiring regularly for damage.

Keep Moving Parts Guarded – Avoid placing fingers or tools near moving parts like belts and extruders while the printer is operating.

Regular Maintenance – Clean and inspect the printer regularly to prevent failures and ensure safe operation.

Use an Enclosure if Needed – For printers with high-temperature materials, an enclosure can help contain fumes and improve safety.

Be Cautious with Post-Processing – Sanding, cutting, or using solvents on 3D prints should be done in a well-ventilated area with proper PPE.

Emergency Preparedness – Keep a fire extinguisher nearby and know how to cut power to the printer in case of an emergency.

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Chat GPT prompt: Safety measures taken while using a 3d printer.

DESIGN RULES FOR 3D PRINTING

These listed items below are the design rules that one should follow while 3D printing .

Supports

A support is used to prevent overhanging layers from collapsing. Source: https://www.raise3d.com/academy/when-and-how-to-use-3d-printed-support-structures/

A support is a structure printed beneath to stop overhanging layers of a design from bending and collapsing due to its own weight. The support structure is printed from the same extruder using the same process as the rest of the body, with the only difference being that the support material is printed in a different pattern to make it easy for the user to remove it without leaving marks on the main body.

There are two main types of support structures, a lattice structure which is the most common and a tree-like support which is less common and can potentially leave you with better surface finishes.

Two types of supports. Source: https://www.hubs.com/knowledge-base/supports-3d-printing-technology-overview/

Overhang

An example of an overhang. Source: https://www.cytron.io/tutorial/what-are-supports-in-3d-printing

An overhang is the portion of a layer that extends beyond the layer below it when sliced in the slicing software. It occurs when the layer is only partially supported by the layer below.

Not all overhangs require a support. As a rule of thumb, overhangs that form an angle equal to or less than 45 degrees with the vertical ‘normal’ axis generally can be printed without requiring supports.

Source: Support is only required if the overhang forms a steep angle, generally above 45 degrees. Source: https://www.raise3d.com/academy/when-and-how-to-use-3d-printed-support-structures/

Bridge

An example of a bridge. Source: https://www.cytron.io/tutorial/what-are-supports-in-3d-printing

Just like overhangs, bridges are also only partially supported by the layer underneath. The main difference is that unlike an overhang, which has layers below it only one side, a bridge has layers underneath it at both sides. Just like overhangs, not all bridges require support. A general rule of thumb is that bridges below 5 mm in length will not need supports while printing.

Support is only required if the bridge is over 5 mm in length. Source: https://www.cytron.io/tutorial/what-are-supports-in-3d-printing

Wall Thickness

The minimum thickness a 3D printer can achieve is mostly determined by how small the nozzle is. For a standard 0.4 mm nozzle, the thinnest line that can be printed is technically a 0.24 mm line, which is made possible by making some modifications in the slicing software.

Dimensional Accuracy

Dimensional accuracy refers to how accurate the physical dimensions of 3D printed part are to the designer’s specifications in the CAD file. These errors occur due to the print temperature, flow rate, shrinkage, problems in the mechanical components, etc. These errors may not be important when printing parts for artistic or aesthetic purposes but become very important when printing functional parts.

Anisotropy

Here, anisotropy means that the physical properties differ in different directions. Since a 3D printer prints in layers, the lines will be more strongly bonded to the lines in the same layer rather than the lines on the next layer on each side.

A piece lined vertically at 0 deg will break easier then a piece lined horizontally at 90 deg. Source: https://www.sciencedirect.com/science/article/abs/pii/S1359836816309052

Surface Finish

Layer lines in 3D printing. Source: https://3dinsider.com/fix-misaligned-layers-3d-printing/

When printing parts that have curved surfaces, layer lines may become visible which reduce the aesthetic quality of a print. These are mainly caused due to two main variables, the layer height, and the angle the surface of the 3D part makes with the print bed.

Thicker layer lines and steeper curves cause more layer lines in 3D prints. Source: https://www.baysingersadditivemanufacturing.com/layer-lines/

Infill

Infill refers to the inner portion of the 3D print that is not exposed to the viewer. Rarely do we use 100% infill (completely filled) or 0% infill (completely hollow) density. The higher the infill density, the more rigid the part is at the cost of printing time. The opposite is true for lower infill densities. The Based on this article by Prusa, the best solid infill density setting is between 10-20%, which achieves the best balance between structural integrity and printing time.

There are different types of infill patterns. The most common types are:

• Line - It is made of multiple parallel lines per layer, followed by parallel lines laid out perpendicularly in the next layer. It is slightly quicker to print than grid and triangular patterns.
• Gyroid - This pattern consists of alternating wavy patterns. It takes more time to print but offers more strength in return.
• Concentric - This pattern is made by tracing the model perimeter lines, making them progressively smaller as they reach the center. It is among the fastest to print and uses very less material, but does not offer a lot of strength.
• Lightning- This pattern is the fastest to print. Lightning-bolt shaped supports are only added where required internally and not evenly across the part.
• Triangular - This pattern is ideal for large and flat surfaces. The grid is made of triangles crossing each other at 60 degrees.
• Tri-Hexagon - One of the strongest patterns, it is created by a hexagonal pattern interweaved with triangles.
• Cubic - This pattern is created by printing small 3d cubic shells on top of each other at a slight offset which gives it structural integrity.
• Grid - One of the most common types of infill patterns that are made by lines that cross over each other at 90 degrees.
• Honeycomb - This pattern is made of small hexagons connected by thin walls, similar to beehives. It is a strong pattern.
• Gyroid - One of the few 3d support patterns that provide structural integrity in all directions, plus it saves material and is relatively fast to print.

For more information about different solid infill patterns read:

1. https://www.xometry.com/resources/3d-printing/what-is-infill-in-3d-printing/
2. https://blog.prusa3d.com/everything-you-need-to-know-about-infills_43579/

BAMBU LAB A1

The Bambu Lab A1 is a high-speed Core XY 3D printer designed for precision, automation, and ease of use. It features a range of automated calibrations, a user-friendly interface, and multi-color printing capabilities. The A1 is ideal for both beginners and experienced users, offering smart automation features like auto Z-offset, auto flow calibration, auto belt tensioning, and real-time flow rate compensation.

Key Features of Bambu Lab A1

• Auto Z-Offset: Precise nozzle probing eliminates manual calibration.
• Auto Flow Dynamics: Automated pressure advance calibration for better extrusion.
• Auto Vibration Calibration: X and Y resonance auto-tuning for improved accuracy.
• Auto Belt Tension: Monitors and adjusts belt tension for optimal performance.
• Auto Filament Loading: One-touch filament handling system.
• Multi-Color Printing: Supports AMS Lite for seamless multi-color prints.
• Real-Time Flow Rate Compensation: Ensures smooth printing with high-frequency sensors.
• Dynamic Motor Noise Suppression: Active noise cancellation for quiet operation.
• Core XY Speed & Precision: Fast and precise printing with a Core XY motion system.
• User-Friendly UI: Intuitive touchscreen interface for easy navigation.
• Offline Mode for Privacy: LAN mode allows local control without cloud dependency.

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Technical Specifications of Bambu Lab A1

Specification	Details
Build Volume (WDH)	256x256x256 mm³
Motion System	Core XY
Filament Diameter	1.75 mm
Nozzle Material	Stainless Steel
Max Hot End Temperature	300°C
Nozzle Diameter	0.4 mm (Included), 0.2 mm, 0.6 mm, 0.8 mm (Optional)
Build Plate	Bambu Textured PEI Plate (Included), Bambu Smooth PEI Plate (Optional)
Max Acceleration (Tool Head)	10m/s²
Max Speed (Tool Head)	500 mm/s
Max Build Plate Temperature	100°C
Supported Filaments	PLA, PETG, TPU, PVA (Ideal), ABS, ASA, PC, PA, PET, Carbon/Glass Fiber Reinforced Polymer (Not Recommended)
Layer height	0.08 mm - 0.28 mm
Filament Run-Out Sensor	Yes
Power Loss Recovery	Yes
Filament Odometry & Tangle Sensor	Yes

Source :- https://gzhls.at/blob/ldb/8/b/9/6/e11ab07c47dfb806a34940bbfce2b6cf2fe6.pdf

Types of build plates

Textured PEI Plate

The Textured PEI Plate consists of a stainless steel sheet coated with PEI powder, resulting in a textured surface on both sides. Its unique rough texture is imprinted onto the bottom of prints, giving them a distinct finish. This plate is compatible with various materials and typically offers strong adhesion without requiring additional adhesives, making it a convenient choice for users.

Smooth PEI Plate

The Smooth PEI Plate is created by bonding a high-quality PEI sheet to a spring steel plate using a heat-resistant 3M adhesive. It provides a flat surface, making it ideal for prints that require a level bottom.

The PEI surface supports a variety of filaments, though only PLA can be printed without adhesive. Other filaments require glue to prevent damage to the PEI sheet.

Cool Plate Super Tack

The low-temperature stabilization print bed uses a Super Tack-coated spring steel plate, providing strong adhesion for PLA and PETG filaments. It minimizes warping by securely holding PLA prints at just 45°C, making it ideal for large models. With a durable coating that lasts over 300 prints and reduced energy consumption, it extends the print bed’s lifespan while lowering electricity costs.

Dual-Texture PEI Plate

The stainless steel plate is equipped with dual-sided coatings, one side featuring textured PEI and the other side featuring smooth PEI.

Source :- https://wiki.bambulab.com/en/filament-acc/acc/plates

Loading process

• Prepare the Filament:
  • Place the filament spool on the AMS Lite in the correct orientation.
• Insert the Filament:
  • Insert the filament tip into the AMS feeder inlet.
  • The system will automatically pull the filament into the PTFE tube.
• Confirm on the LCD Screen:
  • Go to Filament > Load Filament on the screen.
  • Select the filament type and confirm the loading process.
• Heating & Extrusion Check:
  • The nozzle will heat up to the required temperature.
  • Once heated, the printer will extrude some filament through the nozzle to confirm proper loading.

Printer Slicer

Slicing is the process of converting a 3D model (STL, OBJ, 3MF, etc.) into G-code, which is the language a 3D printer understands. The slicer software takes the digital 3D model and divides it into thin horizontal layers. Each layer contains instructions for the printer

Following are the three major types of settings that can be controlled in a slicer software —

1. Print Settings: layer heights, shells, infill per cent, and speed
2. Filament Settings: filament diameter, extrusion multiplier, the temperature of the extruder, and print bed.
3. Printer settings: nozzle diameter, print bed shape (L x W), and Z offset.

G-Code

G-code (Geometric Code) is the programming language used to control CNC machines, 3D printers, laser cutters, and other automated manufacturing tools. It consists of a series of commands that tell the machine where to move, how fast, how much material to extrude, and other key instructions.

In 3D printing, G-code is generated by a slicer (like Bambu Studio, Cura, or PrusaSlicer) and then sent to the printer to execute the print job.

The Flow of 3D printing

Bambu Studio

Bambu Studio is an open-source, cutting-edge, feature-rich slicing software. It contains project-based workflows, systematically optimized slicing algorithms, and an easy-to-use graphical interface, bringing users an incredibly smooth printing experience.

Bambu Studio is the official slicing software for Bambu Lab 3D printers. It is based on PrusaSlicer but optimized for high-speed CoreXY printing and multi-material printing with the AMS (Automatic Material System).

There are defined presets for different layer heights according to the required time and resolution the 3d print. The most common preset used is the 0.20 mm Standard . The lesser the layer height finer the details, smoother the surface but greater time and material consumption.

There are mainly 4 Tabs in the Bambu Studio for slicing parameters.

The Quality Tab has details for layer height, first layer height and seam position. This ensures the quality of the print.

The Support Tab has information about the supports and types of supports for overhangs and features that might require support. There are mainly two types of supports: Normal and Tree. both of these can be set to auto or manual mode according to need.

The others tab consist information of miscellaneous features such as prime tower, Timelapse, etc. We took a timelapse of the tolerance test print.

Slice the object

The Total estimation of the print time, filament usage and cost can be seen in the tab. The above color matched items show every features in the 3D print

The global and objects help to apply settings to global i.e to all objects and the objects tab helps to individually apply settings to each object.

The printing page: The print status and camera feed can be seen on this page

Test 3D Print

A 3D print test print is a small, quick print used to check a 3D printer’s accuracy, It helping to identify issues like poor adhesion, stringing, or incorrect temperatures. Common test prints include Benchy, a small boat for assessing overall print quality, and the Calibration Cube, which ensures dimensional accuracy. A Temperature Tower helps find the best printing temperature for a filament, while a Retraction Test minimizes stringing. Overhang and Bridging Tests evaluate how well a printer handles angles and gaps. in our case we have used an all in one test from Thingiverse.

Link : MINI All In One 3D printer test by majda107 - Thingiverse

We imported the file as STL and imported it into the slicing software then i gave all the parameter and i moved it for printing

Infill was 30% and layer height was 0.24mm ad it took 1hr 30min for completing the print.

This is the final out put

1. Bridge Test

The Bridge Test checks the printer’s ability to print unsupported horizontal spans. A structure with increasing unsupported distances is printed to see if the printer can bridge gaps without excessive sagging or stringing. Poor bridging indicates issues with cooling, over-extrusion, or print speed.

From our observation the 25 mm long bridge started sagging so in design bridge up to 20 mm can be easily printed.

2. Support Test

The Support Test evaluates how well the printer handles overhangs and the ease of removing supports. A model with various overhang angles and structures requiring supports is printed. If support removal is difficult or layers fuse together, it suggests improper support settings or weak layer adhesion.

We were not able to find out how this test works 😁.

3. Hole Test

The Hole Test checks if circular holes print accurately. A test print with multiple hole sizes is measured, and if the holes are too small, it may indicate over-extrusion or incorrect flow rate settings.

For the hole test from the given dimension .04 mm reduction is there this may be due to printer issue or due to the nozzle size.

4. Stringing Test

The Stringing Test determines if the printer produces unwanted filament strands between separate printed parts. Two or more towers are printed at different distances to check for fine filament strings. Stringing occurs due to incorrect retraction settings, high nozzle temperature, or excessive filament flow.

There were no strings found on the string test

5. Scale Test

The Scale Test ensures dimensional accuracy in the X, Y, and Z axes. A cube or rectangular block with known dimensions is printed and measured. Deviations suggest issues like improper steps/mm calibration, belt tension problems, or incorrect flow rate.

The scaling was pretty precise in this test all the cube had a the same dimension in all orientation .

6. Diameter Test

The Diameter Test ensures cylindrical objects print with the correct diameter. A model with different cylindrical sections is printed and measured. Differences between expected and actual dimensions may indicate extrusion multiplier errors, steps/mm calibration issues, or mechanical inaccuracies.

Here for the cylinder’s the actual diameter was 6mm and 8mm but after printing and measuring the dimensions were 5.88 mm and 7.87 mm respectively.

7. Overhang Test

The Overhang Test evaluates how well the printer handles overhangs at different angles without supports. A model with increasing overhang angles (e.g., 10°, 20°, 30°, up to 80°) is printed. Poor performance can indicate insufficient cooling, high print speed, or weak layer adhesion.

From the results obtained errors start to appear after 45 deg .

Clearance Test

This is a simple test print made for finding the tolerance of a printer the findings from this printer can be implemented in the designs.

Link :

This test print there are multiple cubes with different off set ranging from to 0.1 to 1 there is a central cylinder of standard diameter .

In our printer the cube with 0.1 off set was completely fixed to the cylinder , 0.2 offset didn’t have a smooth motion but .3 offset cube was good enough depending on the use case the offset can be varied.

Conclusion

For our group assignment , we did a test print in BAMBU LAB A1. For this, an all in one test model was downloaded from Thingiverse. We measured the test print model and values are noted. These values will be using for future designs. We learned about the test rules and necessary safety measures. We learned about 3D printing and its types. Technical specifications and features of the printer were also discussed.

References

1. https://www.hubs.com/knowledge-base/how-design-parts-fdm-3d-printing/#overhangs
2. https://www.hubs.com/knowledge-base/supports-3d-printing-technology-overview/
3. https://www.cytron.io/tutorial/what-are-supports-in-3d-printing
4. https://www.raise3d.com/academy/when-and-how-to-use-3d-printed-support-structures/
5. https://all3dp.com/1/3d-printing-support-structures/#section-minimize-3d-printing-support-structures-by-reorientation
6. https://dddrop.com/how-to-perfectly-print-a-thin-walled-3d-print/
7. https://formlabs.com/asia/blog/isotropy-in-SLA-3D-printing/?srsltid=AfmBOooav7WNQmhJTYYD_RfVHFQ8U7dmDbPvLb_417Kmx2OfYLdSBMKP
8. https://www.sciencedirect.com/science/article/abs/pii/S1359836816309052
9. https://www.baysingersadditivemanufacturing.com/layer-lines/
10. https://3dinsider.com/fix-misaligned-layers-3d-printing/
11. https://www.xometry.com/resources/3d-printing/what-is-infill-in-3d-printing/
12. https://blog.prusa3d.com/everything-you-need-to-know-about-infills_43579/

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Last update: March 10, 2025