5.3D SCANNING AND PRINTING

This week I worked on defining my final project idea and started to getting used to the documentation process.

• 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, few cm3, limited by printer time) that could not be easily made subtractively
  • 3D scan an object (and optionally print it)

GROUP ASSIGNMENT

GROUP ASSIGNMENT

OVERVIEW

The group’s comprehensive overview of 3D printing technologies provided a valuable context for my work with the Bambu Lab A1, a Core XY FDM printer. The All in One 3D printer test, for example, allowed me to validate some of these design rules like bridging distances. The dimensional accuracy test for hole diameters, in particular, highlighted the importance of understanding printer-specific tolerances, which may affect the design of precision parts.

3D PRINTING

We are using bambu labs printer for our 3D Printing Week .

## BAMBU LABS A1 PRINTER

The Bambu Lab A1 is a high-speed, full-size bed slinger 3D printer with a build volume of 256 x 256 x 256 mm. It features:

• CoreXY design for speed and precision, with a maximum print speed of 500 mm/s and acceleration of 10,000 mm/s²
• All-metal hotend capable of reaching 300°C - Direct drive extruder with hardened steel gears
• PEI-coated flexible build plate heated up to 100°C
• Automatic bed leveling and Z-offset calibration - 3.5-inch color touchscreen interface
• Wi-Fi connectivity and camera monitoring

• Optional AMS Lite for multi-color printing

  

  Download here

  The software can be downloaded using the above URL.

This is the installation setup .

Now we were asked to print the test jig, so I printed the infill pattern. The steps are mentioned below:

• First I created a 3D box using AutoDesk Fusion.
• Then exported it as a STL file, so I could 3D print.

• Then I opened it in Bambu Labs. I copy(Ctrl+C) and pasted(Ctrl+V) the 3D boxes 6 times.

Now to follow up with the operations in Bambu Labs, I will be mentioning the features listed in numbers from the above attachment

1. Used for Arrange Function, so that the 6 box gets arranged in a more compact manner.
2. Objects option, used for individual property assignment, on the other hand in Global options the properties are being assigned to all the figures. So in my project I used Objects option to assign different Infill patterns for the boxes.
3. Slice Plate is used once you are ready for printing, it helps to calculate the time required to print and also helps to analyze different problematic areas like, overhangs.
4. Device option is for to connect the printer available .
5. We could select the available plate out here . In our case we are using cool plate . so we selected that .

This is the Slice Plate tab,

Mentioning the features of the listed numbers:

1. Following picture is the dropdown that shows the required time, overhangs, bridges, etc.

1. I was not aware about how to pause in the midway, then I referred to some You tube videos and found there’s a pause option in the slice plate tab(as shown the above image). Below are the steps to pause:
2. Drag the pointer to the point where you want to pause.
3. By Right clicking one can pause the job(you can see how much time it would take to complete the percentage of job allocated).

Then click print plate to 3d print the item , after selecting the pool of material .

These are the output with different infill pattern .

3D PRINT SOMETHING THAT CANT BE DONE USING SUBSTRACTIVE METHODS .

I decided to make a parametric hexagonal modal inspired by a circular modal that was in our fab academy

The steps are as follows

1. Design Parameters:

• InnerHex: (Numerical Value) - defines the inner hex. Set to 10 initially based on the model from the video.
• BodyThickness: (Numerical Value) - Thickness of each hexagonal body (set to 1.2 mm).
• Gap: (Numerical Value) - Small gap between the hexagonal bodies (set to 0.6 mm).
• BodyHeight: (Numerical Value) - Height of the hexagonal bodies (set to 10 mm).
• Angle: (Angle) - Angle for the beveled edge of the hexagon (set to 130 degrees).
• Quantity: (Number) - number of bodies , initially it is 10.

• BaseBodyOffset: (Equation) - Calculated offset for the base body (see calculation below).

  • Formula: Quantity * (BodyThickness + Gap)

  

2. Step-by-Step Modeling Process:

Step 1: Setting up User Parameters

• Create the following User Parameters. The parameters allow easy modifications to the hexagon design. Go to Modify > Change Parameters and add the parameters as defined above. The formula for base body offset is as described above.

Step 2: Create Base Sketch (Top View)

• Create a new sketch on the top plane.
• Draw a Polygon (Inscribed Polygon): Use the Create > Polygon > Inscribed Polygon tool.
• Dimension the Polygon: Dimension the polygon to the InnerHex user parameter. Apply a horizontal constraint.
• Offset the Polygon: Use the Modify > Offset tool to offset the hexagon outwards by BaseBodyOffset.

• Divide the Sketch: Draw two lines connecting the corners of the hexagon to the center to isolate one-sixth of the hexagon. Draw a construction line from center.

  

• Trim: Use the Trim tool to remove unnecessary profiles, leaving only one-sixth of the hexagon profile. Ensure only the desired profile remains. Finish the sketch.

Step 3: Extrude Base Feature

• Extrude: Use the Extrude tool (E) to extrude the selected profile downwards by a small amount, like -1mm. This creates the initial base for the pattern. Select one sixt profile and extrude by -1mm.

Step 4: Create Side Profile Sketch (Front View)

• Create a new sketch on the front plane.

• Project Geometry: Use the Create > Project > Include > Project tool to project the point at the center of the hexagon. This point will be used for dimensioning.

  

• Draw Construction Line: Draw a vertical construction line upwards from the projected point. Dimension this line with the BodyHeight user parameter.

• Create Side Profile: Draw lines to create the side profile of one hexagonal body.

  • Ensure the lines are coincident with the projected point and the end of the BodyHeight line.
  • Use a horizontal constraint and parallel constraints to define the shape.
  • Dimension the thickness using the BodyThickness parameter.
  • Dimension the angle using the Angle parameter.

  

Step 5: Extrude Side Profile

• Extrude: Extrude the side profile using the Extrude tool (E). Set the operation to “Join” and set the compute option to “Adjust”.
  • Select “Distance to Object” as the Extrude type.
  • Select the outer face of the base hexagon for the first extent.
  • Select the opposite face for the second extent.

Step 6: Rectangular Pattern

• Create Rectangular Pattern: Use the Create > Pattern > Rectangular Pattern tool, select the “Features” type, and select the last Extrude feature.
• Direction: Select the construction line from Step 2.
• Quantity: Enter the Quantity user parameter.
• Distance: Enter the formula BodyThickness + Gap.
• Compute Option: Set the compute option to “Adjust”.

Step 7: Circular Pattern

• Circular Pattern: Use the Create > Pattern > Circular Pattern tool, select the “Bodies” type, and select all the hexagonal bodies.
• Axis: Select the Z-axis (or any axis perpendicular to the top plane).
• Quantity: Enter 6 (for a hexagon).

Step 8: Combine Bodies

• Combine: Use the Modify > Combine tool to join all the bodies into a single body.
• Operation: Select “Join”.
• Keep Tools: Uncheck the “Keep Tools” option.

Step 9: Split Body (Remove Bottom)

• Extrude Cut: Use the Extrude tool (E) to extrude the bottom face of the hexagon upwards with the “Cut” operation.

  • Distance: Extrude upwards by a small amount (e.g., 1mm).

  

3. Parametric Testing:

• Change the Quantity parameter in Modify > Change Parameters. Verify that the model updates correctly without errors. Test with different values to ensure robustness.

SECTIONAL VIEW

Below i have attached the sectional view of the hexagonal model .

i refered a vedio to make this the link of the vedio is attached below .

https://youtu.be/q1Bqo3MO0ss?si=fZTyVAk1X7UqhqI6

Then i used bambu labs to 3d print the item .

Below i have attached the view for that how the hexagon is like when it is about to print using bambu labs printer .

Things to check on before

1. Go to support and check the on build plate only option as shown above . So the support comes to the hook portion only .
2. the other shown function you could check out to auto detect the filaments loaded inside the printer . so you could choose later .

Final Product

I used the tools to remove the brim

Below vedio is the final vedio .

3D Scanning for Documentation: Fire Extinguisher Scan with Artec Leo

This week’s assignment involved exploring 3D scanning technologies. I chose to scan a fire extinguisher using the Artec Leo. This documentation outlines the scanning process, software workflow, challenges encountered, and the resulting 3D model. Understanding 3D scanning is essential for reverse engineering, creating digital archives, and replicating physical objects.

Artec Leo

The Artec Leo is a professional-grade, handheld 3D scanner known for its portability, ease of use, and ability to capture high-resolution, color 3D data. It features:

Wireless Operation: Self-contained with a built-in processor and screen.

Automatic Processing: On-board processing provides real-time feedback during scanning.

High Accuracy: Achieves accuracy up to 0.1 mm.

Color Capture: Captures full-color texture data.

Scanning Process:

Preparation:

Ensured the fire extinguisher was clean and free of any dust, dirt, or loose debris. A clean surface improves the scanner’s ability to capture accurate data.

Cleared the scanning area of any obstructions or clutter that might interfere with the scanner’s tracking.

Familiarized myself with the Artec Leo’s interface and scanning settings. Checked the battery level to prevent interruptions during scanning.

Scanning:

Held the Artec Leo approximately 0.5 meters away from the fire extinguisher, maintaining a consistent distance for optimal data capture.

Initiated the scan by pressing the trigger button on the Leo’s handle. The data started to populate on the screen in real-time.

Moved the scanner slowly and steadily around the object, ensuring smooth and consistent coverage. Paid attention to maintaining a green color indication, which signifies the ideal scanning distance.

Monitored the real-time feedback on the scanner’s screen to ensure complete coverage and proper tracking.

Paid particular attention to areas with complex geometry or surface variations (e.g., the handle, nozzle, safety pin, and label). These areas often require slower and more deliberate movements.

Made multiple passes around the fire extinguisher from various angles to ensure full data capture and minimize any potential blind spots.

Scanning Positions:

Almost scanned everything in this position so it will be better if I can scan details of other sides and bottom as well.

For capturing the bottom I lay down the object on the desk like the figure and then continued my scan. So while continue the scan on the same file a message instructions says to ‘Point at the base and scanned area’.It is searching for areas that it already know. After I shows the scanned area it shows that ‘Ready to scan’ and started to scan.Then I scanned the complete side including the bottom. Then I flipped other side of the object and continues the scan completely upto the bottom of the object.

Software Workflow (Artec Studio)

Import and Alignment:

Connected the Artec Leo to the desktop PC using an Ethernet cable to ensure fast data transfer, as wireless connections can be unreliable for large files.

Opened Artec Studio and selected

File >> Import >> Leo Project (connect to Scanner)

Selected the scanner from the searching list and clicked “Connect.”

Imported the scanned project file from the Leo scanner to Artec Studio. This process can take a significant amount of time due to the large file size (often exceeding 1 GB).

The Scanned files appeared in the left browser of the Artek studio its time for postprocessing Noise Reduction:

Applied noise reduction filters to remove unwanted data and smooth the surface.

Global Registration:

Performed global registration to fine-tune the alignment and minimize errors across the entire model.

Select the global registeration by clicking on the apply button next to it .

Modeling and editing

Next it asked for model creation and then i selected as below .

Then i edited using lasso tool the unwanted parts . Hold ctrl for the tool to function , ie for the selection .

Fast Fusion:

Used the “Fast fusion” algorithm to create a high-resolution, watertight mesh.

Texture Application:

Applied the captured color texture to the 3D model, enhancing its visual realism.

The auto pilot process begin for the model as first step it was started to align and bonds the separate scanned files. Then it continue for fusion ,where the all the scanned data fused together and filling holes ,smoothing surface to creating the final 3D solid.e full data capture.

Below i have attached the image for hole removal .where we should select the holes that we have to be fixed from the bar on left side and unselect the others .

Then we could select one layer which has most captured data to be kept as the reference data for the processing .

After applying the textures you get the final out as the one below .

FINAL 3D Sketch

I uploaded my designs to sketch fab . The link is on below .

sketchfab view

fire extinguisher by abinm1111 on Sketchfab

Challenges Encountered:

Tracking Issues: the Artec Leo occasionally lost tracking, particularly on smooth, featureless surfaces of the fire extinguisher.

Solution: I tried moving more slowly and deliberately, ensuring the scanner had sufficient features to track. I also experimented with different scanning angles to improve tracking stability.

Data Artifacts: Some areas exhibited data artifacts or holes due to reflections or occlusions, especially around the shiny metal parts and labels.

Solution: Re-scanned those areas from different angles, ensuring better visibility. Adjusted the scanner’s brightness settings to minimize reflections.

Large File Size: The large file size made processing time a bit long .

Solution: opt for cloud processing to improve processing speed.

During editing I cleaned the mesh by removing unwanted parts that are scanned.

Mesh simplification to make smaller model size.

CONCLUSION

This week was instrumental in solidifying my understanding of both additive and subtractive manufacturing techniques. The 3D printing tests allowed me to explore the capabilities of the Bambu Lab A1, and I gained practical experience in optimizing print settings for different infill patterns. The parametric hexagon design demonstrated the power of CAD software in creating complex, customizable geometries. Finally, the 3D scanning assignment provided valuable insight into capturing real-world objects and preparing them for digital manipulation.

FILES

BOX 3D PRINT FILE

HEXAGON 3D PRINT FILE

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Last update: February 26, 2025