Week 5: 3D Printing and Scanning

Objectives of the Week

Group Assignment

To test the Design rules of My 3D Printer

characteristics of your printer(s)

Individual Assignment

Linked to the group assignment page

Explained What you learned from testing the 3D Printers

Documented how you designed and 3D printed your object and explained it why it could not be easily made subractively

Document how you scanned an object

Include your Original files for 3D Printing

Included your hero shot

Group Assignment Contribution

In this Week, I have Contributed in the understanding characteristics of My 3D Printer

Characteristics of my 3D Printer

In our Lab we have two Printers one is from Creality and another one is from Flash Forge

For more about Group Assignment

About FlashForge Creator 3 Pro

The FlashForge Creator 3 Pro is a professional IDEX (Independent Dual Extruder) 3D printer, allowing dual-material and multi-color printing. It has a 300°C high-temperature extruder, enabling compatibility with a wide range of filaments like PLA, ABS, PETG, PC, and Nylon. The heated flexible build plate improves adhesion and makes print removal easy. With an enclosed chamber, it maintains stable temperatures for better print quality. The active leveling system ensures precise calibration. It features Wi-Fi, USB, and Ethernet connectivity for remote operation. It cost comes around Rs. 2L

About FlashForge Creator 3 Pro

Feature	Specification
Printing Technology	Fused Filament Fabrication (FFF)
Build Volume	300 x 250 x 200 mm
Layer Resolution	0.05 - 0.4 mm
Nozzle Diameter	0.4 mm (Standard)
Printing Speed	≤ 150 mm/s
Filament Diameter	1.75 mm
Extruder Type	Independent Dual Extruders (IDEX)
Compatible Materials	PLA, ABS, PETG, TPU, PVA, Nylon, Carbon Fiber
Heated Bed	Yes (Max Temp: 120°C)
Nozzle Temperature	Max 320°C
Enclosure	Fully enclosed for temperature stability
Connectivity	USB, Wi-Fi, Ethernet
Power Supply	24V / 500W
Display	4.3-inch Touchscreen
Supported File Formats	STL, OBJ, 3MF, G-code
Compatible Software	FlashPrint, Simplify3D, Cura
Weight	40 kg

Designing the 3D Printed Object

The model was designed in Fusion 360. The objective was to create a hollow interconnected pipe structure that could demonstrate the advantages of additive manufacturing. The geometry contains internal connections and curved paths that would be difficult to manufacture using conventional subtractive processes.

Why this Model Cannot be Easily Manufactured Subtractively?

The object contains multiple interconnected internal channels and curved geometries. Manufacturing such a structure using conventional subtractive machining would require several setups and specialized tooling. Some internal features are inaccessible to cutting tools, making the geometry difficult or impossible to produce using traditional machining methods. Therefore, additive manufacturing is the most suitable fabrication process for this design.

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Creality Slicer 4.8.2

After completing the CAD design, the STL file was imported into Creality Slicer 4.8.2. Slicing software converts the 3D model into machine-readable G-code and allows configuration of print settings such as layer height, infill, supports, and print speed.

We selected the Creality Smart CR-10 Pro printer profile to match the build volume and machine specifications.

Scaling and Rotating the Mesh

Print Configuration and Support Settings

Exporting G-Code

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Machine Setup and Printing

The object was printed using PLA filament. The following parameters were configured before starting the print:

• Nozzle Temperature: 210°C – 220°C
• Bed Temperature: 60°C
• Material: PLA

Printing Process

Final 3D Printed Object

3D Scanning using KIRI Engine

As in our lab we don't have any 3D Scanner, so we have to use the app called KIRI Engine

The object selected for scanning was my computer mouse

About KIRI Engine

Download KIRI Engine from Google Play Store

For the initial 3D scanning experiment, I used the KIRI Engine mobile application. The application uses photogrammetry techniques to reconstruct a three-dimensional model from a collection of photographs. Images are captured from multiple viewpoints around the object and then processed to generate a textured 3D mesh.

To create the model, approximately 50 images were captured while moving around the object. These images were uploaded to KIRI Engine, where they were aligned and processed automatically. The software identified common feature points between images and reconstructed the object's geometry.

Although the generated model successfully captured the overall shape of the object, some surface details and geometric features were not reconstructed accurately. This motivated me to explore an alternative workflow using Polycam to achieve a higher-quality scan result.

Re-Scanning using Polycam

Although KIRI Engine successfully generated a 3D model from the captured images, the reconstructed mesh contained several imperfections and missing surface details. To improve the quality of the reconstruction, I decided to perform a second scanning experiment using Polycam, a mobile-based photogrammetry application.

This second iteration allowed me to compare different photogrammetry workflows and evaluate how different reconstruction algorithms affect the final model quality. For this experiment, I selected a small Shinchan toy and captured a new set of photographs from multiple viewpoints.

About Polycam

Polycam is a mobile 3D scanning and photogrammetry application available for Android and iOS devices. The software uses a collection of photographs captured from different viewpoints and reconstructs them into a textured 3D model. It supports exporting models in formats such as STL, OBJ, FBX, and GLTF, making it suitable for visualization, reverse engineering, and rapid prototyping workflows.

Scanning the Shinchan Toy

For this scanning experiment, I selected a small plastic Shinchan toy. The object contains curved surfaces, facial details, and geometric features that make it suitable for evaluating the performance of photogrammetry-based 3D reconstruction.

Using my smartphone, I captured multiple images while moving around the object from different angles. Photographs were taken from the front, rear, sides, and top views to ensure complete surface coverage. Maintaining sufficient overlap between images helped Polycam accurately identify common feature points and reconstruct the geometry.

Model Processing and Reconstruction

After completing the image acquisition process, Polycam processed the collected photographs and automatically generated a textured 3D model. The software analyzed common feature points between images and reconstructed the geometry using photogrammetry algorithms.

The generated model was then reviewed directly on the mobile device. This allowed me to inspect the reconstructed mesh, verify the captured details, and evaluate the overall quality of the scan before exporting the final model.

Exporting and Visualizing the Model

Once satisfied with the reconstruction quality, I exported the generated model in GLTF format. The exported file preserves both geometry and texture information, making it suitable for further visualization and sharing.

To inspect the model interactively, I uploaded the exported file to Sketchfab. The online viewer allowed me to rotate, zoom, and examine the reconstructed model from different angles. Compared to the initial KIRI Engine scan, the Polycam-generated model demonstrated better texture quality, improved surface reconstruction, and more accurate geometry.

Final 3D Scan Result

After performing the scan refinement process, KIRI Engine generated a significantly improved 3D model. The refinement stage reconstructed the geometry more accurately by analyzing additional image data and improving mesh generation. The final model preserved most of the object's surface details and overall shape, demonstrating the effectiveness of photogrammetry-based scanning using a smartphone.

The generated mesh was exported and uploaded to Polycam for visualization and sharing. The interactive viewer allows the model to be inspected from different angles and provides a better understanding of the reconstructed geometry.

Although the scan successfully captured the overall geometry, some minor surface imperfections and mesh artifacts were still visible. These limitations are common in photogrammetry workflows and can be reduced by increasing the number of input images, improving lighting conditions, and maintaining consistent camera positioning during image capture.

Compared to the initial KIRI Engine scan, the Polycam-generated model showed improved surface quality, better texture mapping, and more accurate geometric reconstruction. This exercise demonstrated how different photogrammetry tools can produce varying levels of detail depending on their reconstruction algorithms.

Learning Summary

• Learned the complete workflow of designing a custom 3D model using Fusion 360, including sketching, sweep operations, and appearance modifications.
• Understood the advantages of additive manufacturing and analyzed why complex internal geometries cannot be easily manufactured using conventional subtractive methods.
• Gained hands-on experience in preparing STL files for fabrication using Creality Slicer, including model scaling, orientation, support generation, and slicing configuration.
• Learned the importance of selecting appropriate printing parameters such as layer height, print speed, nozzle temperature, and bed temperature to achieve successful prints.
• Observed the complete 3D printing workflow from machine setup to final part fabrication and understood the operating characteristics of the FlashForge Creator 3 Pro printer.
• Evaluated the capabilities and limitations of photogrammetry-based 3D scanning using KIRI Engine and identified challenges related to image alignment and mesh quality.
• Explored Polycam as an alternative scanning solution and observed improvements in mesh reconstruction, texture mapping, and overall model quality.
• Successfully generated a 3D scan of a Shinchan toy by capturing images from multiple viewpoints using a smartphone camera.
• Learned how to process, export, and visualize scanned models using GLTF format and online 3D model viewing platforms.
• Developed a better understanding of the complete digital fabrication workflow, from CAD design and additive manufacturing to 3D scanning and digital model reconstruction.

Hero Shot

Finally Leaving my files here

Something.STL

Something.GCode

I can't able to export those STL files of Mouse and Shinchan Toy due to subscription restriction. Sorry :-(