3D Scanning & Printing Report

Group Assignment: Testing 3D Printer Design Rules

Introduction

Purpose of Testing 3D Printer’s Design Rules

The primary goal of testing the 3D printer’s design rules is to evaluate and calibrate its performance across various parameters that affect print quality, structural integrity, and functionality. This process helps to:

Analysis of our Test Setup and Results

Based on the settings we provided for the Ender 3 printer and the image of the output, here’s an evaluation of our test and its implications:

3D Printer Test Model

#D Test Model

Settings and Observations

Individual Assignment

3D Design & Printing

I was part of a team tasked with designing a more organic and comfortable hard hat equipped with sensors for monitoring temperature, pulse, and fatigue. Using surface modeling in SolidWorks, I harnessed its organic modeling capabilities to create a natural, ergonomic fit tailored to the human head. The process began with sketching splines and curves on the front and top planes to define the dome and overhang, followed by lofted and boundary surfaces to ensure smooth transitions and precise contours.

Multiple surface-trim operations shaped the hollow interior and perforated rim—visible as a dotted pattern in the model—enhancing ventilation and providing space for sensor integration. The maroon and blue color render was used to highlight the visibility of the overhang from the hat dome, aiding in assessing the design's structure, with the model optimized for 3D printing on a MakerBot Replicator Z18, including considerations for overhangs and support structures.

This surface modeling approach resulted in a lightweight, anatomically friendly hard hat, ideal for prolonged wear and sensor embedding. The use of advanced tools like lofts, boundaries, and cuts allowed for a seamless design that balances comfort with practicality, while the perforated rim reduces weight and supports airflow and sensor accessibility. The color-coded render enhanced the evaluation of the overhang's feasibility, ensuring a functional and printable design that brings the innovative concept to life.

Include CAD screenshots and STL files.

I modeled the hat with a surface modelling in order to take advantage of the organic features in the solidwrks. These are necessary in producing materials that will be in touch with body parts.

Surface Model

Surface Model in SW

I coverted the solid works file into an STL file type in order for the 3D Printer to recognise it

STL File Conversion

STL File

The picture below shows the hard hat printed on the Makerbot Z18 3D Printer

3D Printed Hat

Hard Hat

3D Scanning & Printing

Expalining the Einstar 3D Scanner

Einstar 3D Scanner: Overview and Features

The Einstar 3D scanner, developed by Shining 3D, is a handheld structured light scanner designed for affordability and ease of use while maintaining high-quality scans. It is suitable for makers, engineers, designers, and researchers who need a portable and efficient scanning solution.

Applications

  • Reverse Engineering: Capturing existing parts for CAD modeling.
  • 3D Printing: Scanning objects to create replicas or modify designs.
  • Heritage Preservation: Digitizing artifacts and sculptures.
  • Medical Applications: Creating prosthetics and orthopedic models.
  • Game Development & AR/VR: Capturing real-world objects for 3D environments.
  • Explain the scanning process, tools used, and any modifications applied.

    The scanning process was done on a Huewei and a computer mouse.It happened by scanning the object by moving the handheld scanner around it to capture its geometry.

    Process

    The scanning process on software

    3D Scanning

    3D Scanning Process, Tools Used, and Modifications

    Scanning Process

    The 3D scanning process involves capturing the shape, texture, and dimensions of a physical object to create a digital 3D model. The Einstar 3D scanner follows these key steps:

    Finalising

    Tools Used

    Modifications Applied