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5. 3D Scanning and Printing

This week was filled with hands-on experience in 3D printing and 3D scanning, allowing me to explore various technologies, materials, and design techniques. I worked with different types of 3D printers, including FDM (Prusa MK3S+, Ultimaker), SLA, SLS, clay, and food printers, each offering unique capabilities and applications. Additionally, I experimented with 3D scanning, gaining insights into how digital models can be created from physical objects for reverse engineering and further modifications.

👉 This Week’s Goals & Schedule

✔ Goals:

  • Work with various 3D printers (FDM, clay, food, SLA, SLS).
  • Define design rules for each.
  • Print a design that can’t be made by CNC.
  • Use a 3D scanner.
  • Extra: Create advanced designs.

✔ Schedule:

  • Thursday: Explored machines & software.
  • Friday: Designed test model.
  • Saturday: 3D design.
  • Sunday: Printed designs.
  • Monday: 3D scanning.
  • Tuesday: SLA printing.

1. Group Assignment

You can find more details on our lab site: TechWorks - 3D Scanning and Printing

1.1 exploring and testing printers

We started by exploring the 3D printers available in the lab and testing their capabilities. To evaluate their design accuracy, I created a 3D test model to assess:

  • Size accuracy
  • Bridge performance
  • Fine details
  • Overall precision

Here are images for my 3d design using SolidWorks:

This model was printed on the Prusa MK3S+:

And this one was printed on the Ultimaker S5:

Both prints demonstrated excellent quality and precision.

Prusa MK3S+ Printer

Key Features: - Uses Fused Deposition Modeling (FDM) technology - High print accuracy and reliability - Removable flexible print bed for easy part removal - Open-source hardware and software - Supports a wide range of filament materials

Before printing, we performed a calibration wizard to ensure everything was functioning correctly.

Animated GIF

The test results showed strong performance in overhang and bridge tests, indicating the printer’s excellent precision. With proper calibration and material selection, the Prusa MK3S+ delivers high-quality, reliable prints.

Ultimaker S5 Printer

The Ultimaker S5 is a high-performance FDM 3D printer with impressive features, including: - Large build volume - Dual extrusion for multi-material prints - Heated print bed for improved adhesion - Compatibility with various filament types (PLA, ABS, TPU, etc.)

Slicing and Printing Process

We used Ultimaker Cura for slicing, which offers: - A powerful slicing engine - Extensive material profiles - Customizable print settings - Seamless integration with Ultimaker printers

Formlabs SLA Printer

The Formlabs SLA printer uses Stereolithography (SLA) technology, where a laser cures liquid resin layer by layer to create high-detail prints.

Key Features: - Extremely high-resolution prints - Smooth surface finishes - Ideal for functional prototypes and intricate designs - Wide range of resin materials for different applications

her’s the test model for SLA FormLabs printer, we used PreForm 3d printing software

Post-Processing Steps

After printing, the material undergoes several post-processing steps to finalize the print: 1. The printed part is first submerged in isopropyl alcohol (IPA) for 5 minutes to remove excess resin. 2. The part is then cured under UV light to harden the material and achieve its final mechanical properties.

This printer is particularly useful for detailed miniatures, jewelry design, and medical models, where precision is crucial.

2. Individual Assignment

3D Printing

1. Daunt 3D Print

I attempted to create a daunt, a hollowed shape that cannot be manufactured using CNC machines due to its internal structure.

1.1 Designing the Daunt in SolidWorks

Step 1: Creating the Base Shape
- Drew a circle as the base.
- Used the Sweep feature to generate a torus-like structure.
- ✨ And there it is—a daunt!

Step 2: Hollowing the Shape
- Created another smaller diameter circle inside the original.
- Used the Extruded Cut feature to carve out the inner section.

Step 3: Adding a Top Cut for Visibility
- Made a top cut to expose the hollowed interior.
- Now, it looks like it has been bitten!


1.2 Preparing the Model for 3D Printing

Slicing the Model in Ultimaker Cura

Step 1: Configuring the Printer:
1️⃣ Opened Ultimaker Cura and added a new printer from Manage Printers.
2️⃣ Selected Ultimaker S5 as my printer model.


Step 2: Importing the STL File:
I Opened the .stl file in Cura.

Step 3: Positioning the Model:
Used the Rotate Tool to orient the model properly.
Ensured correct placement on the print bed using the Lay Flat tool.


Step 4: Setting Print Parameters:
- Resolution: Normal (0.15mm)
- Infill Density: 20%
- Infill Pattern: Triangles
- Supports: Disabled


1.3 Printing Process

Step 1: Transferring the G-code File:
Saved the G-code file onto a flash drive and inserted it into the Ultimaker S5.

Step 2: Loading the Filament:
Inserted a blue PLA filament into the printer.

Step 3: Starting the Print: 🚀 Initiated the print process, and the printer started working!

Animated GIF

Final Result 🏆

✨ The final printed model came out amazing!


🎉 Wow, it looks fantastic! 🎉

2. 3D Printing: Grid

Step 1: Creating the Base Sketch
I started by sketching two opposite arcs to define the base shape of the grid structure.


Next, I created a new plane and drew a circle. This circle was then used for a sweep operation, forming a wavy rod.

Step 2: Mirroring and Pattern Creation
After generating the rod, I flipped it to prepare for pattern formation.


By flipping the rod, I was able to create an interwoven grid structure.



Then, I applied patterning both vertically and horizontally to construct a complete grid.



Step 3: Preparing for 3D Printing
Once the design was complete, I prepared it for printing using PrusaSlicer.

  • Importing the STL File
    The first step in PrusaSlicer was to import the STL file of the grid design.

  • Cropping the Design
    Since my design was too large for the print bed, I used the Crop Tool in PrusaSlicer to adjust the size.


  • Rescaling the Model
    I resized the design to ensure it fit within a practical and printable scale.

  • Selecting Print Settings
    I used the default printing settings for the Prusa MK3S+ to ensure a reliable print.


Step 4: Final Print and Results
After slicing and printing, the final grid structure turned out perfectly!


3. 3D Printing: Circle Inside Circle

🛠 Designing the Model in CAD

1️⃣ Creating the Base Geometry
I started by drawing two half-circles using arcs:
✔ A large arc as the main structure.
✔ A smaller arc inside it, forming the inner circle.

After sketching, I used the Revolve feature to create spheres from these half-circle sketches.


2️⃣ Adding Circular Holes To enhance the design, I applied a circular pattern of holes around the sphere:

✔ Duplicated circular cutouts in a radial pattern.
✔ Ensured even distribution of the holes around the model.



Preparing for 3D Printing

3️⃣ Exporting to .STL Format After completing the design, I converted the file into .STL format, making it ready for slicing.

4️⃣ Slicing with PrusaSlicer I imported the STL file into PrusaSlicer, where I:
✔ Set the print settings (layer height, infill, supports).
✔ Generated G-code for the 3D printer.

Animated GIF

Final 3D Print Output

✅ The final printed object turned out great!

Here’s the final result in motion:
The inner sphere moves freely inside the larger one.

Animated GIF

A fun and functional 3D print! 🎉

4. Flexible Keychain 3D Print

Step 1: Designing the Keychain

To create a flexible keychain, I started by designing the base structure, ensuring it had interconnected segments for flexibility.


I then refined the design by adjusting the thickness, spacing, and joint connections to allow smooth bending.


Step 2: Exporting and Preparing for 3D Printing

Once the design was finalized, I exported it as an STL file and imported it into PrusaSlicer for print preparation.

Step 3: Print Settings and Slicing

  • Selected a PLA filament.
  • Used default material settings in PrusaSlicer.
  • Checked the layer height, infill, and print speed for optimal results.

Step 4: Printing and Final Result

After slicing, I proceeded with printing using a Prusa MK3S+. The final print turned out great, maintaining the intended flexibility and structure!


The flexible keychain successfully demonstrated the advantages of 3D printing, as this design cannot be accomplished using CNC machines.😊

3D Scanning

Using the Spider Handheld 3D Scanner

I used the Artec Spider Handheld 3D Scanner, a high-precision scanner known for its ability to capture fine details. It’s ideal for scanning medium & large objects, intricate details, and complex geometries.

Animated GIF

Scanning with Artec Studio 17

I used Artec Studio 17, a powerful and intuitive software for real-time scanning, processing, and cleaning of 3D models.

📌 Step-by-Step Scanning Process

1️⃣ Preparation 🔹 Ensure the scanner is properly connected to the computer and Artec Studio is running.
🔹 Place the object on a stable surface with good lighting.
🔹 Check for shiny or transparent surfaces, as they might need matte spray for better scanning.

2️⃣ Starting the Scan
🔹 Press the scanner’s button twice to begin.
🔹 Move smoothly around the object to capture all surfaces.
🔹 The software tracks the object in real-time; avoid sudden movements to prevent tracking loss.

3️⃣ Cleaning the Scan

During scanning, unwanted surfaces (like the table or background) may get captured. To remove them:

🔸 Use Base Selection to select and delete large unwanted areas.

🔸 Use Loose Selection for small or tricky areas.

Finalizing the Model

✨ The model is now ready for Autopilot processing, which:
✔ Aligns multiple scans automatically.
✔ Optimizes the mesh for 3D printing or visualization.
✔ Fills small holes and refines geometry.

🏆 Final 3D Scan Result

Here’s the final cleaned and processed 3D model:

Printing the Scanned Model

After processing, I sent the model for 3D printing. The comparison between the real object and the printed one is incredible!

🔹 Pink: Real object.
🔹 Gray: Scanned and printed model.

Successful 3D scanning & printing! ✅

What I Learned:🚀

  • Each 3D printer has different uses—FDM is common, SLA is very detailed, and SLS is strong and durable.
  • Good slicing settings are important—print direction, supports, infill, layer height, and material choice affect the final result.
  • 3D scanning is useful for copying objects, but it needs careful setup for accuracy.
  • Post-processing is essential in SLA printing, including removing supports, washing with alcohol, and curing with UV light for a smooth finish.
  • 3D printing allows creative designs that traditional machines like CNC cannot make, as seen with the flexible keychain, grid structure, and other detailed prints.

Files