Work Process Detail

Printer Selection and Initial Testing:

• We started by understanding the parameters for FDM 3D printing and selected two printers: the Prusa MK3 and the Ultimaker S5.

• I read about the Prusa MK3 printer and its design features before proceeding with the first test print.

3D Printing Settings for the Test Prints

During the 3D printing week, I worked with three different printers. The first was the Prusa MK3S, where I used a 0.2 mm layer height and set the vertical shell parameter. I disabled supports since the design did not require them. The printing speed was set at 45 mm/s, and these settings were consistently applied to all test prints for the week.

Design and Tolerance Testing:

• We used a test file (called the "XYZ CUBE" model) to evaluate the tolerance of each axis.

• After printing the test file, we identified an issue where the printer was burping excess filament at the tip of each layer.

Troubleshooting and Calibration:

• To address the issue, I disassembled the print head, cleaned the nozzle, and ensured that the extruder and nozzle were properly tightened.

• I recalibrated the printer's first bed layer using the wizard calibration cycle, which resolved the issue.

Testing Results:

• The printed test file was re-evaluated for tolerance using a caliper, measuring the inner and outer diameters as well as hole thickness.

• We tested how the layer reacts to circular patterns and determined that a 10° overhang angle was the maximum the printer could handle.

• The bridging test revealed that 20 cm was the maximum bridge length without sagging or defects.

Testing Advanced Multicolor Printing:

• We moved on to the Ultimaker S5, which has a dual extruder setup for multicolor printing.

• After calibrating the offset between the X and Y axes for the two nozzles, we printed a multicolor Benchy model.

• Although the print quality was impressive, we noticed a significant amount of material waste due to frequent color changes between layers.

3D Printing Settings for the Test Prints

For the Ultimaker, I customized aesthetic settings that I plan to keep for future prints. Using Cura slicer, I selected a 0.3 mm layer height, set the wall line count to 4, and used an infill density of 30%. The nozzle temperature was set to 260°C, and the build plate temperature to 80°C. I kept the feed rate at 100%, chose skirt as the build plate adhesive, and applied these settings to both blue and black filament prints.