Week 5 - 3D Scanning and printing

Assignments of the Week

1. 3D Printing Project

Design and fabricate an object with the following specifications:

Requirements:

• Dimensions: Small scale (volume: few cubic centimeters)
• Manufacturing: Additive manufacturing only
  • Must utilize geometries impossible for subtractive methods
• Time: Optimize for efficient print duration

2. 3D Scanning Exercise

Conduct a 3D scanning project:

Core Task:

• Scan a physical object to create digital model

Optional Enhancement:

• Convert scanned data to 3D printed object

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This week, I delved deep into 3D printing technology applications. First, I conducted design rule testing on my 3D printer to ensure print quality and precision. Subsequently, I successfully materialized the model designed in week two through 3D printing technology. Additionally, I mastered the basic operations of 3D scanning technology and used the Bambu Lab X1 Carbon 3D printer to scan a YOKE joystick, experiencing the transformation process from physical objects to digital models.

3D Printing

Advantages and Disadvantages of 3D Printing Technology

3D printing technology offers advantages including rapid prototyping, support for complex geometric structures, and reduced material waste. Different technologies have their unique characteristics: FDM is cost-effective and widely applicable; SLA/SLS offers high precision, suitable for detailed models; DMLS supports metal parts with excellent strength. The main disadvantages include material limitations (such as high metal costs), trade-offs between precision and speed (high-precision technology is slower), post-processing requirements (such as support removal), and expensive equipment (industrial-grade technology). Some technologies have strict design rule requirements (such as overhang angles, minimum hole diameters), which may increase design complexity.

Reference:

https://www.nexmaker.com/doc/3_3dprinter/1.3Dprintingbackground.html

Introduction to Bambu Lab X1 Carbon 3D Printer

The Bambu Lab X1 Carbon is a high-performance FDM (Fused Deposition Modeling) 3D printer that employs multiple innovative technologies to achieve high-speed and high-precision printing.

Reference:

https://wiki.bambulab.com/en/x1

Main Technical Specifications

Parameter	Specification
Print Size	256 × 256 × 256mm
Print Speed	Up to 500mm/s
Minimum Layer Height	0.1mm
Nozzle Diameter	0.4mm
Maximum Bed Temperature	110°C
Maximum Nozzle Temperature	300°C

Core Technical Features

1. Motion System

• The Bambu Lab X1 uses a CoreXY motion system, consisting of two stepper motors that work together to control the toolhead movement. Each stepper motor has an independent belt connected to the toolhead, and the system uses a pair of belts to control the toolhead position. Compared to traditional Cartesian printers, the X1 with CoreXY system achieves faster printing speeds.

Reference:

https://wiki.bambulab.com/en/x1

2. Hot End System

• The hot end is responsible for heating the filament to a specified temperature, melting and depositing it in layers to create the model. Different materials require different heating temperatures. The Bambu Lab X1 printer features an integrated hot end design, combining the nozzle and heat block, connected to the heat sink via a thin metal tube for optimal performance.

Reference:

https://wiki.bambulab.com/en/x1

3D Printing Workflow

1. Material Preparation

• Confirm filament type, using PLA for this print, check if there's sufficient material to complete the printing task, ensure the filament is not damp or damaged

2. Slicer Software Installation and Parameter Settings

Using Bambu Lab's officially recommended slicer software Bambu Studio. Bambu Studio has hundreds of slicing parameters, mainly divided into three categories: printer, filament, and process

Parameter Settings

• Printer Parameters

  • Printer Model: X1 Carbon, Hot End Specification: 0.4mm, where 0.4mm represents the nozzle diameter; smaller diameters can print finer features but require longer printing times
  • Print Platform: Textured PEI print plate, which leaves a specific texture effect on the bottom of prints

• Filament Parameters

  • Add/remove filaments using the "+" "-" buttons
  • Click color blocks to modify filament color
  • Click the edit icon to adjust filament configuration parameters

• Process Parameters

Parameter Type	Range	Description
Layer Height	0.08-0.28mm	- Small layer height (0.08-0.12mm) suitable for fine models, good surface quality - Medium layer height (0.2mm) suitable for daily printing - Large layer height (0.28mm) suitable for quick printing, sacrificing surface quality
Infill Density	5-100%	- 5-15%: Decorative items, non-load bearing parts - 20-50%: General functional parts - 50-100%: High-strength requirements
Print Temperature	Material dependent	- PLA: 190-220℃ - ABS: 230-250℃ - PETG: 230-240℃ - TPU: 220-235℃
Support Settings	Optional	- Support needed for overhang angles >60° - Support density typically set to 15-30% - Tree or normal support options available
Speed Control	20-150mm/s	- Outer walls: 20-40mm/s - Inner walls: 40-60mm/s - Infill: 60-150mm/s - Supports: 60-120mm/s
Cooling Parameters	0-100%	- PLA: 100% fan - ABS: 0-30% fan - PETG: 50-70% fan - TPU: 30-50% fan

Printer Performance Testing

To evaluate the Bambu Lab X1 Carbon's printing performance, I designed a comprehensive test model in Fusion 360. This model contains multiple feature structures to test the printer's precision at different sizes and angles, particularly minimum printable wall thickness and gaps.

Model Export and Slicing Preparation

1. After completing the model design in Fusion 360, export the STL file using the built-in 3D printing function

2. Prepare for slicing in Bambu Studio:

   • Import STL file using the "Add" function
   • Use "Lay on Face" function to optimize print orientation, selecting the appropriate bottom surface for optimal print results

Print Parameter Configuration

Parameter	Value	Optimization Notes
Layer Height	0.2mm	Selected standard layer height, balancing precision and efficiency
Wall Count	5	Ensure model structural stability and test feature accuracy
Sparse Infill Density	12%	Moderate infill, ensuring support strength while optimizing print time

Slicing and Printing

Use Bambu Studio's "Slice plate" function in the top right corner for slicing

Slicing analysis shows:

• Estimated print time: 44 minutes
• Material usage: 15.70g PLA

Test Results Analysis

After printing, the following performance parameters were measured:

• Minimum printable wall thickness: 0.4mm
• Minimum printable gap: 0.1mm

These data indicate that the Bambu Lab X1 Carbon has excellent fine feature printing capabilities, meeting most regular printing requirements.

3D Print Design

3D Printer Status Indicator

This week, I designed and implemented an innovative 3D printer status indicator. This device uses intuitive visual methods to display the printer's real-time working status, allowing users to quickly assess print progress from a distance, improving work efficiency.

Design to Print Workflow

1. Complete 3D modeling in Fusion 360 and export the design in STL format

2. Complete slice settings and parameter optimization in Bambu Studio

3. Print Results Display

Week Two Design Implementation

After completing the status indicator, I continued to print the model designed in week two. Following the same workflow, from 3D modeling to slicing to final printing:

1. Model Slice Preview

2. Printing Process Recording

3. Final Product Display

3D Scanning

In this practice, I used the SHINING 3D EinStar series handheld 3D scanner. This is a professional-grade structured light 3D scanning device that uses blue light structured light technology to quickly and accurately acquire three-dimensional data of objects. I used this device to 3D scan and print a YOKE joystick.

Operation Process

1. Software Preparation

Install the EXStar software. After installation, registration of a SHINING 3D account is required to activate the software features. The software interface clearly displays the complete workflow: device calibration, scanning acquisition, data post-processing, and dimensional measurement.

2. Device Connection and Calibration

After connecting the scanner to the computer, create a new project in the software and complete the device calibration process following the system guidance to ensure scanning accuracy.

3. Scanning Data Acquisition

Considering the smooth surface of the YOKE joystick with insufficient feature points, markers were attached at appropriate positions to assist with scan positioning. During scanning, maintain a distance of 30-50cm between the device and the target object while performing a 360-degree scan to ensure data completeness.

Post-Processing

After scanning, use the software's post-processing tools to optimize the model: Use the lasso tool to remove noise and excess data

After post-processing, complete the final model processing using the wrapping function After model processing is complete, click export data and select STL format

3D Printing

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All related files and resources can be found in my Google Drive: https://drive.google.com/drive/folders/1TQZx8IFBpXFXt3Hf0jB9IhDaVbPX59w0?usp=drive_link