Week 5 — 3D Scanning and Printing¶

Group Assignment

The image of my individual work is presented below.

individual work

Assignment¶

This week focused on studying 3D printing and scanning processes, with particular attention to machine limitations, parameter calibration, and material behavior.

The main objective was to analyze machine performance and establish practical design rules ensuring reliable and high-quality fabrication.

Design Goals¶

Understand limitations of FDM printing
Study surface quality and layer adhesion
Analyze overhang performance
Evaluate volumetric extrusion limits
Define optimal printing parameters

Group Assignment — Machine Testing¶

During the group assignment, the available laboratory printers were analyzed to understand their real-world performance and technical constraints.

Testing included:

Surface quality evaluation
Layer adhesion analysis
Overhang capability testing
Dimensional stability assessment
Material behaviour comparison

Machine Analysis¶

Test prints were conducted using two different materials: PLA and PETG.

I worked with PETG, while Ani used PLA. This allowed comparison of both printer performance and material behavior under identical conditions.

Using identical test files and controlled slicing parameters ensured a fair comparison.

Evaluation Focus¶

Thermal stability
Layer adhesion
Extrusion consistency
Surface quality
Print speed influence

Printing Experiments¶

Calibration models
Overhang testing
Speed and quality comparison
Structural strength evaluation

Overhang Test Model

Temperature Calibration

Slicing Workflow — Orca Slicer Selection¶

During the project, different slicing software options were available such as PrusaSlicer, but Orca Slicer was selected.

Orca Slicer allows precise control of:

Layer height
Infill
Print speed
Temperature
Advanced fabrication parameters

Its visual feedback and fast parameter iteration made it ideal for workflow optimization.

Temperature Tower Calibration¶

Temperature Tower Setup Before the main testing phase, calibration was performed using PETG filament.

Calibration → Temperature in Orca Slicer.

Settings:

Start temperature: 250°C
End temperature: 230°C
Step: 5°C

Each tower section printed at a different temperature.

Temperature Tower

Temperature Tower Results¶

Temperature Tower Results

Each section ranged from 230°C–250°C.

Best quality observed around:

👉 240°C

Lower temps:

slight under-extrusion
weaker adhesion

Higher temps:

overheating
stringing

Maximum Flow Rate Calibration¶

Next step was evaluating volumetric flow limit using white PETG.

Max Flow Setup

The slicer gradually increased extrusion demand.

Final slicer setting adjusted accordingly.

Final Flow Setting

Observed parameters¶

Surface consistency
Layer adhesion
Under-extrusion signs
Line gaps
Structural deformation

Observations¶

Quality degradation began around line 11.

Max Flow Failure

Calculation:

Flow = 5 + (0.5 × 11)

👉 10.5 mm³/s

Flow Calculation

Conclusion¶

Maximum stable flow rate:

👉 10.5 mm³/s

Higher values reduced quality.

Machines Used¶

Prusa MK4S¶

Build volume 250×210×210 mm
Stable and reliable

Bambu Lab X1 Carbon¶

High speed
AMS system

Technical Comparison¶

Specification	Prusa MK4S	Bambu Lab X1 Carbon
Technology	Cartesian	CoreXY
Volume	250×210×220	256×256×256
Nozzle	0.4	0.4
Max Temp	290°C	300°C

Engineering Observations¶

Speed impacts surface quality
Overhang requires supports
Calibration improves reliability

Reflection¶

Improved understanding of:

Additive manufacturing limits
Calibration workflow
Fabrication-driven design

Week X — Computer-Aided Design (FreeCAD)¶

Individual Assignment¶

Design and print an object not manufacturable subtractively.

Workflow:

CAD
STL
Slicer
Print
Documentation

Design Workflow¶

Sketch → Pad → Pocket → Opening → Mechanism → Final

Base Sketch¶

Base Sketch

Pad¶

Pad

Pocket¶

Pocket

Opening¶

Opening

Mechanism¶

Mechanism

Slicer Preparation¶

Slicer Setup

Printed Result¶

Print1

Print2

scan and print¶¶

As part of the individual project, a 3D scan was also performed using KIRI Engine. The resulting file was then processed in Blender, where the model was cleaned and necessary adjustments were made. After that, the model was imported into a slicing program, the appropriate printing parameters were selected, and the file was prepared and sent for 3D printing.

Print2 Print2 Print2

Engineering Considerations¶

Parametric stability
Wall thickness control
Fabrication awareness

Problems & Solutions¶

Issue: feature selection
Solution: hierarchy control

Issue: multi-selection
Solution: CTRL + click

Fabrication Strategy¶

FDM optimized
Minimal supports

Reflection¶

Parametric thinking
Additive vs subtractive
Fabrication-aware workflow