Week 5
AI prompt:
“Can you gnerate image when she started week 5? She learned 3d Scann and 3d printed proces, printed her coursemate 3d scanned model and designed with FreeCAD Eyes, and printed colourful Eyes.”
3D Scanning and Printing
This week was full of information for me. At the same time, it was very interesting, and now my main task is to properly document everything I have learned and tested. I hope everything will go smoothly 😊
First, we studied and understood the process of obtaining 3D models using a scanner, which will later be prepared for 3D printing. We used the CR-Scan Ferret (Pro).
We opened the CrealityScan scanning software on the computer and the phone, connected the scanner to the system via networking.
And I started scanning one of my groupmates. Here are the processing stages of the model.
Next, we performed filament tests for both PLA and PETG materials using three different printers in order to print our scanned models with maximum accuracy. After dividing the work, I conducted the tests using the Elegoo Neptune 4 Max (0.4 mm nozzle).
Test – Neptune 4 Max, Temperature Test, PLA
We were also introduced to a technique used to prepare filament before printing. This involves the Creality Filament Dryer Box, a device designed to remove moisture from 3D printing filament and maintain optimal conditions during storage and printing.
These dryers help improve print quality by preventing issues caused by moisture absorption, such as weak layer bonding, stringing, and poor adhesion.
First, I created a new project and selected the correct printer and filament profiles.
Then, I navigated to Calibration → Temperature and set the temperature range for the test print.
After placing the test model on the build plate, I clicked Slice. The slicer then switched to the Preview tab, showing a layer-by-layer visualization, estimated print time, as well as material usage and cost estimation.
Now the model is ready for printing. We can start the process by selecting Print → Upload and Print.
Since the printer was connected via a network, it was also possible to access additional information using its IP address. Once the connection was configured, I opened the Device tab at the top of the screen. This loaded the printer’s web interface inside OrcaSlicer, allowing me to monitor the printer status and view live camera footage.
Alternatively, the same interface can be accessed by entering the printer’s IP address directly in a web browser.
You can see the printed result in the Group Assignments link.
short conclusion
The temperature tower is a tall model printed in separate sections at different temperatures (in 5°C increments). In this example, it can be seen that PETG printed best in the temperature range of 220°C to 250°C.
Test – Neptune 4 Max, Max Volumetric Speed Test, PLA, PETG
Next, I will present the results of the Max Flowrate test. This test is performed to determine the safe operating limits and to prevent the slicer from exceeding the printer’s physical capability to melt and extrude filament.
By repeating the previously described steps — selecting the correct filament profile, choosing the appropriate printer profile, and connecting to the network using the correct IP address — I then navigated to the Calibration section and selected Max Flowrate. After the test model appeared on the build plate, it was ready for printing.
I performed the Max Flowrate test for both PLA and PETG filaments. The results are shown below.
You can see the printed result in the Group Assignments link.
short conclusion
Max Flowrate Test measures how much plastic the hotend can melt and extrude per second.
For PETG, the optimal printing range is 5–12 mm³/s, while for PLA, the optimal range is 5–10 mm³/s.
Test - Neptune 4 Max, MINI All In One test, PLA
We also performed the Mini All-in-One 3D Printer Test. This test refers to a compact 3D model designed to evaluate a printer’s performance across multiple parameters in a single, quick print.
The model was downloaded from an online source, and I would like to thank the designers for making it available.
You can see the printed result in the Group Assignments link.
short conclusion
- Overhangs: The printer handled slopes up to 60° well, with minimal support needed.
- Bridging: Horizontal spans were printed successfully without significant issues.
- Tolerances: Dimensional accuracy was within acceptable limits for most features.
- Stringing: Minimal stringing observed, indicating good retraction settings.
- Thin Walls: The printer struggled with very thin walls, showing some deformation.
Print Scanned Model
Finally, it was time to print my groupmate’s scanned model. I printed it again using the Elegoo Neptune 4 Max with PLA filament.
Since the chair was not properly captured during the scanning process, I removed the unnecessary parts. Instead of the original chair, I added support structures, which also created an interesting chair-like design. These supports can be removed later, allowing the model to be placed in any desired position 😊
Print Eyes for Final Project
In addition, I decided to print the eyes for my final project car-robot. The goal was to design eyes that would move when attached to the vehicle and set in motion. In other words, I created a model where a small inner sphere can move freely inside a larger, partially enclosed sphere.
Why this model cannot be produced using subtractive manufacturing
The 3D printed eyes contain curved surfaces and undercuts that would be difficult to reach using subtractive manufacturing tools such as CNC milling. Since CNC tools remove material from the outside, they cannot easily create internal shapes or recessed features. Additive manufacturing allows the object to be built layer by layer, making these geometries possible.
The model was designed in FreeCAD using a parametric approach. Here is the design process.
Since this was my first time printing such a model, I conducted several experiments to determine the required amount of support. Initially, I tried printing without supports, assuming the gap was small enough to separate the parts manually. After this attempt failed, I printed the model again with supports.
After these experiments, my instructor showed me how to achieve multicolor results using a single-color printer. This process was very interesting, and I am happy to have learned this new technique. Thank you, Areg jan!
Below is the process showing how I add a new filament and pause the print at a specific layer to change the filament color.
First, I imported the eye model that I created in FreeCAD into the OrcaSlicer environment.
Using the Support Painting tool, I set the object to the bottom view and adjusted the direction to see the inner part of the model, so I could place supports under the internal object.
Then, in the Support settings, I enabled supports and selected the type as Normal (Manual).
After slicing, I moved through the layers to check and make sure the supports were placed correctly and in the right positions(Support interface).
Next, I added a new filament color, assigned it to the required part of the model, and used it to set a pause for filament change during the print.
This week, I focused on 3D scanning, model processing, and 3D printing calibration. I prepared models in OrcaSlicer, and tested different filaments (PLA, PETG) and printers.
I performed calibration tests including temperature, Max Flowrate, and the Mini All-in-One test, experimented with supports and multicolor prints, and designed parametric models in FreeCAD, such as movable eyes for my final project robot-car.
Week 5 strengthened my understanding of the full digital fabrication workflow and gave me confidence to apply these skills in future projects.
Individual assignment
AI prompt:
“AND another image when she finished week 5.”