Week 05 | 3D Scanning and Printing
Week Description
This week focused on understanding additive manufacturing and digital capture technologies through hands-on experimentation. The process involved designing and fabricating 3D printed components, exploring material behavior, and evaluating how post-processing techniques can enhance form and functionality.
By integrating digital modeling, slicing strategies, and thermal shaping, the work explored how 3D printing can enable organic geometries and expressive forms. Additionally, this week introduces 3D scanning as a method for digitizing physical objects and expanding the workflow between physical and digital environments.
3D Printing Process
1. Design Objective
The goal was to develop modular 3D-printed petals that could be assembled onto a laser-cut base, allowing the exploration of formal variations and visual behavior by simulating opening and closing movements.
The design aimed to take advantage of additive manufacturing to create organic geometries that would be difficult to produce using subtractive methods.
2. 3D Modeling
The petals were modeled in Rhinoceros, using smooth surfaces and controlled organic transitions.
Design considerations:
- adequate thickness for printing and thermal shaping
- controlled curvature for post-forming
- flat base for proper bed adhesion
- geometric integration with the laser-cut base
Each piece included an engraved number on its base to guide correct assembly onto the laser-cut structure.
After modeling the individual petal, several tests were performed to replicate and arrange the element radially.
3. File Preparation and Slicing
The model was exported in STL format and prepared in Bambu Studio, the slicing software used for the printer.
Preparation criteria:
- optimized orientation for stability
- supports were not required due to the designed overhang angles
- layer height balanced detail and printing time
- scale and model integrity verification
4. Printing Process
The parts were printed using a Bambu Lab A1, a high-precision FDM printer.
Printer specifications:
- Technology: FDM (Fused Deposition Modeling)
- Build volume: 256 × 256 × 256 mm
- Extrusion system: direct drive
- Bed leveling: automatic
- Maximum speed: up to 500 mm/s
- Material compatibility: PLA, PETG, TPU and more
- Material used:Purple iridescent PLA
During printing, the first layers were monitored to ensure proper adhesion and extrusion stability. The parts printed successfully without deformation or defects.
5. Thermal Shaping and Formal Exploration
After printing, the petals were manually heat-formed to achieve more organic curvature.
This process allowed:
- reducing the perceived rigidity of the PLA
- exploring different opening angles
- simulating how the petals might open or close
- evaluating the expressive and visual behavior of the system
This stage was essential to approximate the dynamic character intended for the piece.
6. Assembly and Evaluation
The pieces were fixed using resin adhesive, ensuring structural stability. The engraved numbering system facilitated correct positioning on the laser-cut base.
Evaluation criteria:
- overall formal coherence
- structural stability
- surface quality
- expressive potential of the system
3D Scanning
To explore object digitization, a damaged vintage television was scanned using the 3D Scanner App on a mobile device.
Capture Process
The scan was performed by slowly moving around the object while maintaining a constant distance and steady motion. The app uses photogrammetry and depth capture to reconstruct geometry.
Methods explored:
- Point cloud capture to record spatial depth data.
- Mesh reconstruction to generate a triangulated surface and texture.
Key considerations during scanning:
- Capture multiple angles around the object.
- Maintain consistent lighting and avoid harsh shadows.
- Avoid rapid movements to reduce tracking errors.
- Ensure overlap between passes for better reconstruction.
Scan Results
Mesh Export
After processing, the application generated a triangulated mesh model. The model was exported in OBJ format, including geometry and texture data.
Mesh Cleaning in Rhino
The OBJ file was imported into Rhinoceros 8 for post-processing. The cleaning process included:
- Removing floating mesh fragments and noise.
- Deleting unwanted geometry from the surrounding environment.
- Closing visible holes where possible.
- Simplifying irregular areas to improve readability.
- Improving the overall mesh structure for visualization.
Evaluation
The scan captured the overall proportions and visual character of the object, but the result was not fully accurate due to limited resolution. Several issues were observed, including holes, missing surfaces, and noise in complex or reflective areas. Because of this, the model is more useful as a visual and dimensional reference rather than a fabrication-ready asset.
Learning Outcomes
- Identify the advantages and limitations of 3D printing
- Apply design methods and production processes to show understanding of 3D printing
- Demonstrate how scanning technology can be used to digitize object(s)