week 05

3D Scanning and Printing

Class with Neil

During the theory class of Week 05, we focused on the fundamentals of 3D printing and 3D scanning. We learned how additive manufacturing works, the different types of 3D printers, materials, and slicing settings such as layer height, infill, supports, and print speed. We also explored how 3D scanning captures real-world objects and converts them into digital models.

This helped me understand how digital designs can be transformed into physical prototypes through additive manufacturing, and how existing objects can be digitized for modification or reproduction. It was an important step toward developing accurate and functional parts for my final project.

Group Assignment:

° Test the design rules for your 3D printer(s)

° Document your work on the group work page and reflect on your individual page what you learned about characteristics of your printer(s)

individual Assignment:

° Design, document and 3D print an object (small, few cm3, limited by printer time) that could not be easily made subtractively

° 3D scan an object (and optionally print it)

Have you answered these questions?

I. Linked to the group assignment page. ✅
II. Explained what you learned from testing the 3D printers✅
III. Documented how you designed and 3D printed your object and explained why it could not be easily made subtractively ✅
IV. Documented how you scanned an object ✅
V. Included your original design files for 3D printing. ✅
VI. Included your hero shots✅

Group Assignment Sumary

Before starting my individual work, we organized a Zoom meeting to coordinate the group assignment. During the meeting, we discussed the type of 3D printers each of us had access to, as well as the printing parameters and slicer software we were going to use for our tests. This allowed us to compare configurations and better understand how different settings affect print quality and material behavior, helping me define the most suitable parameters for my own work.

Introduction:

This week focused on 3D printing and 3D scanning, exploring both the theoretical and practical aspects of these digital fabrication processes. The work started with reviewing the technical specifications of different 3D printers and 3D scanners, understanding their capabilities, limitations, materials, and working principles.

As part of the hands-on activities, I used a 3D scanner to digitize a physical object and then processed the resulting model to prepare it for fabrication. Finally, the scanned piece was replicated using 3D printing, allowing me to complete the full workflow from physical object to digital model and back to a physical replica. This process helped me better understand the relationship between scanning accuracy, model preparation, and print quality.

Individual Assignment

Design, document and 3D print an object

For this assignment, I designed a Knurled Twist container using Fusion 360, focusing on creating a functional object with a threaded twist mechanism and textured grip for better usability. The parametric tools allowed me to adjust dimensions and tolerances to ensure proper fitting between the container and the lid.

After completing the design, the model was exported as an STL file and prepared for 3D printing. The object was then successfully fabricated using a 3D printer, allowing me to test the fit, functionality, and print quality of the container. This process helped validate the design and understand how digital models translate into physical objects through additive manufacturing.

Step-by-Step Design of the Knurled Twist Container in Fusion 360

Design, document and 3D print an object

The images show the step-by-step modeling process of the knurled twist container in Fusion 360. First, the basic cylindrical shapes for the container body and lid were created. Then, the internal hollow and wall thickness were defined to ensure printability. After that, the threaded geometry was added to both parts to allow a twist-to-open mechanism, and the internal section view was used to verify clearances and proper fitting between the threads. This step-by-step approach helped validate tolerances, assembly, and functionality before exporting the final model for 3D printing.

Knurled Twist Container – 3D Design in Fusion 360

°The image shows the 3D design of a knurled twist container in Fusion 360, composed of two main parts: the outer container body and the threaded inner lid. The external surface features a knurled texture to improve grip, while the internal component includes a threaded mechanism that allows the container to open and close by twisting. The model is displayed in an exploded view to verify tolerances, alignment, and proper assembly before exporting the design for 3D printing.

Orca Slicer software download

°To perform 3D printing with the Prusa XL 3D printer using Orca Slicer , an open-source program, the first thing we need to do is download the program from the GitHub folder and then install it on our PC. Once the program is installed, its configuration is extremely easy. We choose the type of printer where we will do our 3D printing and the material we will use, and the next step is to import the .STL file.

Orca Slicer installation process

Microcontroller Selection: Raspberry pico 2040 Microcontroller

I follow the download process, accept the License Agreement, select the folder where I want to save the file, and choose the type of printer I will be using.

Setup Orca Slicer

1)Once the installation process is complete and the configuration window opens, proceed to click Get Started

2)During the initial setup of the 3D printer/scanner software, I was prompted to select the login region. From the available options (Asia-Pacific, China, Europe, North America, and Others)

3)In this step we proceed to select the model of our printer which in my case will be the Prusa XL

4)In this step we proceed to select the model of our printer which in my case will be the Prusa XL

5)At this step we will be able to visualize the work area and the parameters we will use to generate our slicers

Slicing the Model (G-code Generation)

In this part we proceed to import the 3D model that was previously created in Fusion360

⚙️ Open the File

Here I open the stl file into the slicer

⚙️ Slice the plate

Here I open the stl file into the slicer

Printer Setup

Once the G-code was generated, I prepared the 3D printer: Loaded the PLA+ filament. Pre-heated the nozzle and bed. Transferred the G-code via USB because the 3d printer Prusa has a own USB. Calibrated the bed automatically.

Click in Print

🧩 Printing and Monitoring

3D Scanning

To complete the installation of the EinScan HX software, I followed the standard setup process. After selecting the language, I clicked Next, then accepted the license agreement by selecting “I Agree”. After that, I continued by pressing Next twice to confirm the default installation settings and destination folder. Finally, I clicked Install to begin the installation process.

These steps allowed me to properly set up the 3D scanning software required for this week’s assignment on 3D printing and 3D scanning.

Launched EXScan

After completing the installation process, I launched the EXScan HX software to verify that everything was working correctly. The startup screen displayed the SHINING 3D branding, the software name EXScan HX, and version 1.4.1.3, confirming that the installation was successful. A loading bar appeared while the program initialized, indicating that the system was preparing the scanning environment.

Scan Calibration

In this stage, I performed the laser calibration process using the EinScan HX scanner. On the left side of the screen, the EXScan HX software shows the calibration interface, where different options such as Laser Calibration, White Balance, and Standard Calibration are available. The instructions guide the user to correctly position the calibration board and align the scanner vertically to ensure accurate results.

On the right side, I am holding the scanner and positioning it carefully in front of the calibration board. This step is essential to guarantee precise measurements and accurate 3D scanning results. Proper calibration ensures that the scanner captures geometry correctly, reducing errors and improving the overall quality of the digital model.

Open a New Project

Scan Mode_In Progress

Post processing

Export Mesh

Import .Stl in OrcaSlicer

Final Result

Files

Here are the project files available for download:

Stl Knurd_twisted: Download .stl
File in Fusion 360: Download .f3d
Stl Scan Model: Download .stl

What’s coming next week?

Next week will focus on Embedded Programming, an essential topic for adding intelligence and control to digital fabrication projects. We will work mainly with ESP32-S3 microcontrollers, exploring how to program them to interact with different electronic components.

The week will involve learning how to configure inputs and outputs, control sensors and actuators, and establish communication between hardware and software. By programming the ESP32-S3, we will better understand how embedded systems operate and how code directly influences the behavior of physical devices.

This topic will be especially important for future integration into my final project, as embedded programming will enable automation, data processing, and real-time interaction between components.