Week 5: 3D Scanning and Printing

1. Carmen

3D Printer
The Artillery Genius Pro.
This machine has a working area of 220 mm × 220 mm × 250 mm, a printing speed of 60 mm/s to 150 mm/s, a 0.4 mm extruder, a maximum consumption of 10 V and 500 W (with the heated bed turned on), and an XYZ printing resolution of 0.05 mm, 0.05 mm, and 0.1 mm.
The slicing program used was Ultimaker Cura version 5.5.0.

Common materials you can use
✔️ PLA (polylactic acid) – easy to print, ideal for beginners.
✔️ ABS – harder and stronger, but it can warp if temperature is not controlled.
✔️ PETG / flexible PET – a good combination of strength and flexibility.
✔️ TPU / flexible filament – the direct extruder makes printing flexibles easier.
✔️ “Wood” filaments (PLA with wood particles) – decorative effect.
✔️ PVA and HIPS – soluble or special support filaments.

To perform a 3D print with the Artillery Genius Pro using Ultimaker Cura, you must first download and install the program from its official website, ensuring you choose the version compatible with your operating system. Once installed, open the software and add the printer using “Add printer”, configuring it as a custom printer (Custom FFF Printer) and entering its working dimensions (220 × 220 × 250 mm), 0.4 mm nozzle, and 1.75 mm filament. Before starting any print, bed leveling is essential: preheat the printer, place a sheet of paper between the nozzle and the print surface, and adjust the screws at the four corners until you feel slight friction on the paper.

Then, import the STL file into the program, verify the model is correctly placed on the build plate, and make any necessary adjustments such as scale, rotation, or centering. Next, configure printing parameters according to the material used; for example, for PLA it is recommended: nozzle temperature 200 °C, bed temperature 55–60 °C, layer height 0.2 mm, and a slightly higher initial layer to improve adhesion. Once parameters are set, run the slicing process (Slice) to generate a G-code file. Finally, save it to a USB drive, insert it into the printer, select the file from the touchscreen, and start the print—closely supervising the first layer to ensure good adhesion and final quality.

Test without supports
On the Artillery Genius Pro, tests without supports allow you to verify correct calibration and performance when printing steep angles. The machine completes most models without support structures, demonstrating good thermal stability and extruder control.

TEST WITH SUPPORTS
On the Artillery Genius Pro, the support test verified proper performance on models with overhangs and complex geometry. By enabling support generation in Ultimaker Cura, better stability during printing and a more precise finish were achieved in critical zones compared to the no-support test. Supports were generated correctly and could be removed relatively easily at the end, showing correct configuration and solid overall performance.

In the surface finish test, the Artillery Genius Pro printed the model as designed; however, a slight filament excess was observed, creating strings and a less clean finish compared to the reference piece. To optimize results, the printer was calibrated using filament manufacturer recommended temperatures, ensuring adequate parameters and reducing potential failures. In later tests, progressive improvements in surface quality were observed thanks to better tuning of retraction, flow, and temperature, although there is still room for optimization to reach a finer and more precise finish.

The 3D printing experience allowed me to understand that the technology depends not only on the machine, but on the knowledge and precision used to configure and calibrate it. Working with the Artillery Genius Pro taught me that small adjustments in temperature, leveling, or retraction can make a big difference in the final result. Each test, even those with imperfections, became an opportunity for learning and continuous improvement. In addition, using tools like Ultimaker Cura helped me better understand the digital manufacturing process, strengthening my skills in design and prototyping. Ultimately, 3D printing not only accelerates project development, but also encourages experimentation, patience, and constant optimization.

2. David

PRINTER: CREALITY K1 SE
Print volume: 220 × 220 × 250 mm
Maximum speed: Up to 600 mm/s (with acceleration up to 20,000 mm/s²).
Extruder: Dual Gear Direct Drive (direct drive with double gear for firm filament grip and stable feeding).
Standard nozzle diameter: 0.4 mm (can be changed if needed).

Key features
● Tri-metal nozzle (copper with steel tip and titanium heatbreak), wear resistant, blocks heat-creep and is easy to change.
● CoreXY system, providing higher speed and movement precision with less vibration.
● Hands-free auto leveling to adjust the bed easily.
● Flexible PEI-coated plate for easy part removal.

Slicer: Creality Print

Common materials you can use
PLA: the easiest filament to print, ideal for decorative parts and prototypes with low heat requirements.
Hyper PLA: a PLA version optimized for higher speed printing without losing quality.
PETG: more resistant and flexible than PLA, ideal for mechanical parts or outdoor use.
TPU: flexible and elastic material, perfect for covers, seals, or parts that need to bend.

The main slicer for the K1 SE is Creality Print. The program is optimized for wireless connection because it is from the same manufacturer. It also includes three default print options for first-time users. It has more advanced parameter options as well, but it still maintains a friendly interface.

Tests performed on the K1 SE

In the first test, we printed without supports to see the finish of the part without the support option. The program shows a warning message before slicing.

In the second test, we used automatic supports, “normal” type, following the same default parameters as before.

Without supports, it only loses shape on the bottom part.

With tree supports, a uniform finish is noticeable, and when removing them, small tree contact points remain.

With normal supports, this test shows a better finish because supports are removed linearly, blending with the straight shape.

Clearance test

In the “clearance” test, we used automatic normal supports and a layer height of 0.20. After printing, we realized this support type is not highly recommended because it adhered to the bottom base, making cleaning difficult. The result shows the best clearances with these parameters start from 1 down to 0.4, because the last ones are very difficult to move or rotate.

3. Esteban

3D Printer — Bambu Lab A1 / A1 Combo
Print volume: 256 mm × 256 mm × 256 mm.
Maximum speed: Up to 500 mm/s (with acceleration up to 10,000 mm/s²).
Extruder: 0.4 mm stainless steel nozzle (Quick Swap system).
Key features: full auto leveling, active flow compensation, and vibration calibration. In the Combo version, includes AMS Lite for multicolor printing (up to 4 filaments).
Slicer: Bambu Studio.

Common materials you can use
✔️ PLA (Polylactic Acid): ideal for fast printing with high aesthetic quality.
✔️ PETG: greater mechanical and thermal resistance, easy to print on the A1.
✔️ TPU (Flexible): excellent performance thanks to the A1 direct extruder.
✔️ PVA/HIPS: soluble supports (ideally using AMS Lite for interfaces).

To perform a 3D print with the Bambu Lab A1 using Bambu Studio, the first step is to download and install the software from the official Bambu Lab site. Once inside, select the printer (A1 or A1 Combo) and nozzle type (0.4 mm) from the device list, or sync automatically if it is connected to the network. Unlike older printers, manual paper leveling is not needed. Before starting, the A1 runs an automatic calibration that measures bed leveling, motor resonance, and extruder flow pressure, ensuring a perfect first layer without human intervention. If using the Combo, the AMS Lite slots are also configured with the corresponding colors.

Next, we import the test files—in this case anisotropy.stl, finish.stl and angle.stl—into the Bambu Studio workspace. We check orientation to optimize strength and reduce supports, and apply scaling or rotation if needed. Parameters are configured according to the material (e.g., for Bambu Basic PLA: nozzle at 220 °C and bed at 65 °C). Once defined, we click “Slice Plate” to generate the G-code. Finally, we send the file via Wi-Fi directly to the printer or save it to the SD card. From the A1 touchscreen (or Bambu Handy app), the print is started while trusting the sensors to monitor flow quality and adhesion.

Face quality test (anisotropy.stl): This model is an “L”-shaped part placed vertically. Its main purpose is to evaluate the surface quality of vertical faces. When printing on the Bambu Lab A1, it verified Z-axis stability and extrusion consistency, producing flat and uniform faces.

Overhang test (angle.stl): This test verifies layer cooling fan performance. The machine prints steep angles without supports thanks to excellent cooling and stability, maintaining dimensional fidelity even on aggressive inclines.
● Results: the Bambu Lab A1 demonstrated excellent cooling, printing without supports and without problems up to 30 degrees of inclination.
● Machine limit: from 20°, 10° and 0°, overhang becomes evident. At these more extreme angles, layers lose ideal alignment and loose or drooping filament appears, indicating the point where supports become mandatory.

Finish test (finish.stl): This model includes two spheres (one extruded and one subtracted). For this test, the adaptive layer height tool in Bambu Studio was used in two versions:
● Option A (Moderate variation): base layer height 0.28 mm for most of the print to save time; near the top curves, layer height automatically reduced to 0.12 mm to improve resolution.
● Option B (High resolution): more aggressive adaptive setup; straight zones at 0.28 mm, but curved/detailed zones reduced to 0.08 mm. This removes most “stair-stepping” and produces a much smoother surface finish.

4. Jianfranco

3D Printer — Prusa XL
Print volume: 360 × 360 × 360 mm
Maximum speed: Up to 250 mm/s (maximum acceleration approx. 5000 mm/s²).
Extruder: 0.4 mm stainless steel nozzle (Quick Swap system).
Key features: large build volume, high precision CoreXY, and (5-toolhead version) five independent toolheads for multi-material/multi-color printing with automatic tool changing.
Slicer: PrusaSlicer, OrcaSlicer

Common materials you can use
✔️ PLA: ideal for fast printing with high aesthetic quality.
✔️ PETG: greater mechanical and thermal resistance, easy to print.
✔️ TPU (Flexible): excellent performance thanks to the direct extruder.
✔️ PVA/HIPS: soluble supports.

To print with the Prusa XL using Orca Slicer (open-source), first download the program from GitHub and install it. Configuration is very easy: choose the printer type and the material, then import the STL file. Unlike single extruder printers, this printer does not require purging other than the purge tower; with 5 toolheads, it can print up to 5 different colors or materials.

To import an STL file in OrcaSlicer, open the software and ensure the correct printer and filament profiles are selected. Then click “Open File” or drag and drop the STL into the workspace. Once the model appears on the virtual build plate, adjust position, scale, or orientation if needed. After verifying placement, click “Slice” to generate toolpaths, preview layers, and export the G-code for printing.

Next, we imported test files—in this case retraction test.stl and temperature.stl—onto the Prusa XL build plate. We verified orientation to optimize strength and reduce supports, and adjusted scale/rotation if necessary. Parameters were set according to the material (e.g., for Bambu Basic PLA: nozzle at 220°C and bed at 65°C). Once defined, we clicked “Slice” to generate the G-code. Finally, we sent the file via USB, since this printer uses its own USB drive. From the touchscreen, we started the print, trusting the printer’s sensors to monitor flow and adhesion.

Once the STL files were printed, we reviewed results to identify parameters we could change for this material, such as overhangs, temperature, and necessary tolerances to achieve optimal print outcomes.

5. Cindy

For print tests, the Bestgee T300S pro printer was used with the following characteristics:

Printer configuration (With supports)

For the first tests, supports were enabled with these parameters:
● Profile: 0.2 mm
● Infill: 20%
● Support: Enabled
● Print temperature: 215 °C
● Bed adhesion: Brim
● Printer: Ender 3
Supports were necessary in designs with strong overhangs and free spaces because, without an auxiliary structure, melted material tends to sag toward the nearest surface, affecting accuracy and finish.

● We entered the Ultimaker Cura page and downloaded the software.
● We clicked to download Ultimaker Cura.

● We installed Ultimaker Cura and chose the printer type: CUSTOM FFF PRINTER.
● We located the repository to download the files in .stl format: https://academy.cba.mit.edu/classes/scanning_printing/index.html
● We uploaded the downloaded file.
● We pressed flatten so the object sits flat on the bed.
● We selected the material: PLA.
● We verified the scale: Z axis 2 cm, Y axis 1.5 cm, Z axis 2 cm.
● We enabled supports.
● We clicked slice and saw the print time: 16 min, then saved the file as gcode.
● We loaded the gcode to the 3D printer.
● We repeated the same process with the other files.

● When printing, keep in mind: heat the bed to around 60 °C.
● Heat the extruder to around 200 °C.
● Level the extruder 1 mm from the bed.
● For tall/raised shapes (e.g., a chess knight), enable supports in Cura.
● Verify you have enough PLA before printing; check in Cura how much filament will be used.

6. Rocio

The 3D printer used this week was a Bambu Lab A1, designed for fast and precise prototyping. One of its main advantages is the automatic calibration system, which includes bed leveling, vibration compensation, and material flow control.

The software used to prepare print files was Bambu Studio, the official Bambu Lab slicer. This program converts 3D models into instructions the printer can interpret, generating the necessary G-code. In Bambu Studio, I configured key parameters such as layer height, print speed, extruder and bed temperature, infill type, and supports. I also used the preview to verify toolpaths, estimated times, and potential errors before printing.

After importing the test files into the workspace, I configured print parameters according to the material used. In this case, for eSUN PLA I set the nozzle temperature to 220 °C and the heated bed to 65 °C. Once defined, I used “Slice Plate” to generate the G-code and check the print preview.

Overhang test

The printed parts showed very good overall quality. Supports were generated correctly and were easy to remove, leaving only small marks on contact surfaces. Overhang areas were printed with good definition and bridges remained stable without excessive drooping. Layer adhesion was uniform and dimensional accuracy was acceptable for prototyping.

In this test, I learned that correct support configuration is essential to avoid deformation in complex geometries. I also confirmed that the Bambu Lab A1 handles supported structures very well, producing clean surfaces and reliable results.

Angle test

To evaluate the overhang capability of the Bambu Lab A1, I printed an angle test model with different inclinations, from 90° to 10°. This test helps determine the maximum angle that can be printed without supports while maintaining good surface quality.

Results showed the printer produced very clean surfaces down to approximately 20° without needing supports. At angles below 20°, small defects began to appear, such as rough surfaces and slight sagging, indicating the limitations of support-free printing.

This test helped me understand the importance of part orientation during slicing. Knowing the printer performs well down to about 20° helps me design parts that minimize supports, improving surface finish and reducing material waste.

Tolerance test — clearance characterization

To evaluate dimensional precision, I printed a tolerance model with different clearances from 1.0 mm to 0.1 mm. This helps determine the minimum separation needed between moving or interlocking parts so they work without binding.

Results showed pieces with clearances of 0.2 mm or more moved freely, while smaller clearances began to stick or fuse. This indicates that, for my printer settings and material, a clearance of around 0.2 mm is recommended for moving parts or assemblies.

This test helped me understand how printer calibration, material shrinkage, and slicing parameters affect dimensional accuracy. Knowing the correct tolerance allows me to design functional parts that fit properly without sanding or heavy post-processing.

Tolerance (press-fit) test

To evaluate dimensional accuracy, I performed a press-fit tolerance test using a model with numbered slots of different thicknesses. This type of test identifies the minimum clearance needed for a correct fit between 3D printed parts. It was observed that when pressing pieces into the slots, some broke due to insufficient tolerance, while others resisted without damage. The pieces that did not break indicate the correct tolerance for a functional fit in this material and print configuration.

This result demonstrates the importance of considering clearance in 3D print designs, because small variations in tenths of a millimeter can determine whether an assembly works or fails.

Infill test

To evaluate how infill percentage influences strength and finish, tests were run using different infill configurations in Bambu Studio. Three samples were printed with 15%, 50%, and 100% infill, keeping other parameters constant (temperature, speed, and layer height).

During configuration, a grid infill pattern was selected to clearly observe internal structure. At 15%, the part was lightweight with lower material usage but reduced rigidity. At 50%, the part had a good balance between strength and weight with a stable internal structure. At 100%, the part was fully solid with the highest rigidity, but also increased print time and material consumption.

Comparison Between Printers (Summary)

Final Reflection (Group)