3D Scanning & Printing

Introduction

In Week 05, I explored additive manufacturing using 3D printing and 3D scanning. The goal was to understand the design rules of our 3D printer and create an object that could not be easily made subtractively.

Objectives

Group Assignment

• Test the design rules of our 3D printer
• Measure tolerances, overhangs, bridging and clearances
• Document results on the group page

Individual Assignment

• Design and 3D print an object that cannot be easily made subtractively
• 3D scan an object
• Document the full workflow

Tools & Technologies

1. Autodesk Fusion

Fusion is a 3D CAD software used for modeling and engineering design. I used it to design my finger rings.

Download Fusion: Download Autodesk Fusion

2. 3D Printer

We used our lab FDM 3D printer to print PLA material.

3. 3D Scanner

We used a 3D scanning device to digitize a physical object.

Process & Workflow

Group Assignment

Testing Printer Design Rules

We printed a test file to check:

• Overhang angles
• Bridging distance
• Clearance between parts
• Minimum wall thickness

Observing Results

We measured which overhang angle printed successfully without support and identified the minimum clearance our printer can handle.

Reflection

I learned that each printer has limitations. Understanding these characteristics helps to design printable models.

Individual Assignment

Step 1: Download and Install Fusion

Downloading this software wasn't an easy process. I tried different browsers many times and after some time I managed to download a free 30 days trial, but I met with different challenges during the process. I downloaded this software three times and installed it three times due to the challenges faced during design.

I asked one of my architect friends who has a student license to Autodesk (Alexandre) to help me get access because I thought it might have different features not found in the free trial. However, the issue wasn't the free trial itself, but rather not closely following the tutorial video I got the design idea from. The fidget ring design reference can be found here: 3D design YouTube video fidget ring.

After signing in with student access, I downloaded Autodesk Fusion from Autodesk Fusion Download and installed it on my computer.

Step 2: Designing the Finger Rings

I created a new project and named it "COMPLETE Ring" after understanding how to design subtractively/additively from the tutorial. I designed fidget rings with curved geometry and inner patterns containing internal curves and decorative cutouts.

• First, I created an internal circle with a 19 mm diameter, added a second one with 31 mm, followed by 32 mm, 42 mm, 43 mm, 54 mm, 55 mm, and the last one at 66 mm which has curved hollow sections.


• Added a center rectangle with a width of 19 mm and a length of 66 mm.


• Switched from isometric view to top view to draw another rectangle and circle structure.


• Created the profile by selecting the circle parts within the created rectangle, establishing the path to complete the section and sketch.


• Utilized the Sweep feature to build the 3D geometry from the profile and path.


• Here is the final completed design ready for 3D printing:

Step 3: Export the Design File

I exported my design files into various functional formats, including .dxf, .dwg, and .stl.

My ring design includes:

• Internal curved hollow sections
• Undercuts
• Complex inner patterns

These features are difficult to achieve using subtractive machinery (such as CNC milling) because cutting tools cannot reach inside enclosed internal areas.

Step 4: 3D Printing

I printed the ring using PLA material on our lab FDM 3D printer.

Step 5: Hero Shot

Final printed ring production output.

3D Scanning

Step 1: Scanning an Object

I scanned a physical object using a 3D scanner. The scanner captured surface geometry and created a mesh file.

Step 2: Viewing the Scan

The scan result produced a 3D mesh model. I inspected the model to verify captured details.

Challenges & Problem Solving

• Using Autodesk Fusion for the first time.
• Understanding printer limitations.
• Designing proper clearances.
• Avoiding walls that are too thin.
• Capturing clean 3D scan data.

What I Learned

• Advantages of additive manufacturing over traditional techniques.
• Key limitations and physical constraints of FDM 3D printers.
• Fundamental differences between additive and subtractive manufacturing.
• How 3D scanning technology converts physical objects into digital mesh models.

Downloads & References