01. Machine Characterization
Objective: Test the capabilities and limitations of the Prusa 3D printer, including overhang, bridging, surface quality, and dimensional accuracy using the 3D Benchy calibration model.
| Feature Tested | Result | Lesson Learned |
|---|---|---|
| Layer Height 0.1mm | Smooth, Detailed | High detail possible at cost of time. |
| Layer Height 0.2mm | Balanced | Optimal printing setting. |
| Layer Height 0.3mm | Visible Lines | Faster prints reduce detail. |
| Overhangs 60° | Good | Cooling system effective. |
| Bridges | Successful | Proper fan usage critical. |
02. Individual Design
Print-in-Place Rotating Gear Cube
My design features internal gears and enclosed cavities with moving parts printed in one piece, requiring no assembly.
Why it cannot be made subtractively:
- CNC tools cannot access internal trapped gears.
- Undercuts prevent machining from the inside.
- Subtractive methods would require multiple pieces and manual assembly.
PLA
Material Used
0.2mm
Layer Height
ZERO
Assembly Required
03. 3D Scanning
Photogrammetry Method
Object: Small Figurine / Tool
Captured 40+ photos around the object ensuring consistent lighting.
Processed photos into a dense 3D point cloud and mesh via mobile app.
Cleaned mesh artifacts and exported as an STL for digital archiving.
Reflections
Printer Testing
Layer height directly affects surface quality vs speed. First layer calibration is the most critical step for dimensional accuracy.
Design Strategy
Additive manufacturing allows for internal trapped parts. We must account for machine tolerance (clearance) to prevent moving parts from fusing.
Scanning Process
Lighting is the biggest variable; poor lighting creates mesh noise. Scan files are large and often require manual cleanup.
Prusa Analysis
Advantages
- Reliable automatic bed leveling
- Handles complex geometries easily
- Consistent layer adhesion
- Rapid prototyping capability
Limitations
- Visible layer lines (FDM nature)
- Limited PLA material strength
- Long print times for high detail