Week 05: 3D Scanning and Printing¶
In Week 05 started with intensive describtion from Proff. Neil and the Senior Scientist on the sector. I explored the complete workflow of 3D scanning and additive manufacturing, learning how to capture real-world objects digitally and reproduce them through 3D printing and I also studied key additive manufacturing concepts such as layer-by-layer fabrication, infill structures, supports, tolerances, and material behavior, print some design/models that cannot be made with the subtractive methods.
Reference class page:
Fab Academy – Embedded Programming
My SSTM
Start with Local Sessions¶
During Week 05, I learned the fundamentals of 3D printting, scanning and how software working for 3D printing. We introduced to tools, methods,must to do and documentation status update and followup as well how to access the assesment platform. Then additive method by Rico.
## A. Group assignment (Test the Design Rules for Our 3D Printer(s))
Group Assignment: Test the Design Rules for Our 3D Printer(s) We focused on understanding and testing the design rules of our 3D printer(s) to determine their real fabrication limits. Design rules define the minimum and maximum capabilities of a printer, MakerBot sketch is the one I used for this assignmnet and will work on other too:
1. Describe the 3D Printer (3D Printer: MakerBot Sketch)¶
| Parameter | Specification |
|---|---|
| Make & Model | MakerBot Sketch |
| Technology | FDM (Fused Deposition Modeling) |
| Motion System Type | Cartesian motion system |
| Build Volume | 220 × 200 × 250 mm |
| Nozzle Type | Brass nozzle |
| Nozzle Diameter | 0.4 mm |
| Max Nozzle Temperature | ~240°C |
| Max Bed Temperature | Non-heated bed (PLA optimized platform) |
| Compatible Material | PLA |
| Control Software | MakerBot Print |
| Control Electronics | Proprietary MakerBot control board |
| File Format | STL / MakerBot format |
| Enclosure | Fully enclosed build chamber |
| Build Plate | Removable flexible build plate |
2. Printer Characterization / Test Object¶
Test Model Used:
Complete 3D Printer Test – All-in-One Stress Test
https://www.printables.com/model/112181-complete-3d-printer-test-all-in-one-stress-test-be
3. Parameters Tested¶
| Test Feature | Purpose | Observation |
|---|---|---|
| Overhang Test | Determine maximum printable angle without supports | Evaluated angle performance (e.g., 45°, 60°, 70°) |
| Bridging Test | Test ability to print across gaps | Measured clean span distance |
| Dimensional Precision | Compare designed vs printed dimensions | Checked tolerance accuracy |
| Clearance Test | Measure minimum moving gap between parts | Identified functional tolerance (e.g., 0.2–0.4 mm) |
| Fine Detail | Test smallest printable features | Checked text and thin walls |
| Surface Quality | Evaluate layer consistency | Observed smoothness and layer lines |
| Artifacts | Identify ringing, ghosting, stringing | Inspected print defects |
| Wall Thickness | Determine minimum stable wall size | Measured thin wall performance |
4. Design Rules Identified (fromt test model)¶
- Minimum wall thickness: ~0.8 mm recommended
- Clearance tolerance: ~0.3 mm for moving parts
- Maximum overhang without support: ~60°
- Reliable bridging distance: ~15–20 mm
- Optimal layer height: 0.3 mm
5. My observation an dConclusion¶
The MakerBot Sketch performs reliably for PLA prototyping.
Best results are achieved when designs follow tested tolerances and overhang limits identified during characterization.
As a team, we designed and printed a test model by downloading from
https://www.printables.com/model/112181-complete-3d-printer-test-all-in-one-stress-test-be
(without any change to the test model dowloaded) that included different geometric features to evaluate these parameters with the help of our instructor Rico.
Downloading the model from the link attributed above and open in the MakerBot 3D printer app¶
Import the test model from the saved file and open in the MakerBot 3D printer app¶
Correct the setting before expeorting as the testing parameter requirement and correct in the MakerBot 3D printer app setting option¶
MakerBot Sketch, a desktop FDM (Fused Deposition Modeling) machine designed for reliable and user-friendly 3D printing. It uses PLA filament and features a fully enclosed build chamber, which improves print safety and temperature stability. In our lab, we use this printer to test design rules, produce prototypes, and validate 3D models before final production. For more machines in our center This testing model is uploaded befor the currently used MakerBot 3D printers and all the parameters might be modified or changed.*
Slice/set as needed and export to the MakerBot 3D printer (Sketch mini, in my case) to print¶
Printing¶
1. Sending to printer¶
After sliced the test model setting all the machenes starting procedure and sent to the 3D printer with flash disk and start to printing
2. start printing¶
Check the printr start correctly to extrude the filamant
Check the printing progress
3. Final printed test model¶
Evaluate the models for the expected result, my final print tested mode had has the smalldeficit at the buttom face of the model > 80°, other paramethers looks better.
B. Individual assignment¶
Design, Document, and 3D Print an Object That Could Not Be Made Subtractively¶
Learning Outcomes¶
- Understanding of Design for Additive Manufacturing (DfAM)
- Designing internal cavities
- Managing overhangs and supports
- Tolerance and wall thickness control
- Optimizing print settings
Objective¶
Design and fabricate a small 3D object (few cm³) that cannot be produced using subtractive manufacturing (e.g., CNC milling).
Why It Cannot Be Made Subtractively¶
- Includes internal enclosed geometry
- Contains hidden cavities / complex inner structures
- No direct tool access for milling tools
- Demonstrates advantages of additive manufacturing (DfAM)
Step-by-Step Process¶
1. Concept & Sketch and tools to use¶
-
Defined design idea and methods
-
Sketched internal and external geometry
- Considered printer time limitation
2. CAD Modeling¶
- Model an object in CAD software using free model and modefied it in tinkersCad https://www.tinkercad.com/
- Designed internal cavities and complex features that cannot be made with substactive methods
- Checked wall thickness and clearances and neccessary printing steps
Source: https://www.thingiverse.com/thing:7287234
- Modification to additive only methods for manufacturing it
3. Export File¶
- Exported model as .STL
- Verified mesh quality
4. Slicing¶
- Imported STL into slicer
- Adjusted:
- Layer height
- Infill percentage
- Print orientation
- Support settings (if needed)
- Applied design rules identified in group assignment
5. 3D Printing (on progress)¶
- Printed using MakerBot Sketch
- Ensured print time within allowed limit
- Removed supports and cleaned model
3D Scan an Object (Optional: Print It)¶
Learning Outcomes¶
- Proper scanning techniques
- Mesh editing and repair
- Difference between CAD model and scanned mesh
- Reverse engineering basics
Digitize a physical object using 3D scanning and prepare it for fabrication. The week focused on understanding different 3D scanning methods, processing and cleaning scanned models, optimizing mesh files, and preparing designs for fabrication using slicing software.
Scanning my PC mouse¶
Step-by-Step Process¶
1. Scanning¶
- Positioned object properly
- Captured multiple angles
- Ensured full surface coverage
2. Mesh Cleaning¶
- Removed noise
- Filled holes
- Smoothed rough surfaces
- Repaired mesh errors
3. Export¶
- Exported cleaned model as .STL
4. Optional Printing¶
- Prepared file in slicer
- Printed using MakerBot Sketch
- Compared printed model with original object
C. Additive Manufacturing – Key Definitions¶
1. Additive Manufacturing (AM)¶
Definition:
A manufacturing process that builds objects layer by layer from digital 3D models, typically using materials such as plastic, resin, or metal.
Source:
- ISO/ASTM 52900:2021 – Additive Manufacturing Vocabulary
- Gibson, I., Rosen, D., & Stucker, B. (2015). Additive Manufacturing Technologies. Springer.
2. Subtractive Manufacturing¶
Definition:
A manufacturing process in which material is removed from a solid block using cutting tools (e.g., CNC milling, turning, drilling) to create the desired shape.
Source:
- Groover, M. P. (2020). Fundamentals of Modern Manufacturing. Wiley.
3. FDM (Fused Deposition Modeling)¶
Definition:
A 3D printing process where thermoplastic filament is melted and extruded layer by layer to form an object.
Source:
- ISO/ASTM 52900:2021 – Additive Manufacturing Vocabulary
- Chua, C. K., Leong, K. F., & Lim, C. S. (2010). Rapid Prototyping: Principles and Applications.
4. STL (Stereolithography File)¶
Definition:
A file format commonly used in 3D printing that represents the surface geometry of a 3D object using triangular mesh data.
Source:
- 3D Systems. (STL File Format Documentation)
- Gibson, I., Rosen, D., & Stucker, B. (2015). Additive Manufacturing Technologies.
5. Slicing¶
Definition:
The process of converting a 3D model into machine-readable instructions (G-code) by dividing it into horizontal layers for 3D printing.
Source:
- Lipson, H., & Kurman, M. (2013). Fabricated: The New World of 3D Printing.
6. Overhang¶
Definition:
A portion of a 3D printed object that extends outward and is not directly supported by the layer below it.
Source:
- Ultimaker 3D Printing Glossary
- ISO/ASTM 52900:2021
7. Bridging¶
Definition:
A 3D printing technique where filament is extruded across a gap without support beneath it.
Source:
- Simplify3D – 3D Printing Technical Guide
- Gibson, I., Rosen, D., & Stucker, B. (2015).
8. Mesh¶
Definition:
A collection of vertices, edges, and faces that defines the shape of a 3D object in digital form.
Source:
- Botsch, M. et al. (2010). Polygon Mesh Processing.
9. Design for Additive Manufacturing (DfAM)¶
Definition:
A design approach that optimizes parts specifically for additive manufacturing processes, taking advantage of geometric freedom and layer-based fabrication.
Source:
- Gibson, I., Rosen, D., & Stucker, B. (2015).
- ASTM F42 Committee on Additive Manufacturing Technologies
D. Refernces¶
- MakerBot Industries – Official Product Page - https://www.makerbot.com/3d-printers/sketch/ *
- MakerBot Industries – Technical Specifications (Datasheet) https://www.makerbot.com/3d-printers/sketch/specifications/
- MakerBot Print – Official Software Page https://www.makerbot.com/3d-printers/software/