Week 05 | Mohammed Azizi

Group Assignment

## 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) Full details on our **[Lab Group Page](https://fabacademy.org/2026/labs/techworks/week5/week5.html)**.

## Introduction During Week 5, I was introduced to the basics of digital fabrication through both 3D scanning and 3D printing. The focus was on understanding how physical objects can be scanned, digitized, and reproduced using additive manufacturing technologies. Throughout the week, I experimented a lot, learned how to prepare and process digital files, and gained hands-on experience fabricating a bunch of objects I had in mind using two types of 3D printers.

## 3D Scanning Something I was looking forward to in the past weeks was scanning physical objects, 3D scanning is a way of capturing the shape and details of a real object and turning it into a digital 3D model. Depending on the method used such as photogrammetry, structured light, or laser scanning, it can accurately record an object's geometry and surface characteristics and digitize them. The available 3d scanner in our lab is Artec 3D Space Spider known for its high-resolution based on blue light technology.

### 3D Scanning Process * We placed the object on a stable, preferably rotating, non-reflective surface with good lighting. * We connected the Artec Space Spider to the computer and ran the Artec Studio software. Note: The scanner might need to be callibrated. * We prepared the scanning setup by creating a new project in Artec Studio, then adjusted the scanning settings such as resolution, texture capture if needed Note: Ensure the object fits within the scanner's field of view.

Artec Kit components including the handheld scanner device, portable scanning power bank, and charging peripherals.

1. Artec Kit Components

Connecting the main power supply and routing the USB data interface cables to the workstation.

2. Connections and Wiring

Locating and managing the hardware pause and continue control buttons on the physical scanner chassis.

3. Scanner Control Buttons

Initiating the 3D capture sequence, staging the computer mouse on a physical turntable turntable, and maintaining a uniform distance.

4. Scanning Orientation Setup

Capturing real-time telemetry tracking frames as the hardware sensor sweeps across the target object.

5. Real-Time Tracking Capture

The Welcome to Artec Studio 17 home screen window displaying initialization options, user Assignments, and recent project history logs.

6. Artec Studio Launch Screen

Reviewing the raw texture scan of a computer mouse on a floor plane, showing data acquisition geometry and color rendering.

7. Raw Scan Acquisition

Displaying the uncleaned raw solid green geometric mesh data within the workspace environment, revealing significant surrounding background artifacts.

8. Unprocessed Geometry Mesh

Accessing the Editor sidebar panel and toggling the Eraser tool with Lasso Selection mode enabled for precise boundary definition.

9. Enabling Lasso Selection

Isolating a floating cluster of scanning noise with a red highlight boundary using the Lasso Selection tool inside the Editor window.

10. Erasing Noise Artifacts

Running the Fast Fusion mesh calculation algorithm with a progress bar shown at the bottom of the interface to compile the finalized mouse model.

11. Executing Fast Fusion Algorithm

* Started the scan process, held the scanner approximately 20–30 cm from the object. * Begun scanning while moving smoothly around the object, keeping a consistent distance and speed. Covered all sides and angles to avoid missing geometry. * Paused and resumed scanning if tracking was lost, then continued from the last aligned area. * Then I did data processing in Artec Studio: To align scans: Used "Auto-Align" to combine multiple scans into one dataset. Fusion: Run Sharp Fusion or Smooth Fusion to merge all aligned frames into a single, detailed mesh. Outlier Removal: Clean unwanted noise or floating fragments. Mesh Optimization: Fill holes, smooth surfaces, and simplify geometry if needed. T exture Mapping: Apply captured color data onto the final mesh for realistic visualization. * Exporting the Model Export the final mesh as .OBJ, STL, or PLY format.

STL File

## 3D Printing We got into a tour around the lab getting introduced to the 3D printers available exploring the different additive manufacturing technologies they use such as FDM, LDM, SLA, SLS and the differences between them. * **FDM (Fused Deposition Modeling)** is one of the most common 3D printing technologies. It works by melting a thermoplastic filament and depositing it layer by layer through a heated nozzle to build a three-dimensional object. * **SLA (Stereolithography)** is a 3D printing technology that creates objects by curing liquid resin with a UV light source, building the model layer by layer. Known for its high precision and smooth surface finish. * **SLS (Selective Laser Sintering)** is a 3D printing technology that uses a laser to fuse powdered material, typically nylon or other polymers, layer by layer to create a solid object, it does not require support structures because the surrounding powder supports the part during printing. * **LDM (Liquid Deposition Modeling)** is a 3D printing process that extrudes paste-like or liquid materials, such as clay, ceramics, food, silicone, or other viscous mixtures, through a nozzle to build objects layer by layer.

I experimented with 3 printers exploring both FDM and SLA techniques.

### Experimentation with Ultimaker S5 (FDM) Uses a Core XY motion system and a **Direct Drive** extrusion mechanism. The highlight of the S5 is its interchangeable **Print Cores**: * **AA Cores:** Used AA 0.25 for resolution tests and AA 0.4 for standard PLA/ABS. * **BB Cores:** Dedicated to water-soluble PVA supports. * **CC Cores:** Hardened tips for abrasive materials. I used a CC 0.4 for **Wood filament** to prevent the fibers from ruining standard brass nozzles. I started experimenting with Ultimaker S5 printing multiple models as follows: #### Random Geometry In an attempt to mimic a random challenging geometry betweeen a shoe, a baot and random extrusions. I designed the following file and printed it on the ulimaker s5 using default fast 0.2mm settings in the slicer and scaling my model 80% of its original size. I then added to the model a different layer of complexity by a print in place roller extruded from the side and in this print i used supports.

Pro Tip / Warning

The results on the print in place random model 2 did make a turn but then got stuck , I believe a higher clearance is in fact needed Like just a little bit of movement at the beginning but yeah it got stuck afterwards. Mr.Yuichi recommended to print a clearance test in future works to grasp a better tolerance range for future designs of such sort.

Fusion 360 Model

Slicing in Cura

Slicing Preview in Cura

Loading the print

Printing

PLA material used

Print in progress

Results

Print in place roller added

Print in Progress

Results

#### Gear 3D printing a gear is something I always wanted to try, ever since it became the symbol of Mechanical Engineering, so I proceeded with modelling the gear on fusion 360 and slicing it on Cura, it was recommended to 3D print the gear using PETG filament. And this is where I learned that PETG is a tougher material and more heat resistant,and it also has a higher elasticity in addition to having a slicker surface than PLA, however one of its main advantages is that the layer adhesion is very well, giving the overall strucural integrity and lower chances of it being split. This process comes from my [Digital Mannequin](week-twelve.html) design process, where I also printed the rack and further 3D Components. But my curioisity towards the gear has been early on since this week.

Using the scripts tool in Fusion 360

Select Spur Gear Script (the one with the play button, the other is from a plugin)

Enter Gear parameters

Extude Gear Hole/Bore , this also can be done in the parameters

Draw Gear Hole/Bore , this also can be done in the parameters

Extude Gear Hole/Bore , this also can be done in the parameters

For the slicing settings, I set the cura settings to Fast , 0.2mm layer height, but increased the wall count to 5, an infill of 10-20%. For plate adhesions: Brim

Results

#### Final Project Enclosure A more complex iteration was a part of my final project where I designed and 3D printed ,the detailed design can be found [here](dcg.html) the enclosure of the digital contour gauge, I used the same settings , the major difference is I used Ultimaker S6 slicer here.

Slicing using cura on S6, I used normal settings here with supports generated

#### Chair

I had a lucky overlap between my printing excersices below and my CNC machine assignment so I decided to 3D print a prototype of my wooden chair to be which was also interesting to test out my first 3D assembly I picked up from the 3d design in week 07 where I exported the components to stl files as shown and followed it up by slicing them and printing them. Here is my process workflow:

Importing the final sketch

Extrude the sketch to 18mm / plywood thickness

Creating Rectangular pattern

Sketching the chair base

Using Combine tool to create the slot fits for the base

Apply fillet to parts

Save as Mesh from Fusion

Export as STL

Slicing the file on Cura

Opening the file on Cura

Scaling the file on Cura

Centering and aligning

Lay Flat (mistake here that I didnt do supports)

Slice and Preview

Redo the process but for the parts seperated instead, this time I exorted the chair seat components and the base seperately

Slice Preview

Print Outcome

Results

Tip

I used skirt support to minimze print time and cleaned the surface real well before printing the components, this saved time and delivered good results under 0.15mm layer height, I also increased the wall count and minimzed the infill.

#### Watch Case I was very interested to experiment printing articulated chain mechanism so my first experiment was a watch case, from thingiverse[https://www.thingiverse.com/thing:30414]

**Process and Workflow:**

Opening the UltiMaker S5 dual-extrusion print head housing to inspect and verify the installed AA 0.4 and BB 0.4 print cores.

1. Print Core Verification

2. Cura Material Marketplace

Previewing the sliced model toolpath layer-by-layer inside UltiMaker Cura, showing a 10% triangle infill pattern and a stabilization brim.

3. Model Slicing Preview

Using the UltiMaker S5 physical touchscreen interface to select the print job from the local FAB26 or 3D PRINT folders.

4. On-Screen Job Selection

The completed multi-material, flexible interlocking link assembly successfully printed and removed from the build plate.

5. Finished Interlocking Part

6. Finished Interlocking Part

* Prepare Model and export the Stl file ready for slicing. **Slicing the model:** * Open Stl. file with Ultimaker Cura. * Set Printer: Ultimaker S5. * Set Material: PLA * Make sure the model is placed flat on the build plate (Z = 0). * Adjust scale. * Adjust print settings: **Basic Settings** * Layer Height: 0.15 mm, Wall Thickness: 1.2 mm (≈3 lines), Top/Bottom Thickness: 0.8 mm, Infill Density: 15–20% (Gyroid). **Adhesion** * Build Plate Adhesion Type: Brim (8 mm) * Z Hop When Retracted: Enabled. **Temperature & Cooling** * Printing Temperature: 200 °C (PLA). * Build Plate Temperature: 60 °C. Fan Speed: 100% after the first 3 layers for smooth surface finish. **Speed** * Print Speed: 45–55 mm/s. * Wall Speed: 25 mm/s. * Initial Layer Speed: 10 mm/s. * Click Slice and save the file. **3D Printing:** * Connect the USB to the printer. * Load the PLA filament into the Ultimaker S5 if it is not already installed. * Ensure the build plate is clean and properly positioned. * Start the print from the printer's touchscreen by selecting the prepared file. * Monitor the first few layers to ensure good bed adhesion and successful material extrusion. * Once the print is complete, allow the build plate to cool before removing the part. * Carefully detach the printed object and remove any support material if necessary. --- #### 3D Printing Benchmark My second print was the 3d test block, designed to evaluate the capabilities and limitations of the printer. The test assessed dimensional accuracy, overhangs, bridging, fine details, hole sizes, wall thicknesses, text readability, surface quality, and potential warping, providing a comprehensive overview of the printer's performance and print quality.

**Process and Workflow:** *Note: The slicing and printing process is similar to the watch case.*

--- #### Contour Gauge Tine As an additional experiment, I decided to print a prototype component for my final project and fabricated a test tine for the contour gauge to evaluate its geometry, fit, and printability.

**Process and Workflow:** *Note: The slicing and printing process is similar to the previous 2 experiments.*

### Experimentation with WASP 4070 Industrial X (FDM) This printer employs a Delta configuration with three arms on vertical rails. It features a Dual Drive mechanism for high-torque filament grip. It is more "industrial" and requires manual calibration of Z-offset and bed adhesion. I experimented with this machine testing to print an arm stand. #### Hand Stand

**Process and Workflow:** * Prepare Model and export the Stl file ready for slicing. I used meshmixer to prepare the files One of the challenges/confusions I faces was the length of the arm seemed to exceed the allowable print space although it did not add up to me at the time, but I later discovered there is a setting in Simplify 3D to extend the total model height (printable) **MeshMixer Process:**

1. Open Model

2. Align Model

3. Cut Mesh

4. Slice Mesh

5. Separate Shells

6. Align and Move

7. Export Mesh

**Slicing the model:**

1. Download WASP Files

Importing the downloaded WASP FFF profiles into Simplify3D slicing software

2. Import Profiles

Repositioning and orienting the 3D model on the virtual build plate in Simplify3D

3. Reposition Model

Opening the file system directory to import additional 3D mesh files into the workspace

4. Import Additional Files

Configuring the FFF process settings dialogue box in Simplify3D for the WASP printer

5. FFF Settings

Adjusting the infill percentage, internal infill pattern, and structural settings in Simplify3D

6. Infill Settings

Previewing the sliced 3D model geometry showing toolpath and multi-part arrangement

7. Slice Mesh Preview

Final sliced toolpath visualization displaying print layer breakdown ready for export to the WASP 4070

8. Final Export

* Open Simplify3D and create a new process profile for the WASP 4070 Industrial X. * Import the STL of the hand mode (using File then Import Models). * Position the model vertically on the build platform, ensuring the base is fully in contact with the build plate. * Open Edit Process Settings and configure the printer parameters: * Nozzle diameter: according to the installed nozzle (e.g., 0.8 mm or 1.2 mm) * Material: PLA * Extruder temperature: 200–215°C * Adhesion Build Plate Adhesion Type: Brim (8 mm) * Bed temperature: 50–60°C **Set the print quality parameters:** * Layer height: 0.3–0.4 mm * Perimeters: 2–3 outlines * Top/Bottom layers: 4–5 * Infill: 10–20% (Grid or Rectilinear) **Under the Support tab:** * Enable support generation. * Set support overhang angle to approximately 50°. * Generate supports beneath the fingers, palm cavity, and any unsupported overhangs. * Enable Brim (5–10 mm) to improve bed adhesion, especially for tall prints. **Set the print speed:** * Outline speed: 30–40 mm/s * Infill speed: 40–60 mm/s * First layer speed: 50% of normal speed * Click Prepare to Print and review the layer preview carefully, checking: * Support placement * Wall thickness * Finger details * Estimated print time and material consumption * Adjust support structures manually if required and re-slice the model. * Save the generated G-code to a USB drive. **3D printing the model:** * Connect the USB drive to the WASP 4070 Industrial X. * Clean the build plate * Apply adhesion aid if needed * Load PLA filament * Verify nozzle and bed temperatures

### Experimentation with Formlabs Form 4B The Formlabs Form 4B is a high-precision SLA (Stereolithography) 3D printer that uses liquid resin cured by light to produce highly detailed parts with smooth surface finishes. I chose this printer because I needed a highly detailed print that could be used directly for mold making, minimizing or eliminating the need for post-processing before casting. #### Batman

**Process and Workflow:** I used an open-source STL model as a starting point, and the workflow proceeded as follows:

Importing and scaling the Batman STL model to a 0.500 scale factor within the Formlabs PreForm workspace, noting initial print validation flags for unsupported minima.

1. Import & Scale Model

Reviewing the oriented model showing a calculated volume of 32.33 mL and a print time estimate of 1 hour 39 minutes using Formlabs Grey V5 resin.

2. Print Calculation & Verification

Configuring the SLA support parameters menu in PreForm, detailing auto-placement adjustments for touchpoint sizes, overhang angles, density settings, and base rafts.

3. Generate Support Structures

A green confirmation banner indicating the print job was uploaded successfully to the Formlabs Dashboard Group Queues system for automatic assignment.

4. Upload to Print Queue

Resources & Assets

3d print files and gcode

Cura Files (cura)

Formlabs Files (formslab)

Artec Files (artec)

moust.stl (artec stl file)

Simplify3D Reference (simplify3d_ref)

WASP 2040 3D printer - Simplify3D User Guide (PDF)

External Refs

3D Scanning & Printing

Resources & Assets