## 1.0 Hardware & Mechanisms I experimented with two distinct FDM systems to understand how mechanical architecture affects large-scale vs. high-resolution builds. ### Ultimaker S5 (Core XY) 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. ### WASP Industrial 4070 XP (Delta) 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.
## 2.0 Software Ecosystem - **Autodesk Fusion 360:** Post-processing scanned meshes. - **Meshmixer:** Vital for repairing corrupted STL scans, splitting models (for height limits), and surface smoothing. - **Ultimaker Cura:** Deep control over layer height, infill patterns (Honeycomb/Zigzag), and rafts. - **Simplify3D:** Specifically configured for the WASP with a **0.7mm nozzle** profile using custom FFF files.
Parameter Calibration

I manually tuned the Feed Rate during the first layer on the WASP to ensure perfect bed adhesion, often using Scotch tape on the bed for added stability.

Maintenance Hack
### WASP Filament Jam Recovery If filament breaks inside the heated chamber: Use a screwdriver knob fitted with a **1.2mm rod** to manually push the broken segment out of the extruder. This saved significant downtime during the life-size hand print.
## 3.0 Photogrammetry Workflow I explored the **Kiri Engine** app for photogrammetry to see how mobile devices can serve as high-fidelity scanners. ### Project: Vehicle Customization I scanned the center console of my car to design a custom fit compartment in Fusion 360. - **Method:** Photo Scan (150+ photos). - **Challenge:** Unlike a small bench object, a car cannot be rotated. I used the **automatic photo capturing** method while moving around the console. - **Result:** The mesh was imported into Fusion 360 to ensure the new design matched the vehicle's physical dimensions perfectly.
Car Console Scan Raw
Raw photogrammetry mesh.
Car Console Fusion 360
Integrating scan data in Fusion 360.
## 4.0 Material Performance Log
Filament Brand Temp User Verdict
LW-PLAcolorFabb195-260°CActive foaming; unique lightweight properties.
PLA BlackGenericN/ABest: Superior finish for fine details.
PLA WhiteUltimakerN/AGood: High reliability on S5.
PLAFilamentumN/AWorst: Poor consistency.
## 5.0 Experimental Case Studies ### Case A: 12-Test Calibration Block Compared **AA 0.25** vs **AA 0.4** cores. The **AA 0.4 core with Black PLA and a Raft** succeeded in all 12 torture tests (bridging, overhangs, etc.). ### Case B: Life-Size Hand (WASP) The print stopped early due to a height limit setting. I used **Meshmixer** to split, scale, and realign the geometry to finish the part. ### Case C: Final Project Contour Leg Printed a rigid leg as a "Control." - **Conclusion:** While sturdy, the 30-min print time per leg (41 needed) makes 3D printing inefficient for this part. I will transition to **Laser Cutting** for the final production.

Resources & Assets

Source Files
External Refs