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3D Printing

A Experimental Manual
For
Product Designing

Designed & Developed By: Mr. Bramha S Tripathi, Senior Project Associate, CSE

Under the Guidance of: Prof. SRN Reddy, CSE

Computer Science & Engineering Department Indra

Gandhi Delhi Technical University for Women

Kashmere Gate, Delhi - 110006


LIST OF EXPERIMENT

Sr. Practical Name Page


No. No.

1. ToStudyof3dPrinting.................................................. 01

2. How to create a Simple Box.............................................. 04

3. To Design a Basic Hex Nut.................................................. 06

4. To Design a U Bracket Sheet Metal..................................... 09

5. To Design A Project Name Text......................................... 15

6. How to Print the design in 3D printer.................................... 20


EXPERIMENT -1
To Study of 3D Printing
Introduction:- 3D printing allows for rapid prototyping and onsite manufacturing of products.
Initially done with plastic, 3D printing now uses new techniques with new materials, such as
aluminum, bronze, and glass. Biomaterials are also being incorporated, such as 3D printing ear
cartilage and liver tissue. As the 3D printing industry grows, 3D printing will become a big
part of many engineering fields.
Flow layout of Pre 3D Printing
3D Printer
3D modeling (CAD)

.Export
Export Export

Mesh Review m)> Mesh Fixing m) Prepping and


Printing

Components of 3D Printer: •
1. axes
Fixed Rods The three axes that the 3D printer utilizes are on the Cartesian coordinate
system. The linear fixed rods are maintained at right angles to each other and each
represents a coordinate axis.
Movement The timing belts and pulleys allow the movement of the hot end (or the print
bed, depending on the type of 3D printer) along each axes according to the g-code
(generated by slicing software). The stepper motors power this movement.
2. Extruder
Extrusion is the feeding of filament into the hot end of the 3D printer. This movement
is also powered by a stepper motor.
Retraction This mechanism is the pulling of the melted filament from the hot end. This
movement is primarily programmed through the g-code to prevent the formation of
unwanted filament creating a bridge between two areas. The bridging of unwanted
filament is referred to as stringing or the formation of cobwebs.
Dual Extrusion Some models of 3D printers are equipped with dual extrusion
capabilities. This allows for mixed material objects to be printed. Dual extrusion can be

Page I 1
used to print out complex objects with a different colour material as the support, making
it easy to differentiate between the object and the support.
3. Hot End
The hot end is heated to temperatures ranging from 160 C to 250 C, depending on the
type of filament to be used. The hot end melts the filament and pushes the melted
filament through the nozzle. The hot end needs to be thermally insulated from the other
components of the 3D printer to prevent any damage.
4. Print Bed
Heated Print beds that are heated improve print quality of 3D printed objects. The
heated bed is heated to the glass transition temperature of the filament being used. This
allows the model layers to slightly melt and stick to the heated bed.
Non-Heated Print beds that are not heated require adhesion in the form of glue, tape,
hairspray, etc. In the innovation lab, painters tape is frequently used for adhesion.
5. Filament
Filament is a consumable used by the 3D printer to print layers. Filament comes in a
variety of materials and colors. Filament can be composed of metal, wood, clay,
biomaterials, carbon fiber, etc.
i). ABS: - ABS is a thermoplastic that needs to be heated to temperatures from 210C to
250C. ABS can only be printed on a 3D printer with a heated bed, which prevents the
cracking of the object. When ABS is heated, it emits a strong unpleasant odor. ABS
requires a complete enclosure while printing.
ii). PLA: - PLA is a thermoplastic that needs to be heated to temperatures from 160C
to 220C. PLA is also biodegradable and emits slight odors. PLA is most frequently used
in the Innovation Lab on all 3D printers.

PVA PVA is a water soluble plastic that is frequently used for support in dual extrusion 3D
printers. The printed object is left in water where the PVA support is dissolved and the finished
object printed in the other filament remains.
Preparing your 3D Model in CAD Software: •

CAD software is used to create 3D models and designs. This software is available on our
computers and the level of difficulty varies. With the exception of Sketch up Pro and the
industry standard software mentioned, all of these programs are available on the innovation lab
computers.
Solid works main idea is user to create drawing directly in 3D or solid form. From this solid
user can assemble it directly on their workstation checking clashes and functionality of it.
Creating drawing is pretty easy just drag and drop the solid to drawing block.
Preparing your 3D Model for print in Idea maker software:-

These are following step for 3D printing of model


1. Install the 3D print software idea maker
2. Check repair option in this software
3. Set the nozzle parameter and build tack temperature according to the printer guide.

Page I 2
Step:-1 Prepare the design Model using Designing Software(Solids Work,Autocad etc.)

Step:-2 Convert the designed Model file in Stl ,obj format.

Step:-3 Prepare the design model for printing Using Software Idea Maker and Ultimaker. Then
set all parameter (nozzle temp., buildtak temp and support) and also repair your design using
software option. Then after generate the file in geode format
Step:-4 ON the 3D Printer and load the filament in nozzle and give the command print by using
3D Printing Machine.
Precaution of 3D Printer machine: •

These are some following precaution when you print the design in 3D Printer
1. Mechanical: Do not place limbs inside the build area while the nozzle is in motion. The
printer nozzle moves in order to create the object.
2. High Temperature: Do not touch the printer nozzle -it is heated to a high temperature
in order to melt the build material.
3. Always buy replacement parts from the manufacturer for safety related equipment
4. Choose an area that has adequate ventilation and exhaust capability

Safety Equipment:•

• Safety Glasses
• Gloves (recommended for postprocessing)
Application of 3D Printer:•
• Automotive • Medical
• Marine • Engineering
• Aerospace • Architecture
Advantages: •

• Complex shapes • Less waste


• Freedom for design • Fewer unsold products
• Customize parts • Less transport

Limitations:•
• Time
• Cost
• Skill
• Materials

Page I 3
EXPERIMENT -2
How to create simple box

In this First exercise we will design a simple Box as seen in the figure below. This exercise
will build the foundations of how to design 3D parts in SolidWorks and introduce several
fundamental features such as Sketching, Dimensioning and Extruding and printing on rise 3d
machine. Let's begin. Check all Electrical connections.

Step 1. First we install 3d design software in your computer like solids work auto cad, etc.
Step2. Open the solids work software and click New option in software window

1. Click New _J , Option

2. chick Part and ox


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[.f
3. Click on Top Plane and click Sketch.
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4. Click Rectangle D , sketch a rectangle start from origin.

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Smart
5. Click Smart Dimension Dimension, click side edge and click top edge to
dimension it as 1.0in x 1.0in.

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Page I 4
6. Click Features>Extruded Boss/Base
Swept Boss/Base
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Extruded Revolved Lofted Boss/Base
Boss/Base Boss/Base
Boundary Boss/Base
Features Sketch

set D1 as 1.0in
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and clicl

7. It's done. Simple Right?

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Page I 5
EXPERIMENT -3
To Design A Basic Helix Shape
In this Second exercise we will design a simple hexagonal unthreaded nut as seen in the figure
below. This exercise will build the foundations of how to design 3D parts in SolidWorks and
introduce several fundamental features such as Sketching, Dimensioning and Extruding and
printing on rise 3d machine. Let's begin. Check all Electrical connections.
Stepl. First, start a new part by going to New >
9 n Part1 (Default< <Defa
Part > Ok. Since we have already set up fJ History
(l Sensors
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SolidWorks to use MMGS as default units, all our 9 Fro
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units should be in millimeters, grams and seconds.


Section View
You should now be greeted with the main drafting Comment
Parent/Child...
interface of SolidWorks. gJ Add to Favorites
al Saye Selection
pf Properties...
Step2. On the left-hand side, you will see the Feature
Go To..

Manager Design Tree. Right click on "Top Plane" and Hide/Show Tree items...
Collapse Items

click the "Normal To" option. Now we are facing the


Top Plane head-on.
sens wseven»aria«a«satooe EEN -3·a•
Sketch tab at the top of the interface and select the E 0 ·O-rd•
Exit Smart
"Sketch" tool in the top left comer. We are now Sketch Dimension

creating a sketch on the Top Plane. Anything we sketch


will appear on the Top Plane. First, we want to sketch
the basic hexagonal outline of the nut.
i. Click the "Polygon" tool in the Sketch tab. A list of
parameters should appear in the left-hand panel.
ii. Set the number of sides to 6 (hex = 6). Other eters 3
,.
parameters such as center position, angle, etc. are .,
@)inscribed circle
also modifiable, but we will not adjust these. Q circumscribed circle
,.
iii. Next,over the origin (the base of the two red arrows) 0 0.00 w
,.
@ 0.00 .,
until the cursor snaps onto the dot in the middle. ,.
0 173.20508076 .,
Left click once to start the sketch. ,.
c; 0.00° .,
iv. Left click again at some point to the right of the first
New Polygon
point. Press enter to finalize the sketch.

Page I 6
v. Now, select the "Circle" tool in the Sketch tab and sketch a circle starting at the origin,
similar to how we sketched the hexagon.Press enter to confirm the circle sketch.

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3.39

4. Now we will assign dimensions to our outline. Make sure we are still in sketch mode
by looking at the top left comer and seeing that the Sketch button is depressed and now
reads "Exit Sketch". Press the "S key on the keyboard. In the small window, click the
"Smart Dimension" tool.

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Now let's set the center-to-edge dimensions of the hexagon,
i. Left click the center
ii. Then left click the top side (be sure to select a side edge and not one of the points between
two edges).
iii. A dimension measurement should pop up. Left click again anywhere on the screen and a
small window will appear. Enter 10mm into this field and hit enter. The hexagon is now
assigned a dimension of 10mm (center to edge). Double click the dimension label to
change the assigned dimension at any time. Follow the same procedure to set the diameter
of the circle to 10mm. Select Exit Sketch when finished. The sketch should now appear as
follows:

bi@sis; L ]

.21r
Page I 7
5. Now that our sketch is assigned dimensions and finalized, we are ready to bring this
shape into the 3rd dimension. Select our sketch by clicking "Sketchl" in the left
panel. The sketch should tum light blue as it is selected. Next, switch to the Features
tab at the top and click the "Extruded Boss/Base" tool. Immediately you should see
the shape gain depth. Using the parameters on the left panel, give the nut a depth of
7.5mm. Hit enter to confirm the extrusion. The shape should now appear as follows:

Page I 8
EXPERIMENT -4
How to create U bracket Sheetmetal

In this exercise, we will design a U Bracket Sheetmetal as seen in the figure below. This
exercise will build the foundations of how to design 3D parts in SolidWorks and introduce
several fundamental features such as Sketching, Dimensioning and Extruding and printing on
rise 3d machine. Let's begin. Check all Electrical connections.
These are following step for making of U bracket sheetmetal.

[i
1. cek New.±ce P% @EI ok«.
2. Click Front Plane and click on Sketch.

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Use Line , sketch U shape. Dimension sketch with Smart Dimension Dimension ~g 1in x
1.5in xlin and 1.5in height.

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2
Offset
3. Click Offset Entities Entities and click U sketch. Set offset distance as O. lin, check
Reverse box and OK.

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00I-1.500-4-1.000--
Page I 9
4. Use Line _, sketch and connected open end of this sketch and make it close both
end.

@
Extruded
5. Click Features>Extruded Boss/Base Boss/Base set D1 to lin and OK.

Direction 1 ::::::

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6. Click View>Bottom

click on bottom face and click Sketch.

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Page I 10
7. Click Circle 0 and sketch 2 circle on bottom face each side. Use Smart Dimension
0
Smart

",
Dimension to dimension this sketch as sketched below.

.500 .500

.300 b.300

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Extruded
8. Click Features>Extruded Cut cut and cut Through All this circle.
Direction 1 3

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9. Click View>Isometric.

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10. Click Fillet Fillet , check box Full round fillet.
Filet Type
Constant radius
ariable radius
_ Face fillet
o Full round fillet

Page I 11
11. Click side left side face as Side Face 1.
Items To Fillet

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. Face<1>

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[] Tangent propagation Side Face Set 1
@ Full preview

12. Click on pink box and click right side face as Side Face Set2 and OK.

jltems To Fet

® I'"'"'' Sile Face Set 1

8
Sile Face Set 2

[] Tangent propagation
@ Full preview

13. Repeat step 11-13 for the other side.

Page I 12
14. Repeat step 11-13 for inner face and outer face of U bracket.
Center Face Set

Side Face Set 1

Side Face Set 2

Center Face Set


Side Face Set 2

Side Face Set 1

Page I 13
~
Insert
15. Click Sheetmetal>Insert Bene_° jek flat face as reference when it flatten. Set
bend radius to 0.03in and K factor 0.5 and OK.

B
end Parameters

Face<1>

o.o3i

[oooi
[V Ignore beveled faces

[ Bend Allowance

]K-Factor -]
K 0.5

16. Your simple Sheetmetal bend is ready. Look at part tree.

B
end Parameters

Face<1>

....
3 0.03in
....
«I 0.00in

[Vl Ignore beveled faces

[l Bend Allowance :::::::

]K-Factor -]
K 0.5
....
....

Page I 14
EXPERIMENT -5
To Create a Project Name

In this exercise, we will design a create a project name as seen in the figure below. This exercise
will build the foundations of how to design 3D parts in SolidWorks and introduce several
fundamental features such as Sketching, Dimensioning and Extruding and printing on rise 3d
machine. Let's begin. Check all Electrical connections.
These are following step for making of Project Name.
Step 1.:- Open the new file in solidworks software and select the part option as shown in below
figure

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Page I 15
Step 2.: - select the any on plane (top ,front, right) for making of design then select the text
option and write the test as show in below figure.

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Page I 16
Step 3.: - after design of text select the font option and design the text size, height, width as
per parameter of design and then after select the features menu extruded option and increase
the height of text in 3d view as per parameter of design.

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Step 3.: - select the instant 3d option for showing the view of 3d design. after that save, the
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Page I 19
EXPERIMENT -6
How to Print the design in 3D printer
This exercise will build the foundations of how to Print the design in 3D Printer. Let's begin.
Check all Electrical connections. These are following steps before start the printing.
Step 1.:- first we install the software related the 3D printer(idea maker,ultimaker etc.)In idea
maker first open the software and click the open file option as shown in below figure.

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Page I 20
Step 2.:- select the Pan option and select the extruder (left ofright) for printing the design and
then after select the Repair option for auto correction of design of software parameter as shown
in below figure.

Page I 21
Step 3.:- select the Move option for design print postion in buildtack plate and then after select
the Rotate option for rotate the design easily printed and used low print material as shown in
below figure.
ideaMaker.'

ll .L

Ponton X
)1
0.00 mm

0.00 m

"'
2 192

' Ide

Mai Center

Reset
0n Platform

A ?

R0ton X
}
World Trarform Loal Transform

as 0. 'oe :~ ¢
o.o ,be :~ (:
± '-2
2xs: 0.0 ,oe :~ (:

Reset

Page I 22
Step 3.:- select the Scale option for design scale according to buildtack plate area and then
after click the start option and select printing option standard as shown in below figure.

Dee9or X
} .s
idt: •4 mm 16.01

Det: 2920 . "' 16.0! .s

± eght
Ider
$.612
V
. "'
pion Sain
146.0L .s

Reset

Page I 23
RAISED N2

PAL7Sm Rght Dtrude: LAL7Sm

a.a..n Et

~ Spttd• NI· PlA

Sets: 2

l .±

RASE N2
Flament
Left Extruder: UAL7Sm Rgt btrude : UA L7Sm

'@
,,. H cay·N-Pu
I lunclw·Nl•PIA
Et

t en

Page I 24
Easc
Pnter Type : RAISED N2 Settings Tero~ate are Standard·N2-PA

Flament
General
Left Extruder: PAL7Sm Rgt Extruder: PAL7m
Fl Desty: .0 •
Dolce $els :
(@, Hg» cay·R·Pu
,
Et PatonAdton: None
, lllndord • N1 • PlA

t
5==i
Support

en Delete
0y
Advanced
port

bopart

Sek: 2

Il Seed: 90.0 mm./

Step 4.:- After complete the all setting then click the Slice option and export the file in geode
formate.

Page I 25
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Page I 26
Step 5.:- After generate the geode formate then follow the these instruction as shown in below
figure.
■ Switch on the 3d printer.

■ Place your Pen drive in USB.

■ Clean your surface bed plate.

■ Load your filament into the required extruder as per the requirement.

■ Wait until the nozzle & bed plate comes into the required temperature.

■ Close the doors of 3d printer.

■ Open the file from the USB storage and select the Print option.

Page I 27
fight extruder- 21sC-toad

Page I 28
Page I 29
Page I 30

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