MANUFACTURING PROCESS-II

Lab Manual 3&4

Submitted to
Sir Farhan Raza

Submitted by
Abdul Rehman (2019-IM-37)

1
 Department of Industrial and Manufacturing Engineering

LABORATORY MANUAL FOR EXPERIMENTS

RAPID PROTOTYPING (RP)
Experiment # 3 To develop an understanding of manufacturing a prototype on 3D printer using ZPrint
Software.
A. AIM
This experiment has been created to provide the students/researchers with a practical opportunity for
making a real prototype. This practical exercise will also equip the students with working knowledge
of obtaining prototypes.

B. Methodology

2
 Fig. 5 Printing Process using Z 510

C. Description of Procedure
1. Fill feed box with powder.

2. With the printer offline, spread powder over build area by pressing the spread button on the
control button for four spreads. The printer will then automatically spread powder over the
build area.

3. Clean service station by rinsing and wiping the parking caps and rubber wiper.

3
 4. Check binder bottles filled if necessary.

5. Check wash fluid and waste fluid. Fill wash fluid and dispose of waste fluid.

6. Put printer online by pressing the button online on the control panel

Preparing the build in Z-printer software

4
 1 Open or import your STL file

2 Orient and scale the file if needed

3 Check “3D printer setup” in Z-printer software

4 Press 3D Print in Z-printer software

Removing the part

5
1. Wait for part to complete printing. Check software for part orientation.

2. Depowder the part and remove from build area.

3. Find the depowdered part and post process, as needed.

6
STUDENT’S NOTES
From this experiment, I learned that by rapid prototyping we can make a 3D physical model of an
object using our CAD file. The software “ZPrint” is useful because it is a requirement for a 3D printer.
We can send our .stl file to the printer using “Zprint” software. Also, I observe that we can orient and
scale the dimensions using this software. This software slices the layer up to 0.0875-0.1 mm thickness.
I also learn about the functions of different parts of 3D printer like filament, stepper rods, end stops,
PSU, print bed, feed piston, build piston, controller board, frame, motion component, print bed surface,
print head, feeder system, dual extrusion, and file option. Moreover, I also learn that how we can feed
powder in a 3D printer.

STUDENT’S COMMENTS
This experiment is about that how can we make a rapid prototype of an object using the software. The
software we used in this process is “Zprint”. First, we make a CAD file of our object and then convert
it into .STL file and then we load this file into Zprint. The prototype is a physical model which helps
make a new product. In this experiment I familiarized myself with a 3D printer, it's part, working, and
how we can use software and the applications of RP.

7
Experiment # 4 To develop an understanding of building a prototype on HTS FDM machine using
HTS Software.

A. AIM
This experiment is aimed at imparting the practical information about generating a prototype using
fused deposition modelling set up.

B. Methodology

HTS is a high efficiency desktop rapid prototyping system, it consists of gantry frame, platform
movable along Y direction, worm extruder movable along direction X and Z, filament material feeding
system, and control system. The extruder and the feeding system are driven by the same step motor.
Once the external PC sends control signal the worm is driven by the step motor , meanwhile, the plastic
filament is fed into the extruding cylinder through a timing belt （or gears）and roller mechanism.
Then the plastic filament is melted by a heating rod embedded in the brass nozzle and deposited on the
platform. The external PC calculates the cross section data along Z direction of 3D model of object
and the deposition path for each cross section.
The deposition path data is then transferred to control system, each layer is built by the resultant motion
of platform and extruder. After one layer is built, the extruder is raised a layer thickness (usually about
0.1~0.2 mm), the next layer is then build, the steps as above are repeated until the object is formed.
C. Description of Procedure
STL file ready

HTS RP system only accept Stl file, So any other CAD file must be converted to stl format before
you use HTS System.
Attention: if stl file has mistake, please correct it first, otherwise it will cause machine working
problem.
Prepare pasteboard

Use double-side tape to adhere the pasteboard on the work station strongly.
Attention: Don’t let the pasteboard tilt.

Material Installation

8
Install the material roller into the cartridge first, then drag the rod into the extruder.
Power on

Power on the machine, waiting two temp. controller’s temp. up to the setup data.(normally
10~15mins)
HTS Software
Installation
In CD there is a file --setupHTSV1.8E, double click it and then HTS system driver will be
Installed, following in your computer desktop there will be an icon as shown in figure 1.

Figure 1
Running
1. Double click the above icon to run HTS software, choose the right device and com port.

Figure 2
2. Open the stl file
chooseYes，input a new stl file (using open command in File menu).
ChooseNo，software will input the last part (including the filling data).

Figure 3
3. Interface
MinX、MinY、MinZ part ---- XYZ min.
MaxX、MaxY、MaxZ part --- XYZ max.
Current height part ---- current height
Current layer part --- current layer
Elapsed time part --- total cost time

9
 Figure 4
File menu
Open same as the toolbar, for opening the stl file
Save save the stl file
Save as same as the toolbar for saving the stl file with a new name
Restart reset the current height and costing time to initial state
Communication same as the toolbar, initialize the machine system
Simulation same as the toolbar, for slicing simulation
Estimate same as the toolbar, for estimating the total working hour
Build log same as the toolbar, for recording the working file
Exit exit to Windows System

Figure 5

10
Scale modify the size of the part, from 0.1~1000，the default is 1.
Rotate change the direction of the part.

Figure 6
View menu
Wireframe same as the toolbar，for displaying the part in wireframe mode.
Shade same as the toolbar，for displaying the part in shade mode.
View axis for displaying axis
Show support for displaying support structure

Figure 7

Figure 8

Building Parameters.
Click the “Building para” command, the below dialog box will appear.

11
 Figure 9

Part position
It means the part will be produced at the place of working platform. The unit is mm.
X, Y (0, 0) Machine Center
Build height
It means that user can use the following two items to determine the producing height of part.
Start height default is MinZ of stl file
End height default is MaxZ of stl file
Layer thickness slicing thickness, from 0.1~0.25mm, normally use 0.2mm

Part filling
HTS use two kinds of filling mode: contour and hatch filling. Normally we combine these
two modes, that is, at the inner and outer contour, we use 2~4 contours to fill inside. we use hatch
mode to fill the part.
Because the nozzle size is Ф0.5mm, so the default part filling parameters are as follows:
Contour offset: 0.45mm
Compensation:0.25mm
Contour filling times:4
Hatch width:0.7mm
Support filling
In process, if we need support structure, please active button normally the value of support
compensation is from 0.5mm~0.7mm.
Length limit for omitting the very short line
Max ACC is Max. Acceleration, from 500 to 2500mm/s2. The default is 1420 mm/s2
Max positional/dimensional error (PE) limitation with position tolerance, from 0.0001 to 1.0mm，
The default is 0.02mm.

12
 Figure 10

Max. Speed ranges from 20 to 100mm/s, normally using 45 mm/s

Feeding rate
Part normally from 30-40
Support normally from 20-28
Auto create

Figure 11

Click “the Auto create” command, the following dialog box will appear.
When the parameter is set properly, then clickStart Caculating，the software will
auto generate support structure.
Support Edit for modify the support manually. You can use button << and >>
to choose the individual support..
When you find the support which you want to delete, just click Delete
When you find the support which you want to modify, just click ，modify the
value of angel, small value means more support.
When finished, make sure to click to get the support file.

Figure 12

13
STUDENT’S NOTES
From this experiment, I learned that by rapid prototyping we can make a 3D physical model of an
object using our CAD file. The software “HTS software” is useful. We can send our .stl file to the
printer using this software. HTS only accepts .STL file. Also, I observe that we can orient and scale
the dimensions using this software. This software slices the layer up to 0.1-0.2 mm thickness. This
software has a user friendly interface, it provides various facilities like building parameters, part
positioning, part filling, support filling, feeding rate. Moreover, this software can create support for
object with the use of Auto Create in support menu. This auto support is linked with .STL file. I also
learned about Fused deposition modeling (FDM) which is a technology where the melt extrusion
method is used to deposit filaments of thermal plastics according to a specific pattern.

STUDENT’S COMMENTS
This experiment is about that how can we make a rapid prototype of an object using the software. The
software we used in this process is “HTS”. First, we make a CAD file of our object and then convert
it into .STL file and then we load this file into HTS. The prototype is a physical model which helps
make a new product. In this experiment I familiarized myself with a FDM process, working, and how
we can use software and the applications of RP.

14