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3D PRINTER
miniFACTORY
2021
Manufacturing Techniques
Formative
• Injection molding
• Casting
• Stamping
CLASSIFICATION • Forging
OF
MANUFACTURING Subtractive
TECHNIQUES • CNC
• Turning
• Drilling
Additive
• 3D Printing
CLASSIFICATION
OF
MANUFACTURING
TECHNIQUES
Recommended Process Reference
Table
No. of
1's 10's 100's 1000's
parts
CLASSIFICATION
OF
MANUFACTURING Plastic 3D Printing
3D Printing CNC
Inject Molding
(CNC) (Inject Molding)
TECHNIQUES
CNC Investment
CNC
Metal 3D Printing & CNC (Investment or
(3D Printing)
Casting) Die Casting
INTRODUCTION
TO 3D PRINTING
1. Producing a 3D file
2. STL creation and file manipulation
3. Printing
4. Removal of Prints
5. Post Processing
3D Printing walkthrough
Download STL from Create a model using
Scan model
internet CAD Software
*.STL
INTRODUCTION SLICING
A slicer is 3D printing software that converts digital 3D models into
TO 3D PRINTING printing instructions for your 3D printer to create an object.
*.gcode
3D Printing
The 3D printer creates the object by adding layers of materials on top
of each other until the original work are 3D objects.
Websites to Download STL Files for
3D Printing
Cults https://cults3d.com/
Free 3D https://free3d.com/
Yeggi https://www.yeggi.com/
GrabCAD https://grabcad.com/
Pinshape https://pinshape.com/
INTRODUCTION Sketchfab https://sketchfab.com/
TO 3D PRINTING Pileprint http://www.pileprint.com/
STL Finder http://www.stlfinder.com/
CGTrader https://www.cgtrader.com/
Threeding https://www.threeding.com/
TurboSquid https://www.turbosquid.com/
YouMagine https://www.youmagine.com/
Thingiverse https://www.thingiverse.com/
Instructables https://www.instructables.com/
MyMiniFactory https://www.myminifactory.com/
Blender Market https://www.blendermarket.com/
Autodesk Online Gallery https://gallery.autodesk.com/
Powder-based 3D Printing/ Laser Sintering/ How it works ?
How it works
TECHNIQUES
Resin-based 3D Printing/ Stereolithography (SLA)
How it works
How it works?
• A PolyJet 3D printer works like an inkjet printer.
• Instead of jetting drops of ink, the printer jets drops of photopolymer that
solidify when exposed to UV light.
• These layers accumulate on the build tray until the part is complete.
3D PRINTING • PolyJet materials properties vary, ranging from rigid to rubber-like
TECHNIQUES
Filament-based 3D Printing
Multicolour
Additive
Technology Manufacturing Advantages Disadvantages
Plastic
Metal
Resin
Process
No Support required
High Heat & Chemical resistant
Laser Sintering Powder Bed Fusion Post-finishing required Y Y
High Speed
Intricateness
Complex Geometries
Post-finishing required
Stereolithography Photopoly- merisation Smooth Finish Y
Requires Support structures
Detailed parts
Good precision
Good surface finish
Polyjet Material Jetting Slow Build Process Y Y
Multiple materials and colours
No removal of support material
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
Exploring 3D
Heatbed
Printer Machine
Heating Block
Nozzles
Exploring 3D Printer Machine
Extruder Assembly
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
Heatbed Assembly
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
Endstop
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
MotherBoard – MightyBoard (Makerbot)
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
MotherBoard – Ramp 1.4+Arduino Mega 2560 (RepRap)
Exploring 3D
Printer Machine
Exploring 3D Printer Machine
MotherBoard – MKS Base 1.3 (RepRap)
Exploring 3D
Printer Machine
Types of FDM 3DP Machine
FDM - Delta, Polar, Robotic arm &
Cartesian
Exploring 3D
Printer Machine
Types of FDM 3DP Machine
FDM - Delta
Exploring 3D
Printer Machine
Types of FDM 3DP Machine
FDM - Polar
Exploring 3D
Printer Machine
Types of FDM 3DP Machine
FDM - Robotic arm
Exploring 3D
Printer Machine
Types of FDM 3DP Machine
3D Printer Mechanism Cartesian
Exploring 3D
Printer Machine
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
Types of FDM 3DP Machine
3D Printer Mechanism
Exploring 3D
Case 1 : In this case the Extruder will
Printer Machine move in X and Y axis with the support
of Gantry System and the build
platform will move in Z axis with the
support of Threaded Rod . Here the
build platform will move down once
the XY layer completes its modelling
process.
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
Types of FDM 3DP Machine
3D Printer Mechanism
Exploring 3D
Printer Machine Case 3: In this case the Extruder will
move in X and Z direction with the
support of Gantry based systems,
build platform will move in Y
direction with the support of gantry
system.
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
Types of FDM 3DP Machine
3D Printer Mechanism
Exploring 3D
Printer Machine
Case 4: In this case the Extruder
assembly will move in all XYZ
direction with the support of Gantry
systems while build platform will be
fixed with base Support.
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
Types of FDM 3DP Machine
3D Printer Mechanism
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
Types of FDM 3DP Machine
3D Printer Mechanism – CoreXY /
Hbot
Exploring 3D
Printer Machine
http://multiphysics-cae.blogspot.com/2016/06/3d-printer-mechanism-simulation.html?view=snapshot
3D Printer Safety Precaution
• 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.
• HIGH TEMPERATURE
3D Printer Do not touch the printer nozzle – it is heated to a high temperature in order to melt the
COMPUTER
AIDED DESIGN
• Freeform Modeling Tools allow more freedom
by allowing you to create freeform shapes.
• Sculpting Tools are pretty much like using digital clay that
you can push, pull, pinch and grab to form your models.
CAD Tools
Software Developer User Level Comment
SketchUp is a 3D modeling program for applications such as architectural,
interior design, civil and mechanical engineering. Its powerful yet easy to use
Trimble
Beginner to interface make it ideal for beginners in 3D modeling. A freeware version,
SketchUp Navigation SketchUp Make, and a paid version with additional functionality, SketchUp Pro,
Intermediate
Ltd. are available. Note that the free version does not allow you to export to *.stl for
3D printing, you'll need to install a plug-in to do so.
Top View
Showing Build Plate
COMPUTER
AIDED DESIGN
Build Volume: 230 x 150 x 150mm Build Volume: 140 x 140 x 140mm
COMPUTER
AIDED DESIGN
Remove these type of errors from the model/ Model must be watertight
3D Modeling Principles
Clean Boolean
COMPUTER
AIDED DESIGN
3D Modeling Principles
No Interpenetrated and Overlapped
Mesh
COMPUTER
AIDED DESIGN
3D Modeling Principles
Minimum Wall Thicknesses
COMPUTER
AIDED DESIGN
3D Modeling Principles
Minimum Wall Thicknesses
COMPUTER
AIDED DESIGN
In many situations 2mm thickness works best for the thinnest part
3D Modeling Principles
Mesh Normal
COMPUTER
AIDED DESIGN
COMPUTER
AIDED DESIGN
COMPUTER
AIDED DESIGN
COMPUTER
AIDED DESIGN
COMPUTER
AIDED DESIGN
COMPUTER
AIDED DESIGN
It’s important to provide enough distance between the parts that will be
attached together. Always leave at least 0.3 mm between the different parts.
3D Modeling Principles
Rule of 45°
COMPUTER
AIDED DESIGN
The ―self-supporting‖ or ―safe‖ zone does not require any support to print the
model. This area ranges from 135° to 45°. When designing an object, keep
this safe zone in mind if you are concerned your model will require support to
be constructed.
COMPUTER
AIDED DESIGN
3D Modeling Principles
Export as STL File
COMPUTER • In 3D Printer world, the most common file format is the STL file
(STereoLithography / Surface Tesselation Language).
AIDED DESIGN
• STL consisting essentially of a long list of triangles that collectively covers
the surface of the object.
• STL files only contain information about the shape of the surface. No
information about colour/ texture or light is contained in an STL file.
SLICING
What is a Slicer?
A slicer is 3D printing software that converts digital 3D models into printing
instructions for your 3D printer to create an object.
The slicer cuts your CAD model into horizontal layers based on the settings you
choose (three-dimensional model into two-dimensional layers), and calculates
how much material your printer will need to be extrude and how long it will take
to do it.
All of this information is then bundled up into a GCode file which is sent to your
printer.
SLICING Slicer settings do impact the quality of your print so it‘s important to have the
right settings to get you the best quality print possible.
3D Slicer Software Tools for 3D Printers
Software User Price OS
Beginners, Advanced
Cura Free Windows, Mac, Linux
Users
Beginners, Advanced Windows, Mac, Linux,
KISSlicer Free/$35
Users Raspberry Pie
MakerBot Print Beginners Free Windows, Mac
Beginners, Advanced
SLICING MatterControl
Users
Free Windows, Mac, Linux
SLICING
What is a Slicer? (Cont)
A slicer program allows to calibrate printer settings for various types of "areas to
print", like:
SLICING
Slicer Setting - Layer Height
• layer height = resolution of your print.
• specifies the height of each filament layer in your print.
• thinner layers will create more detailed prints with a smoother
surface.
• thinner layers /more time to print (since there will be more layers
that make up your object)
SLICING • thicker layer will get you a faster print but it will be a rougher surface
(individual layers will be more visible).
Slicer Setting - Layer Height
SLICING
Slicer Setting – Strength, Speed, Cost, Quality
SLICING
Slicer Setting - Shell Thickness
• Shells refers to the number of times
the outer walls of the design are
traced by the 3D printer before starting
the hollow inner sections of your
design.
• This defines the thickness of the side
walls and is one of the biggest factors
in the strength of your print.
• Increasing this number will create
thicker walls and improve the strength
SLICING of the print.
• If you print something that will need
more durability, or if you‘re creating a
water-tight print like a vase, you may
want to increase shell thickness.
• Any increase in the number of shells
also increase the amount of time and
material required to print the model
increasing overall part cost.
• Shells typically consist of a specified
number of nozzle diameters. It is
always good to design shells to be a
multiple of nozzle diameter to prevent
voids from being formed.
Slicer Setting - Retraction
• Retraction is used in 3D printing to
stop the flow of melted filament when
the nozzle must be moved between
islands, and a string or ooze is not
wanted.
• Retraction also has the benefit of
preserving the nozzle pressure -
when the un-retract happens the
pressure is restored to near the
SLICING previous level. If a part has many
frequent non-printing moves - then
pressure is lost if retraction is not
used.
Retraction Distance
Direct drive: 0.5-2.0mm
Bowden extruders: ~15mm
Retraction Distance
Direct drive: 0.5-2.0mm
Bowden extruders: ~15mm
Slicer Setting - Infill
• Like most wooden doors are not solid but have a low density core. In 3D Printing
Infill is a value usually represented in percentage that shows how much a solid
model should be filled in with material when printed. Reasonable values range
between 10% and 30%.
SLICING
Slicer Setting - Platform adhesion
Brim adds a single layer flat area around the base of the model to prevent warping. The
brim is connected to the model and will thus make the bottom surface area bigger. This
means that it can better stick to the build plate and in case of warping the corners of the
model are less likely to curl up because of the brim attached to it.
SLICING
Especially materials that have a high shrinkage (e.g. ABS) can benefit from using a brim.
But also models that either have a very big base or very thin parts at the bottom will stick
better to the build plate with a brim.
Slicer Setting - Platform adhesion
Raft adds a thick grid between the model and the build plate. This can
especially be useful when you have a model of which the bottom surface is not
completely flat or has little adhesion to the build plate. With a raft you make
sure that the print will stick better to the build plate.
SLICING
Materials selection and application
SLICING
3D Printer Filament
Print Temp. Bed Temp.
Filament Special Properties Uses Strength Flexibility Durability Print Skills $/Kg
(˚C) (˚C)
Flexible, TPE, TPU Extremely Flexible, Rubber-Like Elastic Parts, Wearables ★ ★★★ ★★ ★★★ 225 - 235 No $50/KG
Wood Wood Finish Home Decor ★★ ★★ ★★ ★★ 195 - 220 No $50/KG
Carbon Fiber Rigid, Stronger Than Pure PLA Functional Parts ★★ ★ ★★★ ★★ 195 - 220 No $80/KG
SLICING
Dual extrusion
Dual extrusion is the process of 3D printing with multiple filaments. You can mix colors or
different materials with a print head that has two extruders and nozzles. With two spools
loaded, the printer alternates between them by printing one at a time. It's not actually
faster at printing because its still using only one extruder at a time.
SLICING
3D Printing
Things to check before 3D Printing.
01. 3D Printer machine in a clean environment.
02. good electricity plug contact.
03. axis rods moves freely & well greased
04. leveled print-bed.
3D PRINTING 05. clean print-bed
06. spooler unwind freely
07. filament free to feed in extruder
08. sufficient filament to print model
09. cleaned nozzle
10. good quality of filament
Bed Leveling
3D PRINTING
Filament Loading
3D PRINTING
LCD Screen Navigation
3D PRINTING
LCD Screen Navigation
3D PRINTING
Step 05. Sit back & enjoy your 3D Printing.
3D PRINTING
Step 06. After Printing, wait model to cool down
Step 07. Remove object from bed, carefully.
3D PRINTING
Step 08. Cleaning/ Polishing/ Paining
3D PRINTING