ENGD3120S-Design for 3D Printing

Step 1 CAD modelling of initial design space

•Reading drawings or CAD planning.
•CAD modelling with single section.
•CAD modelling with mulitple sections (multiload cases).

Step 2 FEA
•Application of correct boundary conditions.
•Appllication of correct mesh parameters.
•Finite element analysis (Stress, Strain and displacements).

Step 3 Design and optimisation

•Topology optimization/ generative design/ lattice design optimization ...
•Design constraints / regions.
•Material removal / retain %age.

Step 4 STL pre/post-processing

•Generation of STL and exporting smoothed STL for design validation.
•STL errors removal, smoothing, simplifying editing.
•Exporting improved STL files for slicing software.

Step 5 Generating sliced files

•Import processed STL file/s.
•settin up 3D printing parameters using Ultimaker Cura slicer or cloud based slicers.
•Generate and export sliced files or G-codes for 3D printing machine.

Step 6 3D printing
•uploading G-codes in Prusa i3 Maker machine.
•Machine callibration and filament installation.
•3D printer settings, start and end.

Step 7 Post processing on 3D printed component

•Removing the suport structures from the 3D printed part.
•Cleaning the 3D printed part with filing or sand paper.
•Verifying dimentional accuracy of the 3D printed part.

Step 8 Experimental testing/ application

•Testing the component in an appratus to validdate the design.
•Plot the theoretical and experimental data together to compare results.
•Document all the process and comment on the improvements.