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4. 3D printing and scanning

Week 04 Summary: 3D Printing and 3D Scanning

Objective

This week, we explored 3D printing and scanning. The tasks were divided into group and individual assignments:

Group Assignment

  • Identify the requirements for various 3D printing machines and filament types.
  • Perform a test on two different 3D printing machines.

Individual Assignments

  • Task 1:
    Download a 3D design from Thingiverse or Printables, slice it, and 3D print it.

  • Task 2:
    Follow a YouTube tutorial to design a 3D object, slice it, and 3D print it.

  • Task 3:
    Design a 3D object with a mechanism, slice it, and 3D print it.

  • Task 4 & 5:
    Scan an object using the Scaniverse and Skanect mobile apps.

This week provided hands-on experience with both the design and scanning processes in the 3D printing workflow.

Introduction to 3D Printing

3D printing, also known as additive manufacturing, is a process of creating three-dimensional objects from a digital file. Unlike traditional manufacturing methods that typically involve subtracting material (e.g., cutting, drilling), 3D printing adds material layer by layer to form an object.

Key Concepts in 3D Printing

  • 3D Model: The first step in 3D printing is creating or obtaining a 3D model. These models can be designed using CAD (Computer-Aided Design) software or downloaded from online repositories like Thingiverse or Printables.

  • Slicing: The 3D model is then “sliced” into layers by slicing software. This process generates a series of instructions (G-code) that tells the 3D printer how to build each layer.

  • Filament: The material used in most 3D printers is called filament. Common types include PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), and PETG (Polyethylene Terephthalate Glycol). The choice of filament depends on the desired properties of the final object.

  • Printing Process: Once the model is sliced and the filament loaded into the printer, the 3D printer begins to build the object layer by layer. The printer’s nozzle extrudes melted filament, which cools and solidifies to form each layer.

Types of 3D Printers

  • FDM (Fused Deposition Modeling): FDM printers are the most common and affordable. They use a heated nozzle to extrude filament onto a print bed, where it solidifies to form the object layer by layer.

  • SLA (Stereolithography): SLA printers use a laser to cure liquid resin into solid layers. This type of printer typically offers higher precision and a smoother finish compared to FDM.

  • SLS (Selective Laser Sintering): SLS printers use a laser to fuse powder material (often nylon or metal). They are commonly used for industrial applications due to their ability to print functional parts with high strength.

Task1: Group Assignment

For this week, our group assignment focused on testing the design rules for our 3D printer. We worked collaboratively to explore how different design parameters, such as layer height, print speed, infill density, and support structures, affect the overall print quality and accuracy. Through hands-on testing and data collection, we were able to identify optimal settings for various print scenarios.

The complete documentation of our group’s work can be found on our project page:
3D Scanning and Printing

Individual Contribution My responsibilities included writing about the safety measures involved in 3D printing, conducting the bridge test to assess print quality, and documenting our results. I made sure all safety protocols were followed and helped analyze the bridge test outcomes to ensure accuracy in our project documentation.

Individual Assignment: Task 1 - Print a Sleepy Cat Model

For this assignment, I used the Creality K1 printer and Creality Slicer to print a Sleepy Cat model. Below is the process I followed:

1. Download Creality Slicer

I began by downloading the Creality Slicer software to my laptop, following the installation steps provided.

2. Select a 3D Model

I chose a design from Thingiverse. After selecting the “Sleepy Cat” model, I clicked on the “Download” button to save the file.
Access the file here

3. Import the Model & Scale it

After opening Creality Slicer, I clicked on the “Import Model” option and selected the downloaded file. Then Iscaled it by 50

4. Add Supports and Slice the Model

I selected the “Add Support” option to ensure the model’s critical areas would be supported, and chose tree support as the support type. Afterward, I clicked the “Slice Plate” button to break the 3D model into layers and generate the corresponding G-code for printing.

5. Send to Printer

I clicked “Send” and selected the Creality K1 printer from the list of available machines.

6. Printer Preparation

Upon receiving the data, the printer began cleaning the nozzles before initiating the print process.

7. Cool Down Process

After the print job was completed, the fan activated to cool the model down to 40°C.

8. Remove the Model

Once the model had cooled, I carefully used a scraper to remove it from the printing plate.

click to download the file This process allowed me to scan myself efficiently using the Kinect and Skanect, resulting in a digital 3D model.

This process ensured that the model was printed accurately and with proper support, resulting in a successful print.

Individual Assignment: Task 2 – Model and Print a 3D Flower Vase

I began the design by following this YouTube tutorial:

1. Create a Sketch

I began by opening Fusion 360, selecting “Create a Sketch,” and choosing the plane to work with. From the “Create” panel, I selected the “Polygon” option, followed by “Circumscribed Polygon.”

2. Draw the Polygon

I drew a polygon with a 50mm radius. Then, I selected one of its edges and applied the “Horizontal” constraint from the “Constrain” panel to make the edge horizontal.

3. Rotate the Polygon

I duplicated the polygon and rotated it by -30 degrees to add variation to the shape.

4. Trim the Shape

I used the “Trim” tool from the “Modify” panel to clean up the shape, keeping only the outline that would form the base of the vase.

5. Extrude the Shape

After finishing the sketch, I clicked “Create Form,” followed by “Extrude” from the “Create” menu. In the “Extrude” panel, I set the faces to 24, the distance to 300mm, and the front faces to 3.

6. Shape the Vase

I started shaping the vase by selecting “Edit Form” and “Edge Selection.” I double-clicked on the first polygon to select it entirely, then scaled it up from the center to 2.2mm. For the upper part, I scaled it to make it narrower, reducing it to 0.15mm, following the same steps.

7. Adjust Bottom and Top Sections

I double-clicked on the bottom polygon to scale it down by 0.6mm, then readjusted the top section to 1.3mm. I applied rotation to both edges by rotating the top and bottom edges by 30 degrees in the same direction.

8. Close the Bottom Surface

After creating the twisted shape, I clicked on “Finish Form” and then created a surface to close the bottom hole. To do this, I navigated to the “Surface” tab, selected “Create,” and used the “Patch Tool” to select the bottom surface.

9. Stitch the Surfaces Together and Add Thickness to the Vase

I combined the newly created bottom surface with the top of the vase by selecting “Stitch” from the “Surface Modify” panel. I then added fillets to the edges, setting the value to 5mm.

I finalized the design by selecting the “Thicken” option from the “Surface Create” panel, applying a thickness of -3mm to create the hollow interior of the vase.

11. Export the Model

The final step was exporting the model as an STL file. I clicked on “File,” then “Export,” selected the destination folder, and saved the file in STL format.

12. Printing on the Creality K1 Machine

  • I began by opening the Creality Slicer software and importing the flower vase model.
  • Using the “Scale” option, I adjusted the size and arranged it efficiently on the printing plate.
  • I ensured the “Enable Support” option was checked and selected the “Support Shape” from the toolbar. After that, I clicked “Slice Plate” to generate the G-code for the printing process.
  • Together with my classmates, we organized the designs on the plate for concurrent printing. Once everything was set, I pressed the “Print” button to start the printing process.
  • The printer began the process, as indicated by the software interface.
  • After approximately four hours, the print was completed.
  • I used a scraper to carefully remove any unwanted parts, including the support material.
  • Finally, we presented the finished prints, as shown in the images below.

Individual Assignment: Task 3 – Design a 3D Object with a Mechanism (Flexible Tiger Keychain)

For this task, I designed a flexible tiger keychain, incorporating a mechanism that would allow it to be printed with movable parts.

To learn how to create the design, I watched the following YouTube tutorial:

1. Download and Convert the Image

I started by downloading a PNG image of a tiger, which I converted to SVG format using an online converter tool to make it compatible for use in Fusion 360.

2. Insert the SVG into Fusion 360

I opened Fusion 360 and inserted the SVG file by selecting the “Insert” button and choosing “Insert SVG.” I positioned and rotated the tiger design to fit my workspace.

3. Clean Up the Design

I cleaned up the design by removing extra lines, such as the tiger’s skin print, leaving only the outline, then clicked “Finish Sketch.”

4. Extrude the Tiger Outline

I extruded the tiger outline. The specific extrusion value wasn’t crucial at this stage, as I planned to adjust it later.

5. Scale the Model

I scaled the tiger to 100mm by measuring its current dimensions and using a scale factor of 100/current size. After scaling, I rechecked the length to ensure accuracy.

6. Adjust Extrusion Height

I returned to adjust the extrusion height. After scaling, the extrusion value was 7.404mm, so I added 0.596mm to reach the desired 8mm.

7. Divide the Model into Sections

I created a sketch on the tiger’s face and divided the model into four sections, leaving a 1mm gap between each part to form joints. I cleaned up the lines and clicked “Finish Sketch.”

8. Cut Voids Between the Sections & Form Connections Between Parts

Using extrusion, I cut voids between the sections to separate the tiger into four pieces. Then, I extruded the bottom of the rectangles to form connections between the separate parts.

9. Create the Joints

For the joints, I created the first knuckle by drawing a rectangle (8mm x 6mm) with an offset of 0.5mm, positioned in front of the gaps. I copied this rectangle for the other gaps. After finishing the sketch, I extruded these areas to create cuts.

10. Organize the Parts

As each part became a new object in Fusion 360, I organized and renamed them for clarity.

11. Design the Hinge Joint

I hid the first segment and created a sketch on the top surface of the connection rectangle to design the hinge. I drew lines and circles to create the hinge joint.

12. Cut the Hinge Joint

I selected the middle circle and edges and used the “Cut Extrude” tool to create the hinge joint.

13. Connect the Parts

I then connected the parts with a bin by hiding the second part and extruding the middle circle to join the top and bottom sections.

14. Repeat for the Remaining Parts

I repeated these steps for the remaining two parts to create the necessary joints and bins.

15. Apply Fillets to Improve Functionality

After completing the joints and bins, I applied a 0.5mm fillet to the circles at the top and bottom of each bin to improve functionality and prevent printing issues.

16. Add Keychain Hole

I added a small circle to the tiger’s head for the keychain connection and extruded it to create the hole.

17. Export the Model

Once done, I exported the file as an STL format by selecting “File,” then “Export,” choosing the location and format.

18. Slice and Print the Model

Finally, I sliced the model using Creality Slicer and printed it on the Creality K1 machine, following the same steps as outlined above. click here to download the file

This process resulted in a flexible, multi-part tiger keychain with functional joints, ready for 3D printing.

Introduction to 3D Scanning

3D scanning is a process that captures an object’s physical shape and appearance, converting it into a digital 3D model. Using technologies like laser scanning, structured light, or photogrammetry, 3D scanning creates detailed point clouds or mesh models.

These digital models are utilized across various industries, including:

  • Manufacturing
  • Product Design
  • Heritage Preservation

Applications of 3D scanning include:

  • Reverse Engineering
  • Quality Control
  • Digital Archiving

By accurately replicating physical objects, 3D scanning enhances precision, efficiency, and innovation, making it a valuable tool for design and analysis.

Individual Assignment: Task 4 – Utilize Mobile App Scaniverse to Scan Objects

Scaniverse is a mobile app designed to help users easily capture, manage, and process 3D scans. Here’s how I used the app for this task:

1. Open Scaniverse

I opened the Scaniverse app and selected the “Mesh” scanning option.

2. Begin Scanning

I began scanning the object by moving my device around it, capturing all angles to ensure a complete scan. After completing the scan, I began processing the mesh before proceeding with the edits.

3. Edit the Mesh

Once the sprocessing was finished, I used the app’s built-in tools to refine and edit the mesh, improving the overall quality of the model and croping it.

4. Export the Model

Finally, I exported the edited 3D model in STL format for further use or printing.

click to download the file

This process allowed me to efficiently create a digital representation of the object using Scaniverse.

Individual Assignment: Task 5 – Utilize Kinect Scanning to Scan Yourself

The Microsoft Kinect, originally designed for the Xbox 360, became popular among developers for its ability to quickly 3D scan and track humans. For this task, we used the Kinect with the Skanect app to scan ourselves. Below are the steps I followed:

1. Open Skanect & Start the Scan

I opened Skanect and positioned myself within the Kinect sensor’s field of view.

My friend started the scan by pressing the designated button, while I moved slowly to capture all angles.

2. Complete the Scan

The scan was completed when my friend pressed the button again to stop it.

4. Simplify the Model

I accessed the process toolbar and clicked “Simplify” to reduce the number of faces in the model.

5. Fill Holes in the Model

Next, I clicked “Fill Holes” and compared the “Open Hull” and “Closed Hull” options. After testing both, I selected “Closed Hull” and clicked “Run” to finalize the model.

6. Export the Model

Finally, I clicked “Share” in the toolbar, exported the model in STL format, and saved it.

click here to download the file This process allowed me to scan myself efficiently using the Kinect and Skanect, resulting in a digital 3D model.

Last update: December 8, 2024