3D Printing Notes PDF

History of 3D printing First Ted Talk focused on 3D printing: 2012 First time Pres Obama mentions it: 2013 First student accessible 3D printers on TMU camous: 2014 "A once-shuttered warehouse is now a state-of-the art lab where new workers are mastering the 3-D printing that has the potentia...

History of 3D printing First Ted Talk focused on 3D printing: 2012 First time Pres Obama mentions it: 2013 First student accessible 3D printers on TMU camous: 2014 "A once-shuttered warehouse is now a state-of-the art lab where new workers are mastering the 3-D printing that has the potential to revolutionize the way we make almost everything" - President Barack Obama State of the Union address February 13th 2013 Order of Invention Stereolithography (SLA) Uses Light and Light-reactive chemicals to build layers of solid material out of liquid or semi liquid. Most common: UV light and UV Sensitive liquid resins. The UV light is applied to the resin in a directed pattern to solidify the resin layer by layer, making a three dimensional solid. Originally relied on an (expensive) Laser or Digital Light Processor (DLP) for projecting the layer-images onto the photosensitive liquid being used. Modern SLA often uses a low cost, high resolution monochrome LCD (similar to those found in eReaders), making them much more affordable. Very high resolution makes it ideal for small objects. Distinctly different from the FFF / FDM technologies we've looked at so far - we'll be reviewing SLA in-depth in a future lecture. The Stereolithography (SLA) process was invented & patented by Charles (Chuck) Hull in 1984 - this is generally considered the first "true" 3D printing process Alain Le Méhauté, a French engineer that worked for General Electric (GE) at the time, actually filed a patent three weeks before Chuck Hull, but GE abandoned the patent before completing the process because "they could not perceive the size of the commercial potential" SLA became the founding technology for 3D systems (with Mr. Hull as Founder and President) in 1986. 3D System operates worldwide, with ~2000 employees, $636 million in sales (2019) and a market cap of ~$2.5 billion USD. The first thing Chuck Hall printed was a tiny cup used as an eye wash FDM/FFF - Makerbot Replicator + Fused Deposition Modeling / Fused Filament Fabrication Uses a spool of filament (typically a plastic), heated to melting point and applied in layers by a print head to build an object layer by layer. Inexpensive (relatively), easy to understand (relatively), and easy to use (relatively). Most common 3D printing technology encountered outside of manufacturing and engineering specialist fields. 1989 Lisa Crump and S. Scott Crump invented the Fused Deposition Modeling (FDM) process and founded the Stratasys company. Scott, a mechanical engineer by trade, says the core idea for FDM printing was inspired by his attempt to make his young daughter a toy frog using a hot glue gun loaded with candle wax and polyethylene Important patents around FDM expired in 2009 Stratasys operates worldwide, with ~2200 employees, $668 million in sales (2017) and a market cap of ~$1.4 billion USD. Fused Deposition Modeling / Fused Filament Fabrication Technically speaking, these are not the same thing (even though they are often used interchangeably): FDM devices use an enclosed, heated print chamber that improves consistency and permits a larger range of material types to be accurately used. They always feature dual + extrusion with soluble support materials in the secondary extruder. FFF is a simplified version of FDM that started gaining traction - particularly in home workshops and maker spaces = after key EDM Patents exnired in 2009 Makerbot was officially founded in 2009 (when key Crump patents expired) with the goal of producing "mass market" FFF 3D printers Makerbot had sold over 100,000 3D printers by 2016 Founded and operates Thingiverse, the worlds largest online 3D printing community site Heavily featured in the 2014 documentary "Print the Legend", available on Netflix Was purchased by Stratasys in 2013 for $604 Million USD Selective Laser Sintering Uses a high powered laser to sinter nylon powder (generally). Sintering is a process of fusing material together without liquifying (melting) it. This causes the power to bind together to form the object being printed. Because the print area is entirely composed of powder, it is self-supporting - only the powder that is sintered sticks together, the rest can be brushed or vacuumed away. First patent of this type of technology was by R. F. Housholder in 1979, but the patent was not developed into a commercial product SLS in its modern incarnation was patented by Dr. C. Deckard and his academic adviser, Dr. Joe Beaman in the mid-1980s. Their research was sponsored by the US Military through DARPA Dr. Deckard founded the company Desk Top Manufacturing (DTM Corp.) in 1987 to commercialize the patented technology DTM Corp was purchased by Chuck Hull's 3D Systems in 2001 for $45 Million USD Gartner Hype Cycle 1. Technology Trigger A potential technology breakthrough kicks things off. Early proof-of-concept stories and media interest trigger significant publicity. Often no usable products exist and commercial viability is unproven. 2. Peak of Inflated Expectations Early publicity produces a number of success stories-often accompanied by scores of failures. Some companies take action; most don't. 3. Trough of Disillusionment Interest wanes as experiments and implementations fail to deliver. Producers of the technology shake out or fail. Investment continues only if the surviving providers improve their products to the satisfaction of early adopters. 4. Slope of Enlightenment More instances of how the technology can benefit the enterprise start to crystallize and become more widely understood. Second-and third-generation products appear from technology providers. More enterprises fund pilots; conservative companies remain cautious. 5. Plateau of Productivity Mainstream adoption starts to take off. Criteria for assessing provider viability are more clearly defined. The technology's broad market applicability and relevance are clearly paying off. If the technology has more than a niche market then it will continue to grow. Some Areas 3D Printing is Currently Helping 1. Trinkets & Toys of Value In one year, 429 makers printed 68,900 toys for Toys for Tots Fully assembled and working Fidget Spinners and similar devices 2. Making objects that are not possible or efficient any other way Complex, interlocking shapes ("Print in Place" objects) 3. Education & Community Local, low budget production of objects and tools 4. Rapid Prototyping Inexpensive and low risk way to verify fit and correct design Scale Prototypes of buildings and structures for client review 5. Replacement Parts "Functional" prints for home and business needs 6. Improving Creative Hobbies Tabletop gaming, cosplay props and more Custom display brackets and adaptors 7. High Quality Prosthetics Much faster to produce than traditional methods 8. Living Bio-tissues Enhancing medical applications "3D printing is a democratic manufacturing method that lets anyone create an idea; Just like children do when they are playing with Lego" - Michael Laws Teaching Tech 3D Printing is quietly changing many industries - but not in ways that many experts and journalists expected. What 3D printing is for used today? Professional Usage Product design & prototyping Manufacturing Jigs & Fixtures Master products for mold making Limited run manufactured items Distributed manufacture of component parts Research and innovation Hobbyist / Maker Usage Art, desk accessories and toys Gadgets and tools Household items and parts Cosplay props Gaming Personalized gifts Why Is it important Subtractive Manufacturing Most traditional manufacturing or craftsperson processes are considered to be "subtractive" manufacturing: The machining process starts with a block of raw material (such as wood, plastic or metal) Cut away (subtract material) until you have made the parts), or use machining, milling, laser cutting, drilling, lathing, welding, etc. Then assemble parts back together with fasteners, glue, nails, etc. These processes may or may not be CNC (computer numerical control) enabled - many are reliant on skilled crafts-persons. We are left with a pile of "offcuts" (waste). Modern Mass Manufacturing Methods There are two main modern methods of manufacturing object / part / component: Injection molding If a large enough quantity is necessary to justify making a mold and to justify the significant set-up costs, injection molding is used. This method will usually result in the lowest cost (per piece) of manufacturing a part. Molds are expensive The tooling, jigs & fixtures required to set up a production line are also expensive Machining In modern manufacturing, if you don't have the volume to use injection molding, you typically use machining. The roots of machining was producing objects by hand, such as a blacksmith forging a sword in medieval times. Additive Manufacturing 3D printing is (by contrast) an Additive Manufacturing process. Conceptually this is straight forward: An object is created by starting with nothing, and adding material a layer at a time, until the object is completed Advantages of Modern Additive Manufacturing Much lower waste Instead of needing to know how to (safely) use a variety of machines, equipment and techniques, you instead need to know how to operate just one machine: The 3D printer Many different manufacturing locations can rely on the CAD skills of a smaller number of designers / engineers through file sharing. Complex shapes and designs can be manufactured without having to fasten or assemble multiple parts together: This means parts can often be lighter, since they may have less components, and in some cases more structurally sound since they are a single object Alternately: multi-part objects can sometimes be printed pre-assembled, dispensing of the need for part assembly. Ideal for lattice structure construction, which is used throughout nature for strong but lightweight and resource efficient structures Generative Design Al driven generative design permits a faster, more efficient design process for load bearing or otherwise constrained parts Stages of Product Design Concept Models Product development begins with drawings and/or 2D / 3D computer models Computer models are quick to make and can be used for analysis Next step is a physical model that demonstrates the concept The model may be non-functional, but gives a general impression of what the finished product may look like Concept allow you to assess feedback internally Conduct preliminary market analysis to gauge whether the product is appealing to consumers Concept models allow people to comprehend an actual physical model rather than an abstract idea Positive feedback both internally and externally means the product may move to production, if not then it's "back to the drawing board" Testing form, fit, and functionality A concept model can provide a general idea of what a finished product will look like You create something with the form, fit, and functionality of a finished product Begin with a 3D CAD (computer aided design) model of the product and its components. Determine if conventional manufacturing (start with a solid block of material and cut away the excess) or use 3D printing / additive manufacturing (to build up one layer at a time) Identifying the right manufacturing process involves understanding part geometry, volume, material used, cost, urgency, and several other important considerations Most often it will take several iterations, as part of the product life cycle to avoid a flaw during production. Low-volume production In a niche market they may be able to produce the entire volume required. Testing often initially leads to low-volume production, even for mass produced products, leading to quick availability to market Companies with expertise in digital manufacturing are well suited for low volume production because of the fast turnaround. Iterative Development and Pivoting Digital manufacturing isn't a single process that uses one type of material. Several different processes and materials may be appropriate during different stages of development and production. Prototypes can be made of test materials that might be less expensive and quicker to produce. This is practical as iterations are tested for form, fit, and appearance. Summary 3D Printing and additive manufacturing isn't "just a new type of gadget" - it is an entirely new ecosystem of fabrication that leverages the combined contributions of millions of people via the internet. It's applications are being researched for everything from food production to medical sciences to building fabrication on other planets. It puts much of the power of an entire traditional workshop into a office friendly device that can be operated with minimal training, to output designs that can be shared and iterated upon at zero cost across the world. We are still learning how to best apply the technologies, and how optimal utilization of 3D print can reinvent entire workflows, processes and supply chains. It is estimated that around 30% of all manufacturing globally will transition from Subtractive (SM) to Additive Manufacturing (AM) Subtractive (SM) & Additive Manufacturing (AM) are complimentary - you will find machines sitting side by on the factory floor. Pandemic has shown us how fragile our supply chains can be. 3D printing is one element that can help us build towards a less wasteful and less transport dependent future. How to access 3D Printing On Campus Digital Media Experience Lab (SLC 2nd Floor) Innovation Studio Design and Technology Lab (Creative School) Specific departmental resources Outside TMU Public Libraries Makerspaces and Tool shares Commercial Service Bureaus 3D Print Software and Design Considerations 3D Print Workflows 3D print workflow so we've talked before about the general workflow for 3D printing being having a concept or idea designing it to open an STL file bringing that STL into a slicer to generate your G-Code then using that G-Code to actually output your object on the 3D printer and then finally any post processing that's required removal of supports sanding painting what have you and that's that's you know 3D print workflow so we've talked before about the general workflow for 3D printing being having a concept or idea designing it to open an STL file bringing that STL into a slicer to generate your G-Code then using that G-Code to actually output your object on the 3D printer and then finally any post processing that's required removal of supports sanding painting what have you and that's that's you know the primary method for most 3D printing that we're doing in this program now this lecture in particular focuses on those two software heavy steps the the the the cad and slicer steps of the process WHAT ARE OTHER WAYS OF GENERATING A 3D FILE FOR PRINT? but what are other ways of generating a 3D file for print you're not always going to be designing something in a 3D design program one way to do it is using a 3D scanner and there's a variety of different 3D scanners we'll be covering later in the term um talking about how you can take a physical object and read in the dimensions of that object to generate a file usually those files require some cleanup afterwards they're not always perfect right out of the gate but you know it is one way to if you have an existing physical object and need to get it into a reproducible STL file format you know a 3D scanner might be the right option for you and then extracting files from existing resources so commonly things like video games will have 3D information 3D file information and objects in their resource files and you can in some cases extract those files and again with a little bit of cleanup um you can in some cases be able to print those fire files or generate G-Code from those files to Output to your printer so there are a few other methods of of generating 3D print files although again we're going to focus primarily in this lecture on using a CAD program itself so let's talk about some key terminology when we when we talk about um how to create and manipulate 3D files Polygon Modeling "Polygon models (also known as meshes) are a collection of vertices, edges and faces that define the model, which allows for easy and precise editing of parts of your object. By changing the coordinates of one or several vertices, you can change the shape of the model." Vertex (plural: Vertices) "A vertex is the smallest component of a polygon model. It is...a point in a three- dimensional space. By connecting multiple vertices with edges you can create a polygon. These points can be manipulated to create the desired shape." The teal dot on the object to the right is a single vertex of this model. Edge "Edges help define the shape of the models, but they can also be used to transform them. An edge is defined by two vertices at their end points" The teal line on the object to the right is a single edge of this model. Face "A face is the most basic part of a 3D polygon. When three or more edges are connected together the face is what fills in the empty space between the edges and makes up what is visible on the polygon mesh." The area marked in teal on the object to the right is a single face of this model. NURBS Modeling "NURBS stands for Non-Uniform Rational Basis Spline. A NURBS model is a mathematical modeling type commonly used to generate curves and surfaces. In contrast to Polygon Modeling... curves are created with a tool that works very similarly to the pen tool in... Adobe Illustrator. The curve is drawn in a 3D space, and edited by moving a series of handles called CVs or control vertices..." Primitives Primitives are the most basic, foundational shapes in 3D design. Common primitives in 3D design software include Cubes, spheres and cones. In the Tinkercad follow-along tutorials we build the CN Tower, Snow Person and Parthenon using primitives available in that software. Extrusion In 3D modelling software, extrusion is the process of turning a 2D shape into a 3D shape. For example, taking a square plotted out on the XY plane, and using the extrusion tools in your program to give it "height" on the Z-axis. Autodesk Fusion 360: Sketches "Sketches are comprised of two-dimensional geometry like lines, circles, arcs, points, and splines. Sketches are created on a plane or existing flat face of a body. You can draw sketch geometry or project edges from existing faces. You can also use dimensions, constraints, and parameters to fully define sketch geometry. This ensures you can control the form of the 3D bodies you create from your sketches." - Autodesk Product Documentation Manifold Geometry Manifold geometry is where each edge of a 3D object is shared by two faces (only). Non-Manifold Geometry When more than two faces share the same edge in the file composition, this is called non-manifold geometry and printers can have significant difficulty processing to print, or printing. In the object to the right, both cubes share one edge so four faces are joined in non-manifold geometry. Watertight Watertight is another way files are described, and is related to the object being manifold. It may or may not indicate that the model is waterproof — that is a different measure. A watertight model has all of the faces connected in a rational / logical way that can exist in the real world and thus be understood by the printer and printed correctly. For various reasons, files may not be watertight. Depending on the severity of the issue this may or may not cause problems for printing. Some slicers will refuse to process / slice models that are not watertight. Fillet Fillets are rounded edges of an object. They are useful in 3D printing for both aesthetic and functional/printability reasons. They can be applied at different radii to make the rounding of the edge different sizes. It is not recommended to apply downward facing fillets, as these may need supports to print cleanly. Chamfers Chamfers are sloped edges of an object. Like fillets, they improve the look and printability of many objects. A chamfer is usually 45 degrees (by default), but can be adjusted. Shallow angled Chamfers are a good alternative to fillets for downward facing edges, as they often do not need supports. Gusset Gussets are sloped ribs that can be used to reinforce and strengthen thin features or areas an object is going to experience stress. The are not as useful as chamfers for improving printability, but can also take less filament to print and speed up printing time. 3D SOFTWARE explore tools that are not even in the the course content so as a quick here are some of the various 3D printing tools obviously we've talked about tinkercad in class we've also talked about Fusion in class um if you've looked at the 3D experience World um that's put on by salt systems or so rather which is SolidWorks um and then you've got zbrush and other softwares in here as well so there's a lot of different different software available and many of them are widely supported they have good communities they're being updated and and they're very much alive as far as software "..it is tempting, if the only tool you have is a hammer, to treat everything as if it were a nail." - Abraham Maslow There is a significant cognitive bias towards tools that you are particularly familiar with and/or comfortable with. Reccomended Autodesk Fusion 360 - Professional "...unifies design, engineering, electronics, and manufacturing into a single software platform... cloud-based 3D modeling, CAD, CAM, CAE, and PCB software platform for product design & manufacturing." Blender "Blender is a free and open-source 3D computer graphics software toolset used for creating animated films, visual effects, art, 3D printed models, motion graphics, interactive 3D applications, virtual reality, and computer games." FreeCAD "FreeCAD is a general-purpose parametric 3D computer-aided design (CAD) modeler and a building information modeling (BIM) software application... It is intended for mechanical engineering product design but also expands to a wider range of uses around engineering, such as architecture or electrical engineering." Solidworks - - Professional "SolidWorks is a solid modeling computer-aided design (CAD) and computer-aided engineering (CAE) computer program published by Dassault Systèmes... SolidWorks does not support macOS." Tinkercad "Tinkercad is a free-of-charge, online 3D modeling program that runs in a web browser. Since it became available in 2011 it has become a popular platform for creating models for 3D printing as well as an entry-level introduction to constructive solid geometry in schools." File Analysis and Repair MESHMIXER Autodesk has actually rolled all of the tools from meshmixer directly into Fusion so you no longer have to use a secondary application and have something else installed on your desktop you can just use the the mesh mixer equivalent tools in Fusion now instead Meshlab Meshlab is a lightweight, open source mesh viewer and 3D object editor with excellent remeshing (mesh optimization) scripts. Autodesk Netfabb Advanced 3D file preparation aimed at engineers and other professional users. Integrates with Fusion 360 to streamline workflow and optimize print output. Has generative design functions to further extend users' design capabilities. SLICING SOFTWARE Ultimaker Cura Easy enough for new users to get into with minimal training and support, but with a depth of features that allow intermediate or expert users to make fine tuning adjustments to their prints. Extensive support and stable releases make this a great choice all-around. Octoprint Web based 3D printing control interface allows users to remotely access features and functions of their printer (s). Has access control, allowing for multiple users to utilize the same equipment from anywhere in the world. Features plug-in support and has an active user community improving things all the time. Slic3r (& PrusaSlicer) Slic3r is a general 3D print toolkit built around a slicer application. It is community developed and releases ambitious (if somewhat experimental, and occasionally unstable) features regularly. PrusaSlicer is a fork of Slic3r, released by Prusa, a large 3D Printer hardware manufacturer and active 3D print research company in Czechoslovakia. Chitubox Slicing for SLA, LCD and DLP 3D printers is different then FDM/FFF, and calls for specific software. The current leader here is Chitubox, available in Basic (free) and Pro versions. Like Cura, it is user friendly but has powerful features that help intermediate and expert users get the most out of their 3D Print equipment. SPECIAL TOOLS Special Tools: Lithopanes "A lithophane is an etched or molded artwork in very thin translucent porcelain or plastic that can be seen clearly only when back lit with a light source" - Wikipedia There are numerous online lithopane file generators. Two of the most frequently mentioned ones are below: https://3dp.rocks/lithophane https://lithophanemaker.com Special Tools: Parametric 3D File Generators Objects and shapes that can be mathematically represented in a defined pattern can have custom software developed to allow users to generate objects based on input parameters. The Snowflake machine is an example of this - on Thingiverse, click the "Open in Customizer" link to get started. You can style your snowflakes using the various style parameters, and generate a unique, printable,.STL file!.STL File Stereolithography files (.STL) are the most commonly used 3D object file format for 3D printing. They contain no inherent scale information, but do use units for mapping on a three-dimensional cartesian co-ordinate system. Almost all software (by default) treats the otherwise non-scaled units as millimeters..OBJ File Object files (.OBJ) are structurally very similar to.STL files, using the same geometry to define the overall shape of an object..OBJ files have the ability to incorporate photographic data as well though, mapped onto the object's geometry via a texture map. This is essential for 3D printing a colour 3D object..FBX files Originally developed by Kardara, purchased by Autodesk in 2006. FBX files are used extensively in the video game and film industries, because they features geometry, colour / texture maps, model skeletons (rigging) and animation. They're also commonly used as an exchange format between different 3D Animation software programs. Specialized & Proprietary formats In addition to the (fairly) universal.STL and.OBJ file formats, there are dozens of specialized or proprietary formats specific to different software and hardware manufacturers. They are often optimized for the specific software or hardware they're meant to be used on..DWG - AutoCAD file format.BLEND - Blender file format.Thing - Makerbot specific working (set up) file format.Makerbot - Makerbot specific output file format (instead of G-Code) G-code G-code stands for Geometric code. It is a programming language that provides a machine controller with details of what components to activate or move and to what levels, controlling motors and sub- components of the machine during operation. The original format was developed in the 1950s, and gained prevalence in CNC (computer numerical control) operated devices, such as CNC Mills and Lathes, in the 1970s forward. It has had many revisions and variants, and - as can be expected of a format almost 70 years old - does not follow conventions of "modern" programming languages. When preparing a file in a slicer such as Cura for a particular printer, G-code is generated to control the various movements, temperatures and details of your 3D print. Many elements of the G-code file created for a printer are specific to that device, so you cannot use the same G-code file on a different model of printer - you would need to go back to your slicer, update the printer and re-output the G-code, even if printing the same object. This is why we save our object files in a different file format (such as.STL) than the file that is sent directly to the printer for printing. Extrusion Based FDM / FFF Printing FDM is the easier term to say even though FFF is techinically mor accurate Extrusion Based FDM: What Is it? Fused Deposition Modeling (FDM) FDM is a specific type of additive manufacturing where (generally speaking) a solid material is heated until it melts just past its transition temperature, and is then extruded. The extruded material is placed on top of (or next to) a layer of previously extruded material. Repeating this process creates an object, by building it up layer by layer. FDM / FFF Fused Deposition Modeling / Fused Filament Fabrication Uses a spool of filament (typically a plastic), heated to melting point and applied in layers by a print head to build an object layer by layer. Inexpensive (relatively), easy to understand (relatively), and easy to use (relatively). Most common 3D printing technology encountered outside of manufacturing and engineering specialist fields Fused Deposition Modeling vs. Fused Filament Fabrication Technically speaking, these are not the same thing (even though they are often used interchangeably): FDM devices use an enclosed, heated print chamber that improves consistency and permits a larger range of material types to be accurately used. They always feature dualt extrusion with soluble support materials in the secondary extruder. FFF is a simplified version of FDM that started gaining traction - particularly in home workshops and maker spaces — after key FDM Patents expired in 2009 Cartesian - 3 points Large, Boxlike frames Linear Rails Relatively inexpensive Simple to understand Very strong Community Support Print height limited to frame height minus component height Delta Extruder supported by three arms on rails in a triangular configuration Can be faster More complicated geometry Hardware: Non-Cartesian / Delta SCARA SCARA stands for "Selective Compliance Assembly Robot Arm", a technology developed in the 1980s Print head is mounted on 2 robotic arms, each with their own motor Relatively Fast Relatively small vs the available build volume Somewhat imprecise Limited community support POLAR Plots points on a circular grid (vs a rectangular one) Angle & Distance is used to locate the XY position Have a spinning circular build plate Print head mounted on a single arm Fewer motors Relatively quiet Relatively slow Print quality subpar. Limited community support Parts of an FDM Printer Filament holder and feed mechanism Hot end (extruder) Cold End Build plate Frame and motors Electronics power supply computer board interface/ display Filament Roll Holders Many varieties of methods used to house filament External spool holder systems can be used but some printers require that their proprietary filament be purchased Filament Feed Mechanism Wide variation of filament feed systems Filament detection systems are becoming more common Nozzle Size Larger Nozzles (>0.4 mm): High strength Reduced print time Fewer nozzle-related print errors Smaller Nozzles (