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ELEC 391 ‐ 3D Printing 2020‐01‐13
1
3D PrintingECE Lightning Lab
Resources
• SolidWorks– Design parts
• Tinkerine Suite– Free Download
• Objet Studio– Lab computers
• ece.ubc.ca/~leos– SolidWorks help– 3‐D Printing help
• Design guidelines• Tutorials / Examples• Documentation• FAQ
ELEC 391 ‐ 3D Printing 2020‐01‐13
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Order Parts
• Link on Website to Tech Support Page & Fab Services
• 3D Printing
• Electrical Fabrication– PCB Printing
• Mechanical Fabrication– Waterjet Cutting
– Powder Coating
– Material Order
• Service Charges Only– Free material (within reason)
• Fe
• Al
• Plywood
– Square only
3D Printing
• Fused Deposition Modeling (FDM)– Extrusion printing– Plastic melted and extruded to create features layer by layer
• PLA (polylactic acid)• ABS (acrylonitrile butadiene styrene)
• Stereo‐LithogrAphy (Polyjet SLA)– Layers of photosensitive resin cured by light
• Laser• UV
• Selective Laser Sintering (SLS)– Layers of powder spread over part and sintered by laser– Metals
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Tinkerine (FDM)
Advantages
• Cheap printer– You have DIRECT access
• Cheap material– Single Material
– Adjustable % Infill
• Durable parts
• Control over Density (honeycomb)
• Short turn‐around time– Low resolution
– Print it yourself
Disadvantages
• Low Resolution
• Dangerous to free parts from bed
• Design Constraints– Wall angles
– Gap bridges
– Pseudo support material
– Minimum feature size
• Open Source Driver Software– Bugs
– Features
Objet (Polyjet SLA)
Advantages
• High Resolution
• Can make ANYTHING– Impossible to machine
– Very thin / fragile parts
– Working assemblies
– Overhangs
• Professional Driver Software– Reliable
– Repeatable
Disadvantages
• Expensive printer & material– No DIRECT access
– Build + Support
• Solid parts only
• Long turn‐around time– High resolution
– Must place order
• Brittle– Worse in Z‐direction
ELEC 391 ‐ 3D Printing 2020‐01‐13
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Support Material
37g4 Hours
24g2½ Hours
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SolidWorks : Save as STL File
5 deg
Smallest Value
Assemblies
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Printing an Assembly in Parts
Delete
Delete
OptionallyDelete
Delete
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Cost : 28 grams (build + support)
28g / 2:27 hours17g / 2:27 hours
Print Orientation
Build: 39Support: 30Time: 4:16
Cost: 69 grams
Build: 31Support: 3Time: 4:59
Cost: 34 grams
ELEC 391 ‐ 3D Printing 2020‐01‐13
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Hollow Parts
Lots of Support MaterialDifficult to Clean
Hollow Parts
Multiple PiecesAdd Pegs/Holes
Crazy GluePress Fit
Minimal Support MaterialEasy to Clean
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Design for PrintingAesthetic / Functional
Structural &FDM / Waterjet
Friendly
Fillet
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Section View
Section View
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InterferenceDetection
&ClearanceVerification
Specs in SolidWorks
• Min. feature width : – 1mm (flexible)– 2mm (sturdy)– 5mm OD (shaft)
• Assemblies– Min. joint gap : 0.2mm– Shaft = 0.5mm : 0.25mm on each
side
• Rotating joint with low backlash– Brass shaft / printed bore– Bore OD = Shaft OD + 0.1mm
• Press Fit– Male OD = Female OD– Chamfer male
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Caveats
• Large STL files– Spherical features– Small angle spec in STL generator– Max: 100MB
• Assemblies not easily freed– Large joint surface area– Coupled joints– Small (fragile) shafts– Interferences– Glossy welds
• Scrape off ALL support material• Do not print threads
– Use insert
• Holes can be expanded but not shrunk– Do not drill FDM beyond wall thickness– Polyjet is brittle and may break when drilled
• Pressing:– Do not hammer– Use vise or press– Chamfer shafts/holes
• Drilling:– High speed chuck– Advance drill VERY SLOWLY
Post‐Processing
• Delicate Parts:
– Ultra‐Sonic Bath in Machine Shop (40 min)
Water
Sodium Hydroxide(Lye)
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• Screws– Threaded inserts– Sheet metal / self‐tapping– Sex/barrel bolts
• Retaining Rings– Internal– External– E‐Clip– Cotter Pins
• Rivets• Crazy Glue
– Hole/stud
Fasteners