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A helpful guide about 3D printing. 3D printing, CAD, Solidworks, Design Procedure. Shells – Passes around surface boundariesInfill – Percent of interior volume that is materialInfill Pattern – Defined by slicing program (cylinders, rectangles, hexagons)
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Colin Sledge and Joe King
Sledge & King
WHAT IS FDM?
FDM = FUSED DEPOSITION
MODELING
FUSED MELTING MATERIAL TOGETHER
DEPOSITION DEPOSITING MATERIAL
MODELING FEATURE CREATION
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WHAT IS FDM?
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WHAT IS FDM?
Normal CNC machining is subtractive
manufacturing
FDM is additive manufacturing
Both CNC machining and FDM use g-
code for control
Program written to file for every aspect
of part manufacturing
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WHAT IS FDM?
G type if motion
X,Y,Z coordinates
E,F feed rate
M machine commands
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FDM MATERIALS
ABS
PLA
PVA
NYLON
T-Glase
Filament with particles
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FDM MATERIAL
Not all material is the same quality
Use of different materials in one print for
support material
PLA and PVA can be dissolved away
from ABS parts
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PRINTER ANATOMY
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PRINTER ANATOMY
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PRINTER ANATOMY
0.4 mm
0.2 mm
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PRINT COORDINATES
Z Y
X
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PRINT FEATURES
IN X-Y PLANE IN Z PLANE
TOP VIEW FRONT VIEW
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INTERIOR PART DESIGN
Shells Passes around surface boundaries
Infill Percent of interior volume that is material
Infill Pattern Defined by slicing program (cylinders, rectangles,
hexagons)
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SLICING PROGRAM
STL and OBJ files
are input into the
slicing program
Slices part in z-axis
Part defined by
surface boundaries
Solid features structure is program
defined
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SLICING PROGRAM
Dual extrusion prints integrate multiple
parts into a single print
Each part component must be a separate
file (Think Nut & Bolt)
Dual extrusion parts are Aesthetically
pleasing with multiple colors
Use of dual extrusion for better supports
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COST OF 3D PRINTING
Small Machines - $1200-$2200
Material - $30-$100 per kilogram
Maintenance - ~$100 for lifetime
(variable)
Electricity 350 watt power supply
Comparable to desktop computer
Kilowatt hour ~$0.15 (http://www.npr.org)
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COST OF 3D PRINTING
Imagine machine is discarded after 1500 hours
1200/1500 to 3300/1500 = $0.8 to $2.20 per hour
30*10/1500 = $0.2 per hour
200/1500 = $0.14 per hour
(350/1000)*0.15 = $0.05 per hour
Total cost per hour = $1.19 to $2.59
Additional costs include overhead for rental space and technicians (expect ~$5 per hour) Sledge & King
3D PRINTING ACCESSIBLITY
3D Printing is accessible to YOU!
There is a wide range of machines and
prices of machines
Many large companies utilize 3D
printers and rapid manufacturing
Understanding the fundamentals will
make you an asset to a company
3D PRINTING IS HERE TO STAY!
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USING THE SLICING PROGRAM Rep-G MakerWare
More customizable
Stronger Parts*
Hard to use for Dual
Extrusion
More advanced
Slower
Great for Dual Extrusion
More intuitive user
interface
Part Preview
More difficult to
customize
Faster
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Rep-G
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MakerWare
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MakerWare
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PART PREPARATION
Check part for printability
Decide best orientation for printing*
Add bottom plate to part to mitigate
peeling and provide a clean surface
Modeled plate provides better support than
rafting and will maintain a better surface
Check slicing program and g-code
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CHECK FOR LEVEL BUILD PLATE
Check added model plate for air gaps
and rough texture
Use only minor adjustments
Only adjust when machine is warm
TOO FAR PERFECT* TOO CLOSE
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DESIGNING THE STRENGTH OF
THE PART
Choose the shells and infill to satisfy
strength requirements
More infill and more shells requires
more time to print
Both shells and infill are important to
part strength
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DESIGNING THE STRENGTH OF
THE PART
5% Infill & 5 Shells 10% Infill & 2 Shells 50% Infill & 1 Shell
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DESIGNING FOR PRINTING
It is necessary to foresee the
manufacturing process to determine the
best way to design a part
Determine minimum size of features
Like wood in terms of orientation for
strength*
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FREEDOM AND BENEFITS OF 3D
PRINTING
Rapid Prototyping
Complex Features
Intricate Details
Tooling
Molding
Presentations
Useable Parts!!!
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RAPID PROTOTYPING
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COMPLEX FEATURES
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INTRICATE DETAILS
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TOOLING
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MOLDING
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PRESENTATIONS
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USEABLE PARTS
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USEABLE PARTS
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MODELING ORIENTATION
In conjunction with orientation for
strength, orientation is also important for
printability
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MODELING ORIENTATION
IN Z PLANE
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INVERTED ANGLES
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INVERTED ANGLES
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INVERTED ANGLES
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INVERTED ANGLES
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INVERTED ANGLES
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OVERHANGING FEATURES
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OVERHANGING FEATURES
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FLAT SURFACES ARE BEST
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ROUND EDGES AND ARCHES
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ARCHES
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HOLES
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HOLES
Holes SHOULD NOT be drilled in post
process
Holes can be minimally enlarged or cleaned*
DO NOT Band-Aid parts!
Fasteners can be screwed into
appropriately sized holes
Lightening holes DO NOT always lighten
the part!
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THREADS
Internal and External threads can be printed and used
The part must be large to ensure threads are a printable size*
Vertical orientation will print easier but will not be as strong while sideways orientation will need to supported but will provide stronger threads
Threads should not come to a point and should be round if possible (FDM Design Handbook, 3rd Edition, Stratasys)
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THREADS
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INCORPORATING FEATURES
Parts should be designed to minimize
post processing
Unlike many machining processes,
additional features do not require tool
changes or much additional time, thus
additional expense
Added features often make the part
stronger and require less post
processing
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INCORPORTATING FEATURES
When adding features, be mindful of
feature orientation and loading
Often compromises are made
Determine if it is better to develop part in
multiple piece and screw or glue in post
processing
Curves print better in the X-Y plane
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INCORPORATING FEATURES
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INCORPORATING FEATURES
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INCORPORATING FEATURES
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STRENGTHENING FEATURES
Because the interior of parts are not solid, adding curves, cuts, and holes tend to strengthen parts, as this adds part boundaries, thus more shelled area
This can be used to add material near holes that screws tap into or holes that may be drilled out Of course, as noted previously, DO NOT drill the
part without designing the hole into the print
The strength often comes at the expense of weight
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STRENGTHENING FEATURES
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STRENGTHENING FEATURES
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SUPPORTS
Supports can be model defined or slicer
defined
Supports can be model from a different,
dissolvable material with a dual
extrusion printer
If supports are model based, make sure
to leave an appropriate gap between the
part: ~ 2 layers in each direction (If
break-away supports are used)
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SUPPORTS
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SUPPORTS
MakerWare
designed support
features can be
useful
Quick, yet not as
customizable
Great if you do not
have access to CAD
software
(www.makerbot.com) Sledge & King
SUPPORTS
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3D PRINTING FOR MAE
PROJECTS
Has the potential to greatly improve the
quality and functionality of your projects
This is NOT magic and DOES NOT
happen instantly
3D printing is an iterative process
3D printing is NOT a remedy for bad
engineering
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ENGINEERING DISCOVERY
3D printing allows you to explore your
designs and skills
Only you can discover the nuances of
3D printing to become an expert at
designing for additive manufacturing
HAVE FUN!
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3D PRINTING RESOURCES
ON-CAMPUS 3D PRINTING RAPIDTECH (4th floor Engineering Tower)
BUY YOUR OWN FlashForge www.ff3dp.com
Talk to Joe King*
MakerBot - www.makerbot.com
Sledge & King