TODO LIST




Introduction

The sixth week at the fab academy, I need to Design a non-subtractive 3D model and 3D print it and then, 3D scan an object and optionally 3D print it. First, i should learn and understand how to use a 3D printer and various types 3D printers. I also need to learn about 3D scanning and 3D scan an object myself. optionally, 3D print the scanned object.



Adictive Manufacturing

Adicitive manufacturing is the method that the techologies that build 3D object by adding layer by layer of material on the previous material. The 3D printer is increasingly used for Additive Manuafcturing. ... A range of different materials like plastics and composite materials may be used for 3D printing. Additive Manufacturing, developed a set of standards to classify the Additive Manufacturing processes into seven categories according to Standard Terminology for Additive Manufacturing. Different 3D printing Technologies that are listed below


image credit www.3dhub.com


3D printing

3D printing or commonly additive manufacturing is a process of making 3D models from a digital files like .STL. The creation of a 3D printed object is achieved using adding layers upon layers also known as addictive manumafturing. In an additive process an object is created by laying down successive layers of material until the object is created. Each the layers can be seen as a thiny sliced horizontal section of the 3D object. 3D printing is the opposite of subtractive manufacturing which is cutting out a piece of metal or plastic or wood with for instance a milling machine. 3D printing enables you to produce complex (functional) shapes using less material than traditional manufacturing methods.


image credit My3Dconcepts.com


Different Methods of 3D print

There is different ways to 3d printing. I'am explained all 3Dprinting methods below.



Fused Deposition Modeling (FDM)

Objects created with an FDM printer start out as computer-aided design (CAD) files. Before an object can be printed, its CAD file must be converted to a format that a 3D printer can understand — usually .STL format. FDM printers use two kinds of materials, a modeling material, which constitutes the finished object, and a support material, which acts as a scaffolding to support the object as it's being printed.






Stereolithography(SLA)

Stereolithography is a laser-based technology that uses a UV-sensitive liquid resin. A UV laser beam scans the surface of the resin and selectively hardens the material corresponding to a cross section of the product, building the 3D part from the bottom to the top. The required supports for overhangs and cavities are automatically generated, and later manually removed.






Stereolithography(SLA)

Material Jetting (MJ) is an additive manufacturing process that operates in a similar fashion to 2D printers. In material jetting, a printhead (similar to the printheads used for standard inkjet printing) dispenses droplets of a photosensitive material that solidifies under ultraviolet (UV) light, building a part layer-by-layer. The materials used in MJ are thermoset photopolymers (acrylics) that come in a liquid form.






Selective Laser Sintering (SLS)

Image result for Selective Laser Sintering (SLS)www.livescience.com Selective laser sintering (SLS) is an additive manufacturing (AM) technique that uses a laser as the power source to sinter powdered material (typically nylon/polyamide), aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure.






3D printer available at Fablab Kochi

At fablab kochi, we have two 3D printers available. One is Ultimaker 2 and other one is Dimensions SST 1200es. The Ultimaker 2 is a commonly used 3D printer. Ultimaker is best for to print small 3D models. In other hand Dimension 3D printer is one of the best 3D printer. Dimension gives us the best print quality.



Ultimaker 2




The Ultimaker 2 is a multifunctional Dutch 3D printer. It comes equipped with a heated build platform and can print at a resolution of up to 20 microns. It supports both PLA and ABS and can print at a speed of 300 mm/s.






Dimension SST 1200es




The Dimension SST 1200es is a powerfull 3D printer. The Dimension 3D printer gives us best in class print quality. In fablab kochi, we use Dimension only for complex printing or for good quality printing.






Group project : Test 3Dprinter(s) design rules

In this week's group assignment is to test and explore the different 3D printer design rules and settings. Understanding the limitations and advantages of our 3D printer is necessory. So, we downloaded a test design from Thingverse. We decided to test and explore the Ultimaker 2 3D printer that in our FabLab.

Ctrl V 3D Test by Suhailjr on Sketchfab

First we tested the 3D model in a standard setting. We used Cura Software to Slice the 3D model. Here is the screenshot of the settings. The printing time tool about 2 hour and 30 minutes, It is tool long to print but it because of the infill we gave 90% infill. The first test is good but the small gaps and walls are not printed what we expected.Most shapes are print in good quality but the walls are little mesup.







The second print we changed the layer height to .02
. And the print time is about 1hour and 16 minutes. The print quality is little bit less than the first pint.




Non-Substractive 3D print

In this week, my individual project is to 3D print a non substractive 3D model. To do do, i fire up my Fusion360 and started to design a model. So decided to design something useful to our Fablab. I designed a SD card and Flash drive holder. Then exported to .STL file. You can see the model in below.

via GIPHY



via GIPHY



3D printing in Dimension


The ultimaker is busy when i came for for 3D print my design. So, i used dimension printer to print my design. The process to print in dimension is completly different. But mostly similar. Dimension is take the control of some process. So all we need is to give the STL file to the Control software of the Dimension printer. The software to control Dimension is Catalyst EX software . The process to 3D print in Dimension printer is given below.



Now you can see the estimate printing time in the software and also on the Dimensions LCD display.




The printing time is almost 14 hours. It is more than half a day. After the printing process, i removed the object from the printing plate. Here is some snapshots the printed object.





Removing Support Materials


The Dimension use to type material same time. One is a ABS material to make the Object and the other one is the support materials. That means The Dimension uses seperate material for supporting layers. So i need to remove the suporting material now. Removing suporting material is not an easy process. To remove the Material, we have another machine called SCA 1200HT.The suport materils will solute in a mixture of chemical liquid. Two type of chemical powder will solute in water and The SCA 1200 HT will boil the chemical in between a user defined time interval. Then i dip my 3d object in to the solution for about 15 hours of time to remove evry tiny suporting material. This how we remove (solute) the suport material.







After removing the suport materials. I carefully cleaned the object with pure water. Then removed the exces small materials using tweezers and files. To smoothen the objects on rough sides, use files to do that.




The final Output of Non-Substractive 3D Model







3D Scaning and Printing



The second assignment in this week is to 3D scan a object. Optionally i can also 3D print the object. I can use any type method to do this. In our Fablab kochi we have Modela MDX20. Modela MDX20 is a milling mechine but we can also use this for 3D scan by replacing the tool head. But the only dis advantage of Modela is, it take too much time to scan a 3D object. Even small ones. I don't have much time. So, i decided to look away another method to 3D scan. The second method is to use a microsoft kinect to 3D scan. This is the easiest, simplest and perfect way to 3d scan objects. But the dis advantage is, we can't properly scan small objects with it. So i decided to scan my self by using kinect.


What is Kinect






Kinect (codenamed Project Natal during development) is a line of motion sensing input devices that was produced by Microsoft for Xbox 360 and Xbox One video game consoles and Microsoft Windows PCs. Kinect is usually used for playing games by sensing our body motion. We can also use the kinect for scanning 3D objects.



3D Scaning Using Kinect



>

I started scaning my body itself using kinect. I used a software called KSCAN.My instructors told me that KSCAN is better than other tools, So i go with KSCAN because i don't have much time (i took most of the time to 3d print). While scanning i made a big mistake. That mistake killed my lot of time. I will explain the mistake later.




To 3D scan using kinect first i installed KSCAN succesfully. Then i conected kinect wia the the USB to the computer. After that, i open the KSCAN. The KSCAN will automatically ditect the Kinect. I will explain how to use KSCAN step by step









Mistakes That I made While 3D scaning

I told you guys that i made a several mistake while 3D scaning with kinect. The mistake that i made was i omitted to combine the scan shots and finalize them. Technically it was not omitted, I doesn't realized that i need to do these two steps. First i thought that it was my mistake. So i modified the number scans and delay in each shots. Also i tried to rotate slowly myself to get good scan. But every time when complete the scan i never cobined those shots and finalized. Its leads me to try more and nore this stupid mistake and losted a lot of time. But i explored in the KSCAN and i realized to combine those scans and finalize the mesh. So, when you 3D scan with KSCAN and kinect. just make sure that you combine your scans and finalize it.




The final Output of 3D scan




I'am so sorry that i cant upload the STL file because the File is already more that 80MB. So i uploaded a screenshot of the 3D model in Cura






DOWNLOAD NON SUBSTRACTIVE DESIGN SOURCE FILE




DOWNLOAD 3D scanning SOURCE FILE