[WEEK05] 3D Scanning and Printing

1. 3D Print Test

I modeled several parts with Fusion 360 and printed them to evaluate the design rules for my 3D printer.
The 3D printer, software. and material that I used are shown below.

3D Printer Trino 2 (Genkei)
Nozzle Diameter 0.4mm
Build Volume φ165×275mm
Slice Software Simplify 3D
Material Poly Plus PLA (Polymaker)

Unless otherwise noted,I set the following.
Extruder Temprerature 210℃
Bed Temprerature 60℃
Print Speed 3500mm/min
Layer Height 0.2mm
Number of Shells 2
Infill 15%




1.1 Cylinder

I examined the following items.

Diameter:
Designed value [mm] 0.2 0.4 0.6 0.8 1.0
Measured value [mm] X None None 1.14 1.24 1.40
Y None None 1.28 1.22 1.31
Designed value [mm] 1.2 1.4 1.6 1.8 2.0
Measured value [mm] X 1.27 1.70 1.60 1.94 2.06
Y 1.51 1.54 1.67 1.85 2.06
Designed value [mm] 2.2 2.4 2.6 2.8 3.0
Measured value [mm] X 2.18 2.38 2.57 2.83 3.02
Y 2.29 2.42 2.63 2.78 2.96
Designed value [mm] 3.2 3.4 3.6 3.8 4.0
Measured value [mm] X 3.19 3.46 3.59 3.75 4.03
Y 3.24 3.40 3.64 3.81 3.95

Text height [Font:Ariel Block]:
Designed value [mm] 0.7 1.40 2.2 2.9
Measured value [mm] None None 2.08 2.97

1.2 Cylinder (hole)

I examined the following items.


Diameter:
Designed value [mm] 0.2 0.4 0.6 0.8 1.0
Measured value [mm] X None None None None unmeasurable
Y None None None None unmeasurable
Designed value [mm] 1.2 1.4 1.6 1.8 2.0
Measured value [mm] X 0.50 0.68 1.06 1.42 1.66
Y 0.48 0.64 0.87 1.32 1.35
Designed value [mm] 2.2 2.4 2.6 2.8 3.0
Measured value [mm] X 1.92 2.05 2.26 2.36 2.53
Y 1.86 2.04 2.18 2.38 2.50
Designed value [mm] 3.2 3.4 3.6 3.8 4.0
Measured value [mm] X 2.80 2.86 3.24 3.21 3.50
Y 2.73 3.03 3.15 3.50 3.62

Text height [Font:Ariel Block]:
Designed value [mm] 0.7 1.4 2.2 2.9
Measured value [mm] None Buried Buried Almost buried

1.3 Cube

I examined the following items.



Length:
Width (X) Depth (Y) Height (Z)
Designed value [mm] 20.0 20.0 20.0
Measured value [mm] 19.92 19.91 20.12
Ratio [%] 99.6 99.6 100.6

1.4 Horizontal print without support

I examined the following items.



Slot width:
Designed value [mm] 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 20.0 30.0 40.0
Measured value [mm] 0.97 1.92 2.83 3.79 4.73 5.76 6.70 7.71 8.73 9.71 19.67 29.51 39.39
Ratio [%] 97.0 96.0 94.3 94.8 94..6 96.0 95.7 96.4 97.0 97.1 98.4 98.4 98.5

Slot height:
Designed value [mm] 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0
Measured value [mm] 9.91 9.87 9.75 9.53 9.56 9.53 9.51 9.44 9.43 9.38 8.95 8.92 8.7

1.5 Angle

I examined the following item.




1.6 What I learnt

Download

test_cyinder (.iges): Download the file
test_cylinder_hall (.iges): Download the file
test_cube (.iges): Download the file
test_horizontal (.iges): Download the file
test_angle (.iges): Download the file

2. 3D Design & printing

I created a 3D data for a pulley that its shaft, base ,and rotation part were integrally modelled. Based on the results of the test above, I thought that if the gap between shaft and rotation part was set for 1mm, and all angles of overhanged area for 45 degree, I could print almost without support. But I attatched the support materials only to a bottom of the rotation part because it was floating. While printing, the overhanged area of the rotation part was warped. So that area looks bad. But mostly it went well and an integral printing pulley that actually rotates was made (though it was a bit big).




Download

Pulley (.iges): Download the file

3. 3D Scanning

3.1 Structure Sensor

Structure sensor is a 3D scanner that is attatched to ipad mini. It can capture dense geometry. It is easy to use and nicely captured. But when I caputured large sized object, for example shole room, it stop to scan harfway.
At first, I tried to scan my hand and fix the data with some software.





I used Meshmixer to fix the hall, cut unnecessary area and modify the form.





I used Meshlab to reduce the number of mesh.



And then, I editted the data with Fusion 360. I tried to subtract the object from scan model by using 2D sketch, but I couln't. I researched the community of the fusion 360 and knew that the captured mesh data(.obj) couldn't be editted directly as solid model, and I had to convert a mesh to a BRep body type.

So I did that operation and then subtract and intersect with 2D sketch. In sucha way, I modelled two parts and print them. This is a 3D sign.







Download

raw.obj.zip: Download the file
hand01_edit (.iges): Download the file
hand02_edit (.iges): Download the file

3.2 Autodesk ReMake

I tried to make 3D model from pictures by using Autodesk Remake. This is pottery saving box. (In our lab the memnber used 3D printer, put the charge for material in this box.)
I took a picture about 20shot per lap. I did it from 3 angles and took a total of 60 photos.
I uploaded them to a cloud server of Autodesk and created a model.





Remake created 3D model, but it included a part of surroundings .



I removed the unnecessary area with a function of ReMake([Edit]→[slice]) and exported as obj file.And then I imported it to Fusion 360 and checked the details. It was a bit rough.



Download

The scanned data (scancat.obj) is included in the ZIP file above (raw.obj.zip).