3D Scanning and Printing

3D Scanning

For the 3D scanning, I used the Sense 3D scanner. The workflow of its software is pretty easy. Firstly, the software asks you whether you would like to scan a person or an object. As I wanted to scan myself, I chose the person function. After I did that, it was giving you options for scanning just the head or the full body. I chose the head and proceeded. If I was to choose the object option, three options would pop up for small, medium or a large object.

After I chose everything correctly, the window for starting scanning showed up. For the scanning I had to use the help of one of my colleagues. My colleague was keeping the 3D scanner still as I sat in a rotating chair. After focusing the 3D scanner (I knew it focused as I turned green on the screen), we pressed start and in the beginning I started rotating very slowly and just once. But, as it had many problems not detecting either my back or loosing focus, what we did was for me to rotate three times in a still slow but faster than before pace. After doing that, the 3D scan was ready to be edited.

The first edit has the options of crop, erase and solidify. The crop option is for us to choose the part of the 3D scan that we actually want. For example, for the 3D print I scanned my hand and as I did that, I had to crop the 3D print, as my head was in the 3D scan also. The erase function is to erase any redundant 3D image that the 3D scanner might have added. Lastly, the solidify function is to close any openings that the 3D scan might have. For example, most of the times the 3D scanner does not 3D scan the top of the head. So, that part of the 3D scan is empty. In order to "put matter" on it we select solidify.

The second edit before saving it has the options of color, trim and touch up. The color function is for us to get rid of the color or not. The trim function resembles the erase function but it is a bit more precise. Lastly, the touch up function is used to smoothen rough surfaces.

After all the edits are done, the selection of share comes up. I could either save the 3D scan to a desired directory, upload it or print it using a 3D printer.

After I finished up this process, I inserted the 3D scan on Autodesk Meshmixer in order for me to have more functions in case I wanted to edit it even more than what the program of the 3D scanner was allowing me to.

3D Design

For the 3D print, I firstly used the 3D scanner to scan my hand, and then I used Fusion 360 to design a hand in accordance with the 3D scan of my hand. After I scan my hand using the method described above, then I imported it to Fusion 360.

After the import of the mesh, I entered the sculpt environment of the Fusion 360 by pressing the create option in the model environment. After I entered the sculpt environment, I chose to use the Cylinder. After I selected the cylinder, I selected the horizontal plane. After, I had to choose the centre point of my cylinder and drag the cylinder across the mesh body.

After I extended the cylinder to all of my mesh desired body, I subdivided the surface of my cylinder using the subdivide function and choosing the whole cylinder on the T-spline face option. Then I used the pull function in order my design to take the form of the mesh body, hence of my hand and again as before I selected the whole cylinder on the T-spline Vertices option.

After I pulled the cylinder in the shape of my mesh, I saw that I had an unwanted piece of cylinder between the thumb and the index finger. So, in order to get rid of that part, I entered the patch environment of Fusion 360, I drew a spline right below the unwanted part of the cylinder by creating a sketch, and then used that sketch used to get rid of that part from the main body using the function of split body. When using the split, I selected the main body as the "Body to Split" and the sketch as the splitting tool. After I pressed ok, we can see on the lef side of Fusion 360 that we have two bodies now instead of one. What I did was to hide the part of the body that I did not want.

After achieving the desired design, I had to make it solid because I could not use this design in order to 3D print it. In order to so this, I initially used the patch function under Create. The patch function is used in order to close the empty spaces of the design. So after selecting the function, I had to chose the two ends in order the design to close. After closing the upper and down part of the design, I selected the stitch function in order to make my design solid. After selecting the stitch option, I chose the main body and the two edges in order to properly stich it together. And this way I made my design solid.

After I made my design solid, I wanted to make the design hollow using the shell function in the model environment but it would not make it as the upper and the bottom faces were rounded. So, what I had to do was to create flat upper and bottom surfaces in my design. In order to do that, I went again to the patch environment, created lines and splines to the upper and bottom part of the design, I extruded those sketches and used them as planes to split the body.

So, after making flat surfaces to the upper and bottom part of the design, I used the shell function in the model environment, selected all the flat surfaces that I wanted to have a hollow space in and chose a shell of 2mm. After this my design was ready to get printed. Finally, I extruded it as an .stl file and carried on to the printing process.

3D printing

For the 3D printing, I used the BigRepOne 3D printer. First of, I copy pasted the original file of the settings of the BigRep in order to make sure that is a new one and made sure that I deleted the version that was used and the one that I copy pasted it. First of, I chose one of the two extruders to work with by deleting the other one, then I set up the layer settings as the height of one layer etc. After that on the additions settings I set the support settings for my design such as the need of the brim or raft, the pattern of the infill of my design on the infill settings and the speed that my design had to printed on the advanced settings. All the above could be found on the left side bottom corner of the program's window on the "Edit Process Settings". Then, on the right side menu of the program I found and set the support generator for any support of my design along the printing process. After I pressed ok, I went back to "Edit Process Settings" to set the printing settings of the support and set my design as two processes. I set it to be printed until 200mm from the outside to the inside because of its A-like shape and after the 200mm from the inside to the outside because of its V-like shape. To do that, I used the advanced and layer settings. After that I pressed to print, selected all the processed, pressed ok and saved to disk. The design it is saved as a gcode.

After having the .gcode, I went to the printer, switched it on and then pressed the yellow light near the screen of the printer in order for it to be turned on. After that, the first page of the GUI appreared and I pressed to prepare print. I plugged in my usb stick to the printer and transferred my file to the local jobs. After that, went to set the temperature of the bed to 70oC (normally it would be set to 60oC but because there is a door leading outside, the temperature bed had to be set higher) and the extruder to 205oC. This process took a while so meanwhile I loaded my print to the printer and went to home all the axis after I extruded some material from the extruder I used (for me T0; it was the only extruder also that I set the temperature of). First, I homed the x-axis, then the y-axis and lastly the z-axis. After everything was ready including the temperature of the bed and extruder, I pressed "Start Print". An important parameter was that for the first layer I used a speed of 60% and then I used a speed of a 100%. To do that I went to the temperature settings of the extruder, pressed advanced and I could set it from there.

Finally, the result looked like this :)

Downloads

The scan of myself can be found HERE.

HandScan.stl | Hand.f3d