Week workflow

Weekly assignment → Test Printer → design as object → Print object → Scan object → print scanned object (optional)

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Tools used

• Delta 3D Printer
• Mini 3D Printer
• Caliper
• 0.4 mm needle
• Uhu glue

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Software Used

• Repetier Host
• Solid Works
• Autodesk Recap

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Files Generated/used

• Test's stl file: 3D Printer test model from thingiverse
• Gcode file: all week's generated Gcode from STL files
• Solid Works file: 3D model for a wire organiser used on my final project
• Chain's stl file: Generated stl file from the solidworks archive

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1. Printers preparation


1. In order to start the test I prepared the printers by cleaning the nozzles and spreading new glue into the platforms



Glue used on the platform



0.4 mm needle used to clean nozzle

2. I tested the extrusion on both printers and it looks good ;



PLA being extruded



PLA being extruded



2. The limits of our printers


1. I started this week's assignment by looking for a test pattern on the website Thingiverse . Simply by using its search engine with the keywords, "test 3d print" it show various results with the purpose of testing the printers.

   

   Print from the search at Thingiverse

2. Then I selected one of the designs. It tests different capabilities of the printers.



Print from the test pattern page at Thingiverse

While on the 3D printer test model's page I downloaded the design and took note of all the parameters it intends to test such as:

• Nut, Size M4 Nut should fit perfectly
• Wave, rounded print
• Star, Sharp Edges
• Name, Complex Shapes
• Holes, Size 3, 4, 5 mm
• minimal Distance: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7 mm
• Z height: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 mm
• Wall Thickness: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7 mm
• Bridge Print: 2, 4, 8, 16 mm
• Sphere, Rounded Print 4.8mm height
• Sphere Mix, 7 mm height
• Pyramid 7 mm height
• Overhang: 25, 30, 35, 40, 45, 50, 55, 60, 65, 70°
• Warp, does it bend?
• 3D Print Font, optimized for 3D printing
• Surface, Flatness
• Size, 100 x 100mm x 23.83 (10mm width)
• Spike, minimum Layer Time, 21 mm height from Bottom (include Baseplate)
• Hole in Wall, 4 mm diameter, check for proper print
• Raft Test, raft should be just under the model
• Retract Travel, check retract settings for longer travel



Bellow is the 3D print test model:

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rendered 3D model of the STL file

The author also supplies an image for reference when checking the print



Infographic from the forum phpBB



3. On the software Repetier Host I loaded the stl file and sliced for each printer. Naming the Gcode with the printer designation in front.



Generating Gcode on Repetier Host for the Mini



Generating Gcode on Repetier Host for the Delta

4. Next I took the Gcode I had save on the SD card and placed on the 3D printers and started the print.

Video of mini starting the test print

5. The prints were not bad but there was a lot of oozing (spider web). So I increased the retraction by .5 mm and then by 1 mm the improvements were very noticeable in both printers.

   

   photo of prints with 1.5(left) and 2.5mm(right) retraction settings

6. The results



	Parameter	Results
		Mini	Delta
1	Nut, Size M4 Nut should fit perfectly	Yes	No
2	Wave, rounded print	Yes	Yes
3	Star, Sharp Edges	Yes	Yes
4	Name, Complex Shapes	Yes	Yes
5	Holes, Size 3, 4, 5 mm	2.9, 3.9, 4.9	3, 4, 5 mm oval
6	minimal Distance: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7 mm	0.1mm not good	0.1, 0.2, 0.3 not good scale wrong 6.5mm instead of 7mm
7	Z height: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1 mm	0.1mm printed with 0.2 and 1.1 with 1	Yes
8	Wall Thickness: 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7 mm	did't print 0.1, 0.2 next walls printed as 0.5 until last as 1mm	Yes
9	Bridge Print: 2, 4, 8, 16 mm	Printed as 2.85, 3.9, 7.9, 15.8	Yes
10	Sphere, Rounded Print 4.8mm height	5.1	Yes
11	Sphere Mix, 7 mm height	7.15	Yes
12	Pyramide, 7 mm height	6.95	Yes
13	Overhang: 25, 30, 35, 40, 45, 50, 55, 60, 65, 70°	Yes	Yes
14	Warp, does it bend?	no	Yes
15	3D Print Font, optimized for 3D printing	Yes	Yes
16	Surface, Flatness	a bit rough	Yes
17	Size, 100 x 100mm x 23.83 (10mm width)	99.45 x 99.8 x 23.2 (10.2 with)	Yes
18	Spike, minimum Layer Time, 21 mm height from Bottom (include Baseplate)	15mm	Yes
19	Hole in Wall, 4 mm diameter, check for proper print	Yes	Yes
20	Raft Test, raft should be just under the model	didn't test	Yes
21	Retract Travel, check retract settings for longer travel	almost no ozzing	Yes
	Conclusion	For a FDM printer I belive the result is very good. The sizes differences are probably due to a PLA shirincage



3. Designing and printing an object


1. I decided to create a necessary part of my final project. It's a wire organiser that when connected together works as a chain.
2. The design is parametric so I can easily change the size as needed



parametric design on Solid Works from beginning to gcode generation



model finished

3. As I finished the Solid Works model I then export the file as stl



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render of my 3D model of the wire organiser



printer almost finished printing chain organiser

Video of printers printing the organiser and the organised assembled in a chain.

4. 3D Scanning


1. For that part of the assignment I used Autodesk Remake. It relies on Photogrammetry.



2. luckily I was at the beach and I saw a model that would be interesting. Someone had but a large rock equilibrated.



equilibrated rock at the Figueira beach near Lagos, Portugal

3. Next step was to take around 40 photos from all angles and in preference without moving background like people or clouds.



sample of the 90+ images taken to make the model

4. Next I uploaded the files to Remake. Its important to select only good images and restrict background moving objects. After upload is done press create model. It can take a while during your model generation.



print from remake uploading images

5. After upload chose option on the generation process. I chose standard as its free.



print from options on remake

6. On the lower part of the screen ReMake shows models being generated and on queue. The top part shows models al ready done.



print from Autodesk ReMake

7. With the model ready you can click on it and entering the edit mode of ReMake.

model generate showing problems with opened faces. no ready for printing.

8. I compile the editing sequence on the following mosaic, in synthesis. I selected the undesired parts deleted it and filled the holes left. finally I generated a stl file that should be ready to print.



collage from screen prints editing sequence of Autodesk ReMake




The result!

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render of my 3D model from Photogrammetry scanning on ReMake