Download slides at https://sphereinabox.wordpress.com/ TEST SLIDE • Is this text readable in the back? • Are the corner dots visible?
ITERATING FASTER WITH A 3D PRINTER More of a 3d printing overview
SLIDES WILL BE ON MY BLOG https://sphereinabox.wordpress.com/
Q'S FOR AUDIENCE Have you watched a 3d printer work? Can you handle millimeters?
SB STARTUP WEEKEND TROPHIES 2014 I made these
VIRTUAL REALITY DISPLAY USING IPAD MINI My first 3d printing based project Completed before the delivery for the Oculus Rift
Another dumb project of mine The ratchet locks the screen in place so the motor can be turned o ff .
Santa Barbara Hackerspace is a Non-Profit to help educate the community and help them build stu ff . Members can use the space, wifi and tools including 2 FDM 3d printers, laser cutter, electronics bench and more. We’re open to everyone on Saturday afternoons after 2PM so stop by and see what we’re working on or ask us questions.
ZAR PLOTTER Early Prototype Notice the motors hose clamped down to a board.
ZAR PLOTTER DRAWING BANNER
RANDY SZARZYNSKI
“SUBTRACTIVE MANUFACTURING” Make a part by removing (subtracting) material Nobody calls it that.
SUBTRACTIVE ShopBot Desktop at Crash Space in Culver City
This part shows up later
ADDITIVE MANUFACTURING Build up part by adding material Video is time lapse of Zortrax M200 print starting
CAN'T MILL THIS Herringbone planetary gear skateboard wheels http://www.thingiverse.com/thing:151216 Yes I know these are a dumb idea.
Download slides at https://sphereinabox.wordpress.com/ UV SENSITIVE RESIN PRINTING • Selectively cure layers of resin, using laser or DLP projector Little RP Form Labs … many more
ENTRY LEVEL RESIN PRINTER KITS $800 INCLUDING THE PROJECTOR LittleRP [pre-release machine shown] [projector not shown]
Super high detail Limited build volume Expensive material ($90/liter or more)
Download slides at https://sphereinabox.wordpress.com/ SLS (LASER SINTERING) • On each layer, spread a new layer of powder, and selectively melt it with laser or heat. • Various materials and costs: • Nylon is cheaper, machine costs [lots] • Metals like titanium are possible but machines would cost over $500,000 Video introduction to nylon SLS printer https://www.youtube.com/watch?v=wD9-QEo-qDk The patent covering this is about to, or just expired so things are going to get fun here.
SLS INTRODUCTION Clip by Solid Concepts Video clip from Solid Concepts (now Stratasys) https://www.youtube.com/watch?v=9E5MfBAV_tA
SLS RESULTS Raw (grainy) or Sanded (Shapeways Strong and Flexible) https://www.shapeways.com/materials/strong-and-flexible-plastic Layers are .12mm SLS patents have started expiring so others will start making these machines
Download slides at https://sphereinabox.wordpress.com/ NO "STANDARD" METAL PRINTING PROCESS • Do lost-wax casting from resin, plastic, or jet process print • Glue metal powder together, move into bed of sand, then use as mold • Laser welding then post-machining • Standard welding then post-machining [Glued metal powder casting process video] https://www.youtube.com/watch?v=i6Px6RSL9Ac Also additive laser welding https://www.youtube.com/watch?v=yKnlmfuMSgo
FUSED DEPOSITION MODELING (FDM) / FUSED FILAMENT FABRICATION (FFF) Draw part by drawing lines of plastic layer by layer FDM is a Stratasys trademark
WHY ARE 3D PRINTERS A POPULAR THING NOW? … answered in future slides
REPRAP PROJECT Make a machine that replicates itself when supplied raw materials
OPEN SOURCE
Download slides at https://sphereinabox.wordpress.com/ TYPICAL OPEN SOURCE LICENSE • You can use this and create derivatives as long as: • You make the source files available for others to build on. • And your derivative works are also available under the terms of this license Paraphrased GPL “Available” means “include them with your copy” or “have a process to get them for the cost of media and postage”
FEBRUARY 2008 DARWIN First model to replicate it’s major parts http://reprap.org/wiki/Darwin University of Bath (England)
OCTOBER 2009 MENDEL
MAKERBOT CUPCAKE April 2009 Photo by Bre Pettis (Founder of MakerBot) Wow this thing is terrible. Repeating wobble due to riding on Z threaded rods which aren’t straight. Motors VERY loud because current/voltage is wrong. Extruder calibration is nearly impossible because it’s driving a DC motor without an encoder. Later models had a stepper driven extruder. You can yell over one. Here’s the SB hackerspace’s printing https://www.youtube.com/watch?v=bN6HSEdB3co Photo by Bre Pettis CC-BY 2.0 https://www.flickr.com/photos/bre/3458247336/
MAKERBOT REPLICATOR January 2012 http://www.makerbot.com/blog/2012/01/09/introducing-the-makerbot-replicator
MAKERBOT REPLICATOR 2 September 2012 End of open source updates from MakerBot, likely in response to clones. https://en.wikipedia.org/wiki/File:MakerBot_Replicator_2.jpg
NOW Hey look, a MakerBot clone.
Download slides at https://sphereinabox.wordpress.com/ CONSUMER FDM/FFF MATERIALS • PLA • ABS • PET variants • Nylon
Download slides at https://sphereinabox.wordpress.com/ CONSUMER FANCY FDM/FFF MATERIALS • Co-Polyester-based plastics • Flexible Urethane based plastic (Ninjaflex) • PLA with metal powder (Bronze, Copper, Iron, Stainless) http://www.ninjaflex3d.com http://www.proto-pasta.com
Download slides at https://sphereinabox.wordpress.com/ EXOTIC FDM/FFF MATERIALS • These require higher temperature nozzle, and a controlled temperature chamber. • Polycarbonate (Print 300°C in 100°C chamber) • PEEK (About 350°C nozzle in 100°C chamber)
HEATED BED Lulzbot TAZ 5 printing HIPS on 110°C bed
WITHOUT SUPPORT MATERIAL This is one of our most successful makerbot cupcake prints. Yes I know it looks terrible.
SUPPORT MATERIAL (REMOVABLE)
Support removed in left photo, sitting behind part. Lower right photo shows interior of object is hollow.
SUPPORT MATERIAL (DISSOLVABLE) PLA dissolves PLA caustic soda in ultrasonic water bath HIPS: Dissolve HIPS with Limonene PVA: Dissolve PVA in water Pictured: HIPS (White) support ABS (Black) print material Print is the comet the Rosetta space probe landed on.
Create a plaster mold around the original 3d printed part, with vent and pour inlet Burn/melt out printed material Pour in molten metal When cool, brake plaster to get part. Then trim spout+vents and polish. This perfectly replicated our print defects.
Download slides at https://sphereinabox.wordpress.com/ TYPICAL PRINTING WORKFLOW • Design in a computer, export STL file • Load STL file in "Slicer" to generate g-code. Choose options like layer height, fill density, and support material. • Send g-code to printer to print file.
CAD or whatever Export STL Load into Slicer and nearly instantly get result
OPTIONS Only really need two of these Support material on/o ff is about the only setting I change If I’m switching between printing strong parts and ones that look good, I may change shell thickness and layer height
Download slides at https://sphereinabox.wordpress.com/ DESIGN APPROACHES • Solidworks, OnShape or other solid modeling packages • Sculpting • 3d Scanning
Download slides at https://sphereinabox.wordpress.com/ DESIGN CONSTRAINTS • Solids • Thin features • Thin walls • Overhangs Shapeways description pages do a good job of describing each of these but I don’t want to read you the material pages for a full hour. https://www.shapeways.com/materials/?li=nav
OVERHANGS Nice beard
NON-MANIFOLD Usually the opposite of “Watertight” http://www.thingiverse.com/thing:40262 I expect this was intended for video games where the inside of the car didn’t need to be solid.
CURA (SLICER) TRIES ITS BEST
CURA X-RAY PREVIEW Highlights problems in red
Download slides at https://sphereinabox.wordpress.com/ TOLERANCES (CHEAP FDM/ FFF MACHINES) • Small holes tend to be 0.4mm too small in diameter. • Outer shapes tend to be 0.2mm too large • Layer heights of 0.1-0.3mm are typical
Download slides at https://sphereinabox.wordpress.com/ FDM LIMITATIONS • Temperature for printed part. PLA gets soft at 65°C (149°F) • Strength and durability isn’t as good as molded or metal • Parts weaker between layers then along their length
Download slides at https://sphereinabox.wordpress.com/ PRINTING SPEED • Typical speed of moving print head is 30mm-80mm/sec (70-190 inches per minute) • Typical layer height 0.1mm-0.3mm • A part 4 inches long, 2 inches wide, and 1 inch tall may print in 2-6 hours.
PRINTING FASTER Increasing federate has limits: Melting plastic Under extrusion (from https://ultimaker.com/en/community/5586-can-your-um2-printer-achieve-10mm3-s-test-it-here )
MOVING FASTER IS HARD Mechanics can only look nice moving so fast
INFILL DENSITY To reduce print time and required materials, objects are not printed solid. I’m told stratasys doesn’t let you adjust this :-(
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