Hands-on Workshop: Basics of 3D Printing Introduction Ville Kukko-Liedes IdeaSquare 3.-4.11.2018
Hands-on Workshop: Basics of 3D Printing Introduction
Apr 07, 2023
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PowerPoint PresentationVille Kukko-Liedes IdeaSquare 3.-4.11.2018
[email protected]
• MA student of Product Development and Machine Design • 3D PrintShop manager in Aalto Design Factory
• Hobbyist 3D printing, 2012 • Rapid Prototyping and model making services, 2013 • Product development consulting services, 2014 • Design Factory PrintShop, 2014
Own DIY machines:
• RepRap Industrial 2014 --> SOLD
• CoCo, 2017 -->
• What is 3D printing and where it can be used?
• Understanding 3D Printing methods
• Hands-On 3D Modeling & printing
• Understanding 3D Printing methods
Sunday
(CAD = Computer Aided Design)
What is 3D Printing?
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
(CAD = Computer Aided Design)
dimensional objects
- Parts usually need to be supported from below
Principle
Advantages of 3D Printing – Freedom of design – complexity is free
Form optimization, pre-assembly, easy customization..
– No need for tooling No cost from design changes & cheap small volume prod.
– No need for inventory
On-demand manufacturing, minimal investment,
– Fast lead times & responsiveness Quick alteration in design to respond to customer needs
– Localized manufacturing Manufacturing where needed, savings in logistics
– Wide material range – seamless transitions
Innovation potential with new opportunities
– Affordable low volume production Price per piece constant regardless of production size
Uses: Rapid Prototyping
of 3D printing
- Fast testing of form, fit, function,
ergonomics..
prototypes provide early feedback
charging station for a
products
- Result of process and material
development & media hype
- Medical: Personalized solutions
- Aerospace: Weight optimization
high-end products
adoption
Customized parts in MINI cars
Uses: Rapid Tooling
- Masters for sand & silicon casting
- Lost wax casting
- Fixtures for drilling
- Takes advantage of low investment cost, fast
process, and AM introduced benefits such as
contouring cooling channels in injection molds
Masters for silicone casting
3D Print
Cores for Glass/Carbon-fiber parts
Freedom of design
– Minimize part count while optimizing topology
– Pre-built assemblies – minimize labor time & QC
– Customization without additional cost – Every part
can be different from the others, even in same batch
Design for AM – Case: bottle opener
Design for AM –
Case: F-18 cooling air system
– Complete re-design for functionality & weight
– This unit: part reduction from 16 to 1
– Improved air flow
– No assembly required
– No tooling required
– Spare parts on demand and on location
Case: Align / Invisialign tooth retainers
Case: Invisialign tooth retainers
– Innovative example of utilizing customizability
– RP machines & processes modified for excessive use
Other medical uses
AM as innovation enabler
AM as innovation enabler
technology encourages innovation
back to making physical things
Role of 3D printing in the future
– Disruptive potential in manufacturing – happening already 3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use
production.
– Supply chain renewal – future possibility Away from traditional towards more centralized, on-demand, rapid manufacturing.
– Flourishing innovation around AM New applications, AM techniques, & businesses emerge on daily basis
– Will every home have a 3D Printer and traditional manufacturing will end? No – Perhaps for occasional use in hobbies or garage-tinkering
Hands-on Workshop:
dimensional objects
- Parts usually need to be supported from below
Categories of 3D printing
•Thermoplastic is extruded to ‘draw’ a layer at a time
• Build platform lowers with the part and process
repeats
commonly used in lower end printers
•Materials:
•ABS
•PLA
•Polycarbonate
•Nylon
•Manufacturers:
Extrusion lines visible
Open Source, community driven, self REPlicating RAPid prototyper
- Founded 2005 by Andrew Bowyer, University of Bath, UK
- First RepRap 3D printer to print parts for itself, 2006
- Reprap inspires Makerbot, first commercial hobby printer, 2009
- Stratasys and 3DSystems both hit consumer market also
- 2016: hundreds of different “consumer 3D printers” available
- Most still hobbyist and DIY maker targeted
as they fail to meet user’s expectations
Not all 3D printers are the same
~200€ ~900,000€
General perception of all levels of 3D printing
Reality
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape “Designer”: Rhino, Maya, Zbrush “Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape “Designer”: Rhino, Maya, Zbrush “Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object – Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Thingiverse, Youmagine, GrabCAD modifiable with Meshmixer
STL file format – triangulated mesh approximation
Remember to set good tolerance!
More triangles = Better results
Remember to set good tolerance!
More triangles = Better results
Orientation and support material
Avoid overhangs Consider overhang angles when designing and orienting
Orientation and support material
Orientation and support material
Orientation and support material
Design for FDM Example
designed for FDM, which doesn’t need
supports and showcases possibilities of FDM
Features: •Overhangs
Happens to PLA and ABS in open printers
Insert
Slicers – Software that link 3D file with printers movement
- Software depends on the printer or user prefence - Makerbot Makerbot Print
- Ultimaker Cura
- Many are free and even open source
Settings Checklist for Slicer software
- Material
- Diameter (Usually 1,75mm or 3mm)
- Orientation of model - before “slicing”
- Layer height
- Infill percentage (how dense/hollow the part is)
- Supports (if needed)
Before starting print
- PLA: gluestick, (hairspray, blue tape)
- ABS: Kapton tape, BuildTak
- Check Printers material & nozzle
- Always observe first layers of printing – They are most crucial!
Categories of 3D printing
FDM, but have their drawbacks.
Strong parts: SLA < FDM
Big parts: SLA < FDM
Need supports: SLA < FDM
vat (or rises from it in some cases)
•New layer of resin is cured and process
repeated
•Materials:
•Which software would be most suitable for you?
•Should you use and modify existing files instead?
•How could you use 3D printing?
•In your work? Hobby? As a new skill?
•Which technology would be better for your application?
•What requirements do your prints have?
•SLA or FDM?
Ville Kukko-Liedes IdeaSquare 3.-4.11.2018
Categories of 3D printing
•The powder bed lowers with the part
•New layer of powder is added and process
repeated
•Materials:
•PA-Al (30% Aluminium)
Method Material For Tolerance
Wax Casting
comparatively inaccurate
All specs vary depending on machine used
Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production.
•New layer of powder is added and process
repeated
•Materials:
•Single component:
chromium, maraging
Additive Industries – Metal 3D printing station
Categories of 3D printing
•New layer of powder is added and process
repeated
•Materials:
•Color printers available
•Uses: Visuals, cores & molds, casting patterns
Full color sandstone + binder - Shapeways
Digital Metal – Höganäs, Sweden
Categories of 3D printing
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Laborious manual support removal
sensors
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Laborious manual support removal
sensors
molten to the part with laser
•Platform moves, while nozzle is usually
stationary
•Materials:
•Metal
•Features machined
Categories of 3D printing
of resin that is cured instantly with UV
•Platform moves down, process repeats
•Materials:
•Highly accurate
changing
Material jetting
Kalevala – Jewelry
•SLS Selective Laser Sintering
[email protected]
• MA student of Product Development and Machine Design • 3D PrintShop manager in Aalto Design Factory
• Hobbyist 3D printing, 2012 • Rapid Prototyping and model making services, 2013 • Product development consulting services, 2014 • Design Factory PrintShop, 2014
Own DIY machines:
• RepRap Industrial 2014 --> SOLD
• CoCo, 2017 -->
• What is 3D printing and where it can be used?
• Understanding 3D Printing methods
• Hands-On 3D Modeling & printing
• Understanding 3D Printing methods
Sunday
(CAD = Computer Aided Design)
What is 3D Printing?
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
(CAD = Computer Aided Design)
What is 3D Printing?
As opposed to e.g.
(CAD = Computer Aided Design)
dimensional objects
- Parts usually need to be supported from below
Principle
Advantages of 3D Printing – Freedom of design – complexity is free
Form optimization, pre-assembly, easy customization..
– No need for tooling No cost from design changes & cheap small volume prod.
– No need for inventory
On-demand manufacturing, minimal investment,
– Fast lead times & responsiveness Quick alteration in design to respond to customer needs
– Localized manufacturing Manufacturing where needed, savings in logistics
– Wide material range – seamless transitions
Innovation potential with new opportunities
– Affordable low volume production Price per piece constant regardless of production size
Uses: Rapid Prototyping
of 3D printing
- Fast testing of form, fit, function,
ergonomics..
prototypes provide early feedback
charging station for a
products
- Result of process and material
development & media hype
- Medical: Personalized solutions
- Aerospace: Weight optimization
high-end products
adoption
Customized parts in MINI cars
Uses: Rapid Tooling
- Masters for sand & silicon casting
- Lost wax casting
- Fixtures for drilling
- Takes advantage of low investment cost, fast
process, and AM introduced benefits such as
contouring cooling channels in injection molds
Masters for silicone casting
3D Print
Cores for Glass/Carbon-fiber parts
Freedom of design
– Minimize part count while optimizing topology
– Pre-built assemblies – minimize labor time & QC
– Customization without additional cost – Every part
can be different from the others, even in same batch
Design for AM – Case: bottle opener
Design for AM –
Case: F-18 cooling air system
– Complete re-design for functionality & weight
– This unit: part reduction from 16 to 1
– Improved air flow
– No assembly required
– No tooling required
– Spare parts on demand and on location
Case: Align / Invisialign tooth retainers
Case: Invisialign tooth retainers
– Innovative example of utilizing customizability
– RP machines & processes modified for excessive use
Other medical uses
AM as innovation enabler
AM as innovation enabler
technology encourages innovation
back to making physical things
Role of 3D printing in the future
– Disruptive potential in manufacturing – happening already 3DP can change product design and manufacturing approaches drastically. Materials and processes are developed more for end-use
production.
– Supply chain renewal – future possibility Away from traditional towards more centralized, on-demand, rapid manufacturing.
– Flourishing innovation around AM New applications, AM techniques, & businesses emerge on daily basis
– Will every home have a 3D Printer and traditional manufacturing will end? No – Perhaps for occasional use in hobbies or garage-tinkering
Hands-on Workshop:
dimensional objects
- Parts usually need to be supported from below
Categories of 3D printing
•Thermoplastic is extruded to ‘draw’ a layer at a time
• Build platform lowers with the part and process
repeats
commonly used in lower end printers
•Materials:
•ABS
•PLA
•Polycarbonate
•Nylon
•Manufacturers:
Extrusion lines visible
Open Source, community driven, self REPlicating RAPid prototyper
- Founded 2005 by Andrew Bowyer, University of Bath, UK
- First RepRap 3D printer to print parts for itself, 2006
- Reprap inspires Makerbot, first commercial hobby printer, 2009
- Stratasys and 3DSystems both hit consumer market also
- 2016: hundreds of different “consumer 3D printers” available
- Most still hobbyist and DIY maker targeted
as they fail to meet user’s expectations
Not all 3D printers are the same
~200€ ~900,000€
General perception of all levels of 3D printing
Reality
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape “Designer”: Rhino, Maya, Zbrush “Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Create models yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Free and commercial sites available
“Engineering”: SolidWorks, Creo, Catia, Fusion 360, FreeCAD, OpenSCAD, OnShape “Designer”: Rhino, Maya, Zbrush “Easy-to-use”: TinkerCAD, Google SketchUp
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object – Modify or replicate as is
3. Download existing files – Free and commercial sites available
3D files to print
1. CAD software – Model yourself
2. 3D scan an existing object– Modify or replicate as is
3. Download existing files – Thingiverse, Youmagine, GrabCAD modifiable with Meshmixer
STL file format – triangulated mesh approximation
Remember to set good tolerance!
More triangles = Better results
Remember to set good tolerance!
More triangles = Better results
Orientation and support material
Avoid overhangs Consider overhang angles when designing and orienting
Orientation and support material
Orientation and support material
Orientation and support material
Design for FDM Example
designed for FDM, which doesn’t need
supports and showcases possibilities of FDM
Features: •Overhangs
Happens to PLA and ABS in open printers
Insert
Slicers – Software that link 3D file with printers movement
- Software depends on the printer or user prefence - Makerbot Makerbot Print
- Ultimaker Cura
- Many are free and even open source
Settings Checklist for Slicer software
- Material
- Diameter (Usually 1,75mm or 3mm)
- Orientation of model - before “slicing”
- Layer height
- Infill percentage (how dense/hollow the part is)
- Supports (if needed)
Before starting print
- PLA: gluestick, (hairspray, blue tape)
- ABS: Kapton tape, BuildTak
- Check Printers material & nozzle
- Always observe first layers of printing – They are most crucial!
Categories of 3D printing
FDM, but have their drawbacks.
Strong parts: SLA < FDM
Big parts: SLA < FDM
Need supports: SLA < FDM
vat (or rises from it in some cases)
•New layer of resin is cured and process
repeated
•Materials:
•Which software would be most suitable for you?
•Should you use and modify existing files instead?
•How could you use 3D printing?
•In your work? Hobby? As a new skill?
•Which technology would be better for your application?
•What requirements do your prints have?
•SLA or FDM?
Ville Kukko-Liedes IdeaSquare 3.-4.11.2018
Categories of 3D printing
•The powder bed lowers with the part
•New layer of powder is added and process
repeated
•Materials:
•PA-Al (30% Aluminium)
Method Material For Tolerance
Wax Casting
comparatively inaccurate
All specs vary depending on machine used
Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production.
•New layer of powder is added and process
repeated
•Materials:
•Single component:
chromium, maraging
Additive Industries – Metal 3D printing station
Categories of 3D printing
•New layer of powder is added and process
repeated
•Materials:
•Color printers available
•Uses: Visuals, cores & molds, casting patterns
Full color sandstone + binder - Shapeways
Digital Metal – Höganäs, Sweden
Categories of 3D printing
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Laborious manual support removal
sensors
•Layer shape is cut into sheet
•Platform lowers and process repeats
•Materials:
•Laborious manual support removal
sensors
molten to the part with laser
•Platform moves, while nozzle is usually
stationary
•Materials:
•Metal
•Features machined
Categories of 3D printing
of resin that is cured instantly with UV
•Platform moves down, process repeats
•Materials:
•Highly accurate
changing
Material jetting
Kalevala – Jewelry
•SLS Selective Laser Sintering
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