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3D scanning and printing

Last edited by Behnaz Norouzi

TO DO:

  • 1: GROUP WORK
  • 2: 3D DESIGN AN OBJECT THAT COULD NOT BE MADE SUBTRACTIVELY
  • 3: 3D PRINT THE SAME OBJECT THAT YOU DESIGNED THAT CANNOT BE MADE SUBTRACTIVELY
  • 4: 3D SCAN AN OBJECT
  • 5: Reserve the 3D printers from now for the next week for printing the objects for your individual assignments. The print time is dependent on some factors including the size of your object. So, reserve at least 3 hours.

A: GROUP WORK

  • FabAcademy Page for 3D Scanning and Printing Week

  • We will do the groupwork while we have the local lecture. So, be present in the Fab Lab.

  • We will 3D print the test model with some of the 3D printers for testing the design rules for them!

  • Find my guide to the group work HERE.

  • Find the material for your group work HERE.

    • I'll email you the material before the local lecture.

  • Good Group Work Documentations From The Previous Years:

B: 3D DESIGN AN OBJECT THAT COULD NOT BE MADE SUBTRACTIVELY

Additive vs. Subtractive Manufacturing

Additive manufacturing is a process that adds successive layers of material to create an object, often referred to as 3D printing. Subtractive manufacturing, as the name suggests, is the opposite. Rather than adding layers, subtractive manufacturing involves removing sections of a material by machining or cutting it away. It can be carried out manually or, more commonly, by a process known as Computer Numerical Control (CNC) machining. (Reference)

From Neil's Lecture (FabAcademy 2019):

Design a small abject that cannot be made subtractively. So the object has to have nested features, overhangs, parts within parts, something that you couldn’t make with the milling machine.

Some Examples of Previous Fab Academies

  • Marta:

    My design consists in a round box with a ball inside that should follow a path. The ball should not fall from the box; which means its diameter is bigger than the width of the path, therefore it cannot be introduced afterwards. This cannot be done substractively because: * it is not possible to do the inner rail where the bit needs to drill inside side wise * it is not possible to sculpt the ball inside the hole with a vertical bit. So this object needs to be created in an additive process, that is, stacking layers of material.

    Marta

  • Heidi

    As I understood it, a design that can not be made subtractively, means creating a design that you cannot easily mill on a CNC mill or similar. I was further explained by local instructors that it means an item that can't be fabricated with 3 axis limitations or even if it could, it would be too complicated. I started out with a rather simple idea to print out a box with round holes on each side, and inside of it, a ball that is slightly larger than any of the holes. A simple rattle. I think that it can not be made subtractively as the drill bit could not "bend" to cut the insides of the box that consists of just one piece, and it could not bend to cut the the ball that is larger than the holes on the side.

    Heidi
    Heidi

  • Peetu:

    I got an idea from one of my fellow student´s to create diamond necklace jewerly piece with some kind of rock inside. Therefore, I decided to create a diamond shaped shell...: ... and put a ball inside which would be connected to jewerly ring outside of the diamond. The ball would be sized so that it could´t be taken out from the diamond shell. This design can´t be made subtractively because the ball is inside the hollow diamond, so subtractively process would break the diamond on the top.

    Peetu_1 Peetu_2

  • Gleb

    The box consists of two parts, but it can be printed in one piece. There are two round pins which create an axis of rotation on one part and holes in another. The clearance in-between the pin and the hole is 0.2mm. And there is a clip on the other side to secure the box in closed position. This model cannot be made subtractively because of hidden pins: it is easy with printing layer by layer (with a right clearance), but totally impossible with milling process because of the joint hidden in solid stock of material.

    gleb

  • Perttu:

    The gyroid structure is impossible to manufacture with subtractive methods and is also difficult to make via FFF additive methods because of the overhangs and bridges of the structure. The blind surfaces(surfaces that cannot be accessed from outside) inside the structure cannot be accessed directly and the structure needs to be supported when printing. Traditional breakaway support cannot be used. Only way to print gyroid is to use solvable support. In this print I used ABS as the print material and PLA as the support material. The PLA is dissolved into NaOH buffer solution after the print is finished.

    Perttu

  • Michael

    I chose to design a cube inside another cube. Additive manufacturing is designing by layering components whereas subtractive is when layers are cut from a design until the desired model. The design outlined below is only possible to fabricate using additive manufacturing because the inner cube’s dimensions are slightly bigger than the holes on the sides of the bigger cube, the two cubes are not attached, the smaller cube moves freely inside the bigger one and it can’t come out through the holes.

    Michael

  • Xinhui:

    For this week's assignment, I decided to design and print a Five-Intersecting Tetrahedra , which consists of five right tetrahedra that are tangled with each other. The complex internal structure and irregular hollows of this object make it impossible to be made subtractively. Similar to my strategy during the computer-controlled cutting week, I decide to make this object because its complex structure can be made with multiple basic geometric objects.

    final_product

  • Noora:

    I decided to make a small hinged box...The box meets the standard that it cannot be made subtractively. The joint part is made so that upper joint is built layer by layer inside bottom joint. It can’t be made by cutting material away from one piece of material.

    26 28

  • Mona:

    So, I decided to go with a simple idea of a ball stuck in a cube. This object can not be made subtractively because the ball cannot come outside of the cube and therefore, needs to be designed by a 3D software and 3D printed such that removing the ball will require breaking the cube.

    Mona

C: 3D PRINT THE SAME OBJECT THAT YOU DESIGNED THAT CANNOT BE MADE SUBTRACTIVELY

D: 3D SCAN AN OBJECT

3D Scanning Options in Fab Lab Oulu:

  1. Kreon Ace-skyline >> Gleb will teach you this one if you are interested to use it.

  2. MAKERBOT DIGITIZER DESKTOP 3D SCANNER

  3. Sense 3D Scanner

  4. Sprout

Other Options:

  1. Photogrammetry & ReCap

    • How to Set up a Successful Photogrammetry Project
    • Camera resolution is important -> Minimum 5 megapixel
    • Platform is important. A Matt with pattern (such as this one), A clock (such as this one), or a newspaper or anything else. It is also important to consider having backgrounds and platforms that have color contrast with your object.
    • If there are moving objects in the background, it might be problematic.
    • Objects that are untextured, completely flat, very thin, transparent, shiny and reflective might be difficult to capture.
    • It is possible to keep the object still and you rotate around the object or vice versa. The former one is a better way of doing it.
    • Having enough light is important. Having shadows at some parts of the object might cause gaps or holes in the final mesh.
    • It is important to take a series of pictures (let's say 24 is good enough, or could be even more) from different angles (ideally every 10-15 degrees and no more than 30 degrees of changing the viewpoint).
    • Shooting for Photogrammetry
    • Photogrammetry & Other Free Software (For example: Colmap)
    • Check HERE for the guidelines and all the necessary links!
    • Good video Tutorials : ONE, TWO.

  2. Mobile Apps (Remember to check beforehand whether you can save the result file or not with the app you use. You need to upload the result file for this assignment just like the other assignments!)

  • Find steps for Photogrammetry & Recap and sense scanner, as well as reducing the size of .obj file in Fusion 360 in my documentation.
    • Briefly: in Fusion 360 > select the Body > Modify > Reduce > Reduce Type: Adaptive; Reduce Target: Density; Density: (Change the density here)
    • Why reducing the size in Mesh environment?

ADDITIVE VS. SUBTRACTIVE MANUFACTURING

Additive manufacturing processes build objects by adding material layer by layer, while subtractive manufacturing removes material to create parts.

  • Subtractive:
    • removing material through cutting, boring, drilling, and grinding.
    • These processes are either performed manually or more commonly, driven by computer numerical control (CNC).
  • Additive:
    • In contrast to the subtractive process of removing material from a larger piece, additive manufacturing or 3D printing processes build objects by adding material one layer at a time, with each successive layer bonding to the preceding layer until the part is complete.
  • Reference

FDM VS. SLA

  • FDM
    • Melts and extrudes thermoplastic filament
    • Lowest price of entry and material
    • Lowest resolution and accuracy; not good for printing the parts that need to be close to perfection!
    • Best for: basic proof-of-concept models and simple prototyping
  • SLA
    • Laser cures photopolymer resin
    • Highly versatile material selection (basic, jewelry, dental, etc.)
    • Highest resolution and accuracy, fine details
    • Best for: functional prototyping and patterns

IMPORTANT TO REMEMBER

  1. As soon as you come up with an idea for this week's 3D printing assignment, check your idea for designing an object that could not be made subtractively with us! You should make sure about it.
  2. Add a picture of the object that you choose for 3D scanning in your documentation. After 3D scanning, if the result is not close enough, you should try to understand what the issue is and try again. The process seems simple but it might take time so don't leave it for the last days close to the next Wednesday that your assignment should be ready! You also usually need to modify the 3D scanning results a bit. Check the guidelines and links to understand how to do it!
  3. Use the following slicer software: Cura slicer for Leapfrog creatr HS 3D printer, 3DWOXDesktop slicer for Sindoh 3D printer, and PreForm slicer for Formlabs Form3 3D printer.

ADDITIONAL TUTORIAL

  1. How to put a cube in a cube cube_in_cube_fusion_tutorial.pdf

  2. Form 3 Design Guide Form_3_Design_Guide.pdf

  3. PreForm PreForm.pdf

  4. GrabCAD GrabCAD.pdf

  5. PrusaSlicer PrusaSlicer.pdf

  6. MakerBot Replicator 2 MakerBot_Replicator_2.pdf

  7. Formlabs Form 3 Formlabs_Form_3.pdf

  8. Stratasys Stratasys_Fortus_380MC_3D_Printer.pdf

  9. Insight Software / How to printwithout support with Stratasys Insight_Slicing_Software.pdf

  10. How to use Cura slicer? A YouTube Tutorial

  11. Slicer Software for Sindoh 3DWOXDesktop Printing

  12. Slicer Software for Sindoh 3DWOXDesktop Support Editing

  13. Learn about build plate adhesion: Skirt, Brim, and Raft

CHECKLIST AND GUIDELINE FOR THIS WEEK'S DOCUMENTATION

ChecklistAndInstructions_FOR_3DPrintingAndScanningWeek_2022.pdf