3D Printing

3D Printing is a process that is useful in making 3D models. Two-dimensional printers recreate flat images onto paper (or other material) by using ink, either extruded liquid as is the case for an inkjet or as a patterned ink powder as is the case for a laser printer. Three-dimensional printers recreate 3D models that are not limited to one plane and are also not limited to a paper medium. A material -- such as a plastic or even metal in some machines -- is formed one layer at a time until the entire object is complete as one solid object. These layers represent cross-sections of the object that vary from bottom to top. Each layer is similar to what a 2D printer would create, but each subsequent layer is attached to previous layers at a slightly incremented height.

Consumables

Other Useful Items

Software

The end-goal of your design is a file that provides the 3D printer with control instructions, but it may take a few steps to get there.

2D Vector Design

The 2D design that we need is required to be in a vector format. Check out the 2D Digital Design project page for more information about vector design.

3D Design

We need a *.stl or *.obj file in order to begin printing. Check out the 3D Digital Design project page for more information about creating 3D models.

Cutting 3D Models

Sometimes your model is too big and won't fit on the build plate. If you can split the model along a straight line and the cross-section of that cut has a large enough area, you can glue the two pieces together after printing them separately.

Slicers

The 3D printer needs instructions for how to move around a three-dimensional space in order to create your model. It is often useful to work through this step on your own in order to check that the entire model will print successfully.

3D Printing Processes

There are four main categories of 3D printing techniques:

• Photopolymerization: resin printers that cure using UV light

• Fusion deposition: filament printers that deposit melted material such as plastic

• Laser melting: laser systems that selectively melt powdered material into a continuous form

• Lamination: cut individual layers out of a material and then stack them

Each one of the categories falls under an industrial technology called "additive manufacturing". Rather than removing material from a bulk mass ("subtractive"), material is being added in order to complete your finished object.

Two of our 3D printers are fusion deposition printers that use plastic filament. In a fusion deposition printer, the material is extruded into shape for each layer, and layers are deposited onto previous layers to build the model up one cross-section at a time.

Our other 3D printer is a resin printer. It starts with a liquified plastic that is cured by a UV light. The solid model is slowly pulled out of its resin bath, and then we wash it in a separate machine. The prints are more detailed, but smaller and take longer to create.

Applications

Recent developments in 3D printing have made printers more common, more reliable, and more versatile. They have become an indispensable step in the manufacturing process for some industries such as medicine, architecture, and custom art.

From a general manufacturing perspective, the 3D printer adds production capabilities. Materials used in 3D printers are mass-produced and inexpensive, but the quality is often good enough for a final product that allows for rapid production. Custom designs can be easily constructed and transmitted to the manufacturers, who can easily swap designs, so mass customization is also possible.

3D printed parts have many uses, among which a few examples stand out:

• food decorations

• figurines for animated films

• medical implants and prosthetics

• car parts

• concrete walls

Lessons

There are a few pre-built tutorials that you can follow.

Tutorials

JON-A-TRON's 3D Printing lessons:

• Beginner

• Easy

• Intermediate

• Advanced

thehardwareguy's PrusaSlicer tutorial videos:

• Import, Slice, and Print

• Custom Supports

• Variable Layer Height

Project Ideas

Download a Model

Thingiverse is a website that hosts 3D models for free and these works are often protected under a Creative Commons copyright which permits you to use them with few restrictions. This is also a great place to start when you need inspiration for your next project. All you have to do is search for want you want or browse through a collection of common projects.

A simple search for "gears" can give you over 4000 matches. Clicking on a particular project will take you to that project's page. This page usually contains a few useful features that you should look at before deciding if this is the right print for you. For an example to follow, look at the "Nautilus Gears" that appear on this page.

First, notice the pictures. There is usually one large picture and smaller thumbnails. Full-color photos are usually the proof of a good design, because these are pictures of the item after it has successfully printed. Sometimes you can even find a video in these thumbnails. For example, the Nautilus Gears page includes one picture of the gears printed in a gray material and a video right next to it. But what you are ultimately looking for is the original mesh file(s), which are represented as blue objects on a gray plane with white grid lines. Clicking on one of these allows you to view the model in 3D.

The second thing you want to check for are the details, and you might have to scroll down a little bit to see them. Instructional projects on Thingiverse will include a description of the project, including a summary of how it was designed and instructions for printing or assembling the model. For example, the Nautilus Gears require printing four pieces, which are snapped together after printing.

Note: If these instructions contain information about "supports" or "infill", keep those in mind when you are slicing the model later.

The last thing you want to check is the license, which will be on the left column next to the details. If you hover over the icons, you can see the individual conditions that the creator has set. For example, the Nautilus Gears are by MishaT and you are allowed to use this model as long as you give the proper credit to MishaT.

When you download from Thingiverse (the link on the top right of the project page), you are downloading a zip file that contains several files. The *.STL files (or *.OBJ files) are required for proceeding with your print.

From this point, it is possible to proceed directly to slicing the model. If you want to customize the design, jump down to "Designing a Model" below.

The following repositories also offer free models that you can download:

• GrabCAD

• STL Finder

• Youmagine

• 3D Warehouse

• Prusa Printers

The following repositories contain some free models alongside models that you can purchase:

• Cults

• Free3D

• MyMiniFactory

• Pinshape

• Sketchfab

Scan a Model

Our Makerspace includes a 3D scanner that is capable of creating a 3D mesh from a physical object. Check out the 3D Scanning project page for more information about how to use this scanner.

Adhesion

Supports

3D Printers

Prusa i3 MK2

Prusa Mini

Prusa SL1

Post-Printing

After your model is done printing, there may be a few defects that can be cleaned up. The material can actually be quite resilient to most applications of force and you probably don’t need to be delicate with parts of the model unless they are less than a millimeter thick. Sometimes an emory board or sandpaper is good enough to smooth out rough edges. If you need to grind away a little harder, you can use a metal file. If you are not satisfied with the precision or want to etch anything manually, you can also use a Dremel tool.

If you printed parts that need to be assembled together, you can do so as soon as the print is done. Some models have plans that include nuts and bolts in their design. If you need to glue anything, use a super glue, epoxy, or hot glue as desired.

If your choice of filament color is limited, you can try painting to the color you desire. An acrylic paint or any paint you might use on a plastic surface works just fine. You can also write on your model with a Sharpie.

Ideas for Lesson Plans and Programming

(Under Development)