Lego Brick
The main body of my Lego brick , I need a rectangular prism. First, I clicked Create Sketch and selected a plane. Then I selected Create and 2 point Rectangle or click R to create a rectangle. After creating a rectangle, I used Extrude (click E) to change the rectangle into rectangle prism.
There're several circular knobs on the rectangular prism. To make these knobs, first I used diameter-center circle or clicked R to make a circle. Next, I used Dimension or (click D) to make the distance between the circle and edges of the circle fixed. Then I used extrude to add thickness to the circle.
I needed to duplicate the knobs I just made. I went to Create drop down menu and selected Rectangular Pattern feature. I changed the Pattern Type to Features to easily select the whole knob. For the Directions, I selected one of the edges and I typed out the number of copies I wanted. I also needed to set the space between the knobs. Check the preview and click OK to finish.
I used Shell command from the Modify dropdown list to hollow out the body. For the Face/Body, I selected the bottom face because that's the area I need to hollow out. Then I typed in the inside thickness and it would give me a nice preview of the shell. Click OK to confirm the result.
For the bottom columns, I first selected the inner plane of the brick. I used Create Sketch and create two construction lines ( click L ) for reference purpose. Then I created a circle that was tangent to the holes. I created another circle inside the circle I had just created.
I went to Extrude and selected the the circle which automatically excluded the area of the inner circle. Next, I typed in the thickness that I wanted and one column was done.
I used the Rectangular Pattern Feature to duplicate the column. The Pattern Type needed to be Features. I selected the column I made and selected the edge and typed in the number of copies I wanted. The three column were finished.
After I completed the overall Lego brick, the last thing I needed to do was to add fillets to some of the edges. Adding fillet is to make sure that the edges are not sharp. I went to Modify dropdown list and selected Fillet command (click F). I selected the lines that I wanted and adjusted the fillet width. The fillets were added onto the edges.
Use Create Sketch and select Text. I typed in my name. I used Extrude and type in negative numbers in order to make my name embedded in the surface of the brick. The Lego Brick was done!
Final digital design of Lego Brick
Home view
Bottom view
Top view
Back view
Side view
Book Page Holder
The first step of making the book page holder is to make a circle. I selected Create Sketch and selected the Diameter-center Circle command. I typed in the diameter of the circle and locked it.
Because the book page holder is symmetric, I could just create one arc and copy it. So first I needed to create two construction lines to be the symmetric lines for reference. I selected Line command and create the lines.
I went to Create Sketch and selected 3-Point Arc command. I selected a spot on the vertical symmetric line and another point on the horizontal one. After creating a satisfying arc, I needed to copy the arc I had just made. I went to Create and selected Mirror. I selected the arc and chose the horizontal symmetric line as me Mirror Line. Then the right half of the circle had the arcs. I repeated the process to get my left part done. The only difference was that I selected two arcs at a time. I also needed to use the vertical symmetric line as the Mirror Line.
I needed to limit the distance between the circle and the arc so that the 3D printer would be able to print it. I selected Dimension (click D). Before I selected anything, I right clicked and selected Pick Circle/Arc Tangent. Then I picked the circle and the arc and it would create a distance between them. Next, I put the distance I wanted to be and clicked Enter. Now I changed the dimension into what I wanted.
After creating the arcs, I dragged the corner to change the size of the arcs. I selected Fillet command under Modify. There would be an arrow after selecting the two arcs. I could drag the arrow and see the change of the fillet. I chose a dimension. I held Ctrl and selected the opposite two arcs in order to make the two fillets symmetric (the other would change if one is changed). I did the same thing to the other pair of arcs.
Now I needed to change my width. I selected the Dimension and chose two endpoints of the opposite two arcs. I changed the dimension. It might look very strange. I could use Constraint to fix it. I selected Symmetry under Constraints menu. I selected the two opposite arc and the vertical symmetry line and it automatically changed the arcs into symmetric shape. I changed the height in the same way.
After I finished the sketch, I could change it into 3D. I selected Extrude and put whatever thickness I wanted and the book holder is almost done.
I added some fillets onto the edges of the book holder. I selected Fillet and dragged the arrow to see the change of the fillet. I chose the width I wanted and locked the number.
In order to hold the book holder more comfortably, I added the fillet to the hole so that the edge wouldn't be sharp.
Final Digital Design of Book Page Holder
Home view
Back view
Left Side view
Right Side view
Thingiverse Design Modification
First, I selected the whole mesh and went to Mesh tab and selected Generate Face Groups in the Prepare dropdown list. I changed the type to fast so that the computer wouldn't break down. I clicked Preview to see the modified product.
I went to Modify under the Mesh tab and selected Covert Mesh. I changed the Method into Prismatic and clicked OK. The mesh was converted to a solid body.
I chose to add a text on the back of the ghost keychain as the modification of the product.
I selected Create Sketch and a plane and choose Text.
I typed down Halloween and changed the font. Then I changed the position of the text to make it in the center.
I used Extrude command to add a thickness onto the text so that the text was imbedded in the body of the ghost.
3D Printer Workflow
Export the designed file to STL Format.
Use the Prusa Slicer 2.6.1 .
Import the .stl file.
Change the Print settings.
The smaller the unit is, the more delicate the product would be. On the contrary, the more time the 3D printer would take.
You can change the scale factor to change the size of the final product.
Click Slice now.
When moving the progress slider, you can see how the product is built by the 3D printer.
After finishing changing the settings, change to Gcode.
Open the link for the 3D printer.
Upload the .gcode file.
Select the file you want to print and click Print.
Make sure the platform of the 3D printer is clean. If not, use the alcohol to wipe off the remains on the 3D printer.
When the printer reaches its temperature settings, it will start working.
After the 3D printer finishes printing, take the product off after it cools down.
Video of 3D printing Lego Brick
Final 3D Printer Object------Lego Brick
Dimensions of the 3D printed Lego Brick
The Process of 3D printing
I first chose the color I wanted my Lego brick to be, which determined which 3D printer I would use. After I decided the printer, I first use alcohol to clean the remnant on the platform. I went to the link that the printer match and uploaded the gcode file I had converted. Then I selected Print. The 3D printer would first heat up to the temperature setting and after testing a line, it started to work. After it finished, I needed to wait until the object cooled down and took it off.
The difference between the digital design and the final physical product is that the physical product is much smaller than I expected. It's too time consuming to make a bigger one.
The Reflection of NC State article
The article moved me. I am a pet owner and maybe someday my dog will be in the same situation as Sheeba does. I am really glad that people actually find a very innovative way to save Sheeba's life, which means my dog and other dogs or even all the animals may have a chance to stay alive when they face such a similar situation. The success of implanting 3D models pushing a revolution in medicine further. The success proves that 3D printer is not just a recreational thing, but a life-saving product in the future. 3D printing can be and will be applied on medicine, which will save hundreds of people's lives in the future.
Problem Encountered
When I was converting the mesh body of the Thingiverse product to face groups, I followed the instructions in the video to change the Type to Accurate. However, my computer kept breaking down when I was doing the Accurate Type. After several times of failure, I decided to change the Type into fast. This time it worked.