3D Printing Hardware

Lulzbot Mini - Quick Start Guide, User Manual

uPrint SE - User Guide

3D Printing Software

• Catalyst EX

• Thingiverse - Download .stl files to manipulate and print

  • Find premade objects to print in Thingiverse! Make sure you read the notes and comments sections for extra printing tips. No username/passwords needed. Use Google Chrome!!!!

• Tinkercad (Online Access) and Solidworks (Desktop Link)

  • Use 3D shapes to create objects that you can then print! You must make a free account before using the site. However, the teacher can make one account and the whole class can log into that account at the same time.

• • HOW TO PRINT FROM ADOBE PHOTOSHOP CC

3D Printing Supplies

• ABS Plus Standard Thermostatic Material

• Polymaker: Polylite PLA - 2.85mm (print temp = 210-230 C, print speed = 40-90 mm/s)

File Types

• STL file - A 3D drawing of your part created by a CAD software program.

• CMB file - This file is created from an STL file through a process run by the CatalystEX software. It is the CMB file that is sent to a printer.

Changing the Filament

Lesson Plans and Project Ideas

ENGINEERING

• Research an architectural landmark and build a scale model or recreate it with newly designed features

• Explore a range of monuments and determine how they are viewed differently across time, then design and create a model for a monument that memorializes events within your own generation

• Determine the different style bridges that engineers have constructed over time, then design your own

• Research ergonomics and discover how a wide range of objects have been designed to fit our needs, then design something for your own everyday use

FINE ARTS

• Identify types of instruments and how they work, then design and create your own instrument

• Research jewelry designers and work to define their unique style, then create your own line of jewelry

• Determine how molds and stamps are used with a variety of media and design your own

SCIENCE

• Explore weather conditions and the formation of snowflakes, then use this knowledge to create your own

• Combine toy design with concepts of forces and motion to design an object for creative play

• Research game design throughout history and create your own game pieces or puzzle pieces

• Determine the structure or different chemical molecules and then design your own model to study

• Create a cross section of an anatomical structure to study

• Learn about the solar system and design a space rover that would function on the planet of your choice and explain how it would transmit information back to Earth

• Discover animals that are extinct or close to extinction and create a model with statistics

HISTORY

• Research a range of artifacts from a single culture and recreate them

• Learn about Egyptian hieroglyphics and design your own obelisk using the hieroglyphic alphabet

• Create a 3D bar chart that presents information and statistics related to your local areas and communities

• Research the cultural achievements that led to the expansions of the vikings and create your own rendition

• Learn more about your family's history and create a memory box that highlights you learned

1. Open the program called “Cura-Lulzbot” on the desktop. It is in the bottom left corner.

2. Open up your file by clicking the button with an open folder on the left.

   1. Tinker CAD is a great resource for beginners to create 3D design: https://www.tinkercad.com/

   2. Sketchup is also good: https://edu.sketchup.com/app

You can find premade designs at: https://www.thingiverse.com/

1. You can move your project around on the plane, and you can add more than more object on the plane as long as it all fits.

2. When you are happy with your set up, connect the printer’s USB to the computer.

3. Turn on the printer.

4. Go to “Monitor” and start to preheat the hot end and the hot bed.

   1. The temperatures of the ABS Village Case (the filament provided) are 230-250℃ for the hot end and 110℃ for the hot bed.

5. Click the “All Home button” which is a little house.

6. Wait for both the hot end and hot bed to heat up.

   1. To test to make sure everything is working, change extrusion amount to 10 and hit extrude. Filament should come out and you can carefully remove it using the tweezers.

7. Once both are at temperature, hit print.

   1. The printer will not start running right away it will cool down slightly, move around a bit, heat back up, clean the nozzle, and calibrate the hot bed.

8. Watch your masterpiece come to life. Seriously, someone has to be watching the pinter at all times while hot.

9. Let the printer cool down by setting both temperatures to 0℃.

10. The hot bed will come forward automatically when it is cool enough to remove. Use the knife to carefully detach your object from the hot bed.

11. Remove your project from the online program by right clicking on your object and pressing delete selected model.

12. Turn off the printer.

PARTS OF A 3D PRINTER

Print head/motion controls

Motion Controls

• The nozzle gantry needs to move very carefully in order to draw out the correct shape in each layer. If the nozzle is too far away or too close from the build plate than the filament will not stick together correctly causing the shape to look wonky. The movement and positioning of the nozzle gantry is achieved by the use of linear motors and belts.

• The positioning and movement of the build plate is all accomplished with a form of linear actuator. To achieve the necessary movement and positioning, the nozzle gantry uses linear motors of stepper motors with belts. These create straight line motions.

• The nozzle gantry is placed horizontally while the build plate is placed vertically. Both need to be placed as precisely as possible.

• Click and Move is the overall program that makes sure that the printer prints smoothly. It can also regulate the nozzles and the build plate temperature.

Print Head Parts

• The Print Head, also known as the extruder is the part of the printer that turns the filament into a 3D model. It has 2 sections. The cold end and the hot end. The cold end grabs the filament and takes it down to the hot end where it is melted and deposited to the platform to begin creating the 3D design.

  • • Filament/Extruder Drive Gear- pushes filament into the hot end.

    • Heat Sink- makes sure the filament doesn't melt before it reaches the nozzle.

    • Heat Sink Fan- makes sure the filament doesn't melt before it reaches the nozzle.

    • Heater Cartridge- heats up the filament.

    • Thermistor/Thermocouple- temperature sensor for the hot end.

    • Cooling Fan- cools the filament as soon as it reaches the platform, helps the design holds it shape.

    • Nozzle- Where the melted filament is dispensed. Sizes are easily interchangeable. The smaller the nozzle, the more detail and a slower printing process. Vice Versa with a larger nozzle.

Slicing Engines

To determine the coordinates where it needs to move, and the rates at which it will do so, the slicing engine uses:

• • • the nozzle diameter

    • movement speeds

    • layer height

    • other variables

• This information is exported using a GCODE file. This is a plain-text file that has a series of text-based codes and the X, Y, and Z-axis coordinates used for printing the 3D structure.

Lulzebolt Mini Software

• In order to operate the desktop 3D printer, you need to install software packages onto your computer. You will need:

  • • a 3D printer host

    • an .STL to .GCODE generator

    • an optional CAD or 3D modeling software.

• Cura LulzBot Edition is the recommended software for the LulzBot 3D printer. Visit LulzBot.com/cura to download the Cura LulzBot Edition.

• • This software converts 3d models into GCODE files, which are the file types used for 3D printing

  • There are 7 slicers that can be used for the 3D printer but only Cura LulzBot Edition is recommended by the official website.

  • The newest software is more user friendly and more slicing options an updated slicing engine, and better print quality than pervious softwares. The current versions is: 3.6.21

    • 3.6.21 has not been yet been tested.

    • The stable version of Cura LE for mac and windows is v3.6.20, and for those who use LulzBot Bio need to use the most current version: 3.6.21

    • If ever there is a problem or a bug with the software you can submit a bug report

  • The software is distributed recently under GNU Lesser General Public License Version 3 (LGPLv3) terms.

  • Under these terms you can redistribute and/or modify the software.

  • There is no warranty

Alternative Printer Host Software

• • • OctoPrint- Website: https://octoprint.org/

    • BotQueue- Website: https://www.botqueue.com/

    • MatterControl- Website: https://www.matterhackers.com/store/l/mattercontrol/sk/MKZGTDW6

Source Files

• • • LulzBot Download Server: http://download.lulzbot.com/

    • LulzBot Development Server: https://devel.lulzbot.com/

    • Aleph Objects Code Repository: https://code.alephobjects.com/

Frame/balance issues

Common Issues

• • The Printer is working but nothing is printing

  • The nozzle is to close to the print bed

  • incomplete and messy infill

  • messy first layer

  • print looks deformed and melted

  • cracks in tall objects

  • Extruder frequently becomes jammed, but works fine briefly after clearing the jam

Troubleshooting

• You could raise/lower the corner to minimize/increase the extrusion width to match the others.

• Verify both axis for good movement- If the X-axis motor moved without trouble or loud noise the problem would likely be in either in the board/stepper driver or the connections for that axis."

• Most problems are cause by incorrect extruder spring tension

• If the extruder jams, it could be too hot or too cold

  • • Leaving printer extruder heated up for 20 minutes or more without extruding, the extruder jams.

    • Try replacing thermal isolator or isolator sleeve.

    • Put a small fan on the hot end to cool the top.

3D PRINTED DESIGNS AND RESEARCH

How 3D Printing is Transforming Everything from Medicine to Manufacturing

How 3D Printing Has Changed the Art World

3D Printers at Work

Manufacturing:

• Because of the versatility of 3D printing, companies across aerospace, automotive, defense, and medical fields have employed it as a means of manufacturing.

• It is more beneficial to 3D parts in house for manufacturing companies, to make the process more efficient and reduce costs

• 3D printing custom tools for manufacturing can be easier and more efficient than waiting on a custom ordered part

• Available filaments include both metals and plastics.

• Research and development departments usually require prototypes, which are typically handcrafted or made from mold, which take a lot of time.

• Using a 3D printed prototype saves designers both time and money, and it also allows them to see their work in action before committing to a full scale model.

• 3D printing also reduces risk for injury and create less waste.

• Companies can start new projects more frequently.

• It is way more efficient than traditional manufacturing.

• Increase the speed of manufacturing which drive innovation within product lines

• Products that originally went for higher prices now are more affordable to the masses.

• Less risk of messing up the model, which helps with time management.

• There is more design freedom and precision accuracy.

EXAMPLES:

• General Electric, Boeing, Ford, and Nike use 3D printing in their manufacturing

  • General Electric prints fuel nozzles for jet engines, ribbed gearbox covers for the company’s new turboprop engine, and intricately designed fuel heaters.

  • The airline company Boeing was an early user of 3D printing, & had made more than 20,000 3D printed parts for 10 military & commercial planes.

    • In January of 2019, Boeing was ready to try out a prototype with engines that had six different parts that were 3D printed.

    • The six parts included turbine blades and fuel nozzles. 3D printing the turbine blades ended up reducing the overall engine weight.

  • Ford has a dedicated 3d workshop in the pilot plant to create tools to make manufacturing of the cars faster, such as making 3D printed car parts that are no longer sold.

    • Ford has also been using 3D printing technology since the 1980s (recently printing its 500,000th part with a 3D printer)

    • Ford also teamed up with the #d Systems Sugar Lab and printed a model made from chocolate and sugar of the 2015 Mustang

  • Nike and other sneaker companies have focussed on 3d printing midsoles, but in April 2019 they announced the release of their first 3D-printed textile footwear, called Flyprint.

  • Robotics engineers utilize 3D printers for end-of-arm tooling and end-use parts, from fingers to entire robot components.

  • Food can also now be manufactured using special 3D printers.

• Medical professionals

  • They are used to make tissues and organs (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/)

  • used for making prosthetics, implants, and for medical research for drug dosage forms, delivery, and discovery(https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/)

  • 3D printing is good because it lowers the price of prosthetics and implants and it is costumed-made for people (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/)

  • helps with rapid production of medical devices (https://www.hindawi.com/journals/jhe/2019/5340616/)AH

  • Bioprinting tissues and organoids (https://www.medicaldevice-network.com/features/3d-printing-in-the-medical-field-applications/)

    • Good because instead of having a something that is not quite the "right fit" we can now print with our own DNA and "re-grow" our own (https://www.medicaldevice-network.com/features/3d-printing-in-the-medical-field-applications/)

  • Surgical students and residents can practice on a fake (3D-printed) instead of having to go in without experience or know what to do in the situation (https://www.medicaldevice-network.com/features/3d-printing-in-the-medical-field-applications/)/(https://www.lpfrg.com/blog/3d-printing-in-the-medical-industry/)

  • Soon we will be able to print specific pacific organs (i.e. liver, heart) though this is in early stages of testing/development (https://www.fda.gov/medical-devices/3d-printing-medical-devices/medical-applications-3d-printing)

  • 3D printers can handle different materials (https://www.lpfrg.com/blog/3d-printing-in-the-medical-industry/)

    • For example the Bolt Pro can print soft tissue and bones (https://www.lpfrg.com/blog/3d-printing-in-the-medical-industry/)

  • The Bolt Pro can print at different temperature so the print can be serialized (https://www.lpfrg.com/blog/3d-printing-in-the-medical-industry/)

  • 3D printing can be used for dental doctors too, to print patient-specific "braces, dental restorations, castable crowns, dental bridges, and denture frameworks and bases" (https://all3dp.com/2/3d-printing-in-medicine-the-best-applications/)

  • To turn medical images into 3D models.

http://www.healthtechzone.com/topics/healthcare/articles/2019/08/07/442906-why-3d-printing-perfect-medical-applications.htm

• 3D printers have changed the way tat medical professionals plan their procedures-have made it easier.

• Predicted that the wait list for medical implants will decrease thanks to 3D printers.

• Cure process-changing in consistency to make successful end product.

• https://www.hindawi.com/journals/jhe/2019/5340616/

• Some researchers are working on 3D printers what would be able to make drugs by making chemical compounds and molecules (https://3dprintingindustry.com/news/12-things-we-can-3d-print-in-medicine-right-now-42867/ ).

• Personalized sensors are used to create the model of organs doctors can print. They would use a sensor to monitor and "photograph" the organ then 3D print the organ (https://3dprintingindustry.com/news/12-things-we-can-3d-print-in-medicine-right-now-42867/ ).

• Not only can advanced organs be 3D printed, but also simple or complex medical equipment and devices can be 3D printed to reduce cost (https://3dprintingindustry.com/news/12-things-we-can-3d-print-in-medicine-right-now-42867/ ).

• The most common 3D printer technologies in medical fields are selective laser sintering, thermal inkjet projection, and fused deposition modeling. (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/ )

• The ability to make custom size and shape medical products and equipment through 3D printing is a huge plus. (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/ )

• 3D printing can be faster than the traditional methods of making and receiving prosthetics and implants (https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4189697/ )

• Surgical implants require complex and organic structures to be accepted by the host tissue. These structures are usually expensive with traditional manufacturing methods, but a 3D printer can create them with no additional cost. http://www.healthtechzone.com/topics/healthcare/articles/2019/08/07/442906-why-3d-printing-perfect-medical-applications.htm

• 3D printers give users the freedom to choose different designs, forms, sizes, colors of their protheses.

https://www.lpfrg.com/blog/3d-printing-in-the-medical-industry/

https://all3dp.com/2/3d-printing-in-medicine-the-best-applications/ . JW

• WAYS THAT 3D PRINTING HELPS IN THE MEDICAL FIELD:

• Surgical preparation

• Prostheses

• Dental

• 3D printing of tissues and organs

• Medication dosage and pharmacology

• Manufacturing of medical tools and devices

• https://all3dp.com/2/3d-printing-in-medicine-the-best-applications/ JW

Artists:

• Artists will use 3D printing in many different ways depending on their specific style of art. Some will use clay 3D printing, others will use metal 3D printing, and many will use regular filament to create their different pieces. It all depends on the artists preference, as 3D printing is very versatile.

• Artists use 3D printers to create pieces of art, as well as mini versions of sculpture ideas.

• Artist Tomoko Nagao uses 3D printers to create "micro-pop" sculptures.

• Two other artists, Rob and Nick Carter, used 3D printing to 3D print life-sized tree trunks.

• 3D printers can be used to make molds.

• Artists can make more accurate sculptures, like head busts of people.

  • Traditional sculpting of an object is becoming less popular as artists are choosing to print sculptures.

  • Sugar lab printed sculptures made entirely of sugar.

• Handheld 3d printers can be used like the LIX 3D printing pen.

• Tactile elements can be made for blind people.

• 3D printing can help create more wearable art.

  • Two NYU students created the first ever 3D printed wearable nails.

  • Victoria's Secret used 3D printer for the wings worn at their annual fashion show.

  • Guitars and other instruments can be 3D printed.

• It is easier to make models of collectors items.

• Custom camera lenses have been 3D printed.

Life Before 3D Printers

What can 3D printers now do that traditional manufacturing could not?

• 3D printing began with Dr. Hideo Kodama of Nagoya Municipal Industrial Research Institute in 1980 when he discovered how UV light can be used for printing. https://www.digitaltrends.com/cool-tech/history-of-3d-printing-milestones/ JW

How were these things made before 3D printers?

• In 1859, Francois Willeme used 24 cameras for photographing subjects from different angles - TL

• In 1984, Charles Hull invented stereolithography, which used a UV laser beam to hit a vat of liquid photopolymer and the light exposed tuned into solid plastic. - TL

• In 1986, Chuck Hull invented stereolithography apparatus (SLA) which refers to a method of printing objects layer by layer. - TL

• In 1987, Carl Deckard pioneered an method which turned loose powder into a solid, instead of Chuck Hall's liquid resin process. - TL

• In 1989, S.Scott Crump invented Fused Deposition Modeling involving melting a polymer filament and depositing it onto a substrate by layers. - TL

• In 1999: the use of 3D printed organs in surgery. - TL

• https://www.autodesk.com/redshift/history-of-3d-printing/ , https://www.digitaltrends.com/cool-tech/history-of-3d-printing-milestones/

• Tagging fish and other aquatic animals was a longer, and more expensive process. MV

• Automotive and aviation machinery was more expensive to make. MV

https://3dprinting.com/aviation/

• Personalized car parts were very rare and extremely expensive before 3D printing. MV

https://gizmodo.com/objects-that-couldnt-be-made-before-3d-printers-existed-1718072112

• light(er) air planes (https://gizmodo.com/objects-that-couldnt-be-made-before-3d-printers-existed-1718072112) AH

• Detailed molds of peoples jaws (https://gizmodo.com/objects-that-couldnt-be-made-before-3d-printers-existed-1718072112)AH

• Customized Surgical Stents (https://gizmodo.com/objects-that-couldnt-be-made-before-3d-printers-existed-1718072112)AH

• Plastic can be reused in 3D printing-so 3D printers are making a positive impact for the environment. MW

• 3D printers have helped a lot of medical professionals. (printing organs, proshtetics, etc). MW

• Sustainable and work well in remote locations. MW

• http://blog.zmorph3d.com/3d-printing-inventions-everyday-life/

• Injection molding was the norm for mass produced objects EJ

• Airplanes were heavier - 3D printing can reduce weight up to 55% EJ

• Really strong things were really heavy - 3D printing has allowed for greater strength with less weight EJ

https://gizmodo.com/objects-that-couldnt-be-made-before-3d-printers-existed-1718072112

• Currently, LEGOs are not made using 3D printing, but they are made out of a plastic used in 3D printing called ABS. (https://www.compoundchem.com/2018/04/09/lego/ ) BA

• The plastic is heated like in 3D printing, but the plastic is poured into models. (https://www.compoundchem.com/2018/04/09/lego/) BA

• Using 3D printing could potentially reduce manufacturing cost for LEGO because the models LEGO uses are very expensive. New models need to be bought everything LEGO comes out with a new piece, if they used 3D printing it would just be a new file. BA

3D Printing Logistics

What kinds of designs are good for 3D printing?

• Simple, symmetrical designs AB

• Designs that have a flat bottom are good for 3D printing because it does not need support. While support beams can be added to the design, it works best when the design can be build upon itself. -BA

• Designs with thicker walls are better to print. -LB

• Rounder edges avoid warping - LB

• Try to avoid overhangs because they are more complicated- LB

• Any shape that can be desembles into small and easy parts can be printed (https://all3dp.com/1/diy-room-decor-ideas-3d-print-home-decor-diy-ideas/) AH

• must be able to be made from the "base" up (https://www.3dhubs.com/knowledge-base/key-design-considerations-3d-printing/#intro) AH

• If for example one wanted to make a room with a chandelier the would ave tp make it up side down because a 3d printer work in layers/slicers (https://www.3dhubs.com/knowledge-base/key-design-considerations-3d-printing/#intro)AH

• The software used is very important in a successful creation. MW

• The type of material use must be taken into consideration. (strong, flexible, smooth, etc.) MW

• https://i.materialise.com/blog/en/5-mistakes-to-avoid-when-designing-a-3d-model-for-3d-printing/

• Solid v. mesh models-make sure which type works better for your object before printing. MW

• https://pinshape.com/3d-printing-design-guide#over-chapter-2

• Shapes that can be layered. MV

• Stable and sturdy shapes. MV

• Any shape that has a flat bottom. MV

• You can easily 3D print bracelets EJ

• Did you lose a keyboard key? Just 3D print one! EJ

• Petree dishes/ring holders/key dishes are all good things to print as they are simple shapes. EJ

http://www.3dprinterprices.net/20-cool-things-3d-print/

What kinds of designs or not printable or needed to be modified in order to print?

• Perfect spheres. MV

• Extremely "short" or flat pieces. MV

• Very sharp or pointy edges. MV

• Overhangs do not work well for structures. MW

• https://www.instructables.com/id/3D-Design-For-3D-Printing/

• Wall thickness must also be determined otherwise object could break. Walls too thin or too thick. MW

• File resolution is another problem if the file is low quality. MW

• https://i.materialise.com/blog/en/5-mistakes-to-avoid-when-designing-a-3d-model-for-3d-printing/\]

• Anything with an overhang cannot be printed without the proper printer or support EJ

• Overhangs over 45 degrees need to be properly supported, you should be in the clear below that EJ

• If you have a bridge longer than 5mm, it won't print properly without support. The filament can't stretch longer than 5mm without drooping significantly. EJ

https://all3dp.com/1/3d-printing-support-structures/

• A room with a chandelier (https://all3dp.com/1/diy-room-decor-ideas-3d-print-home-decor-diy-ideas/) AH

• A lamp (https://all3dp.com/1/diy-room-decor-ideas-3d-print-home-decor-diy-ideas/) AH

• pip boxes with handles (https://all3dp.com/1/diy-room-decor-ideas-3d-print-home-decor-diy-ideas/) AH

3D designs are best if they are somewhat simple and have a base for the material and machine to start with. JW