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Since I work a 9-to-5 job, I love decorating my desk with things that are cool and fun. That's why I chose these two projects:
The astronaut: This represents my childhood dream of becoming an astronaut and exploring the universe.
The robot design: I've always loved the idea of making robots that move, and it felt like science fiction to me. Now that I'm getting into it in this diploma program, I wanted this to be my first project.
For 3D printing - Astronaut design
Thingiverse the used open source library for the design
for slicing and preparing the file to be printed
the used fab-lab machine - PRUSA i3- mk2
PLA plastic filament
For laser cutting - Robot design
3axis.co the used open source library for the design
laserworks for preparing the file for cutting
the used fab-lab machine - El Malky ML149 CO2 Laser Cutter
PLY wood 3mm
I searched for a design on various open source websites, mainly 3axis.com.
I downloaded the file in DXF format and also tried downloading other formats and conversion.
Then, I added the design to Laserworks. I changed the dimensions and edited the middle section of the design.
Next, I moved the design closer to the origin. then I started by selecting lines based on the action they represented, then assigned speed and color to each selection.
I chose the following colors to represent each action:
Cut - Black
Scan - Red
speed cutting - Yellow
I set the cutting action as the last step to ensure it wouldn't affect the design, finally export the file in RLD format.
(The photos show the used power and speed for each action, note that we did a little changes in the lab) .
First I used Thingiverse open to find open source design for astronaut.
After downloading the design as STL file format, I opened it in Cura software , choosed the machine and adjusted size and parameters to fit the target.
For the settings parameters, I consulted the settings provided by the design owner on the website, but I made some edits.
Believing the design needed support, I added 10% support with no adhesion. Additionally, I set the layering to 2 mm to reduce printing time and have reasonable finish.
checked slicing to see the time and no of grams used.
the final dimensions are : 254.5x 22.9x 56.4 (35% scaling down of the original file.)
Finally, Saved the file in g- code format , with naming convention of the desgin name, needed time and grmas.
as a challenge: I kept accidentally changing the scaling while zooming in.
Now, I'm satisfied with the dimensions, although it fits just right. Ideally, I'd prefer a small gap from the maximum size.
In this stage, and after uploading the design on the machine, adding the 3 mm sheet on the machine.
making sure that it is fixed and sit flat .not skewed nor wobbling , then we checked the cutting space on the sheet by using the origin button.it took less than 2 minutes.
Don't forget to close the machine door and turn the Ciller on.
To print the design we took the g-code file, after checking the parameters and edit the speed and heat ,and upload it into the machine.
first thing we unloaded the old filament and added the gray PLA one, started heating the nozzle and bed , the machine did calibration on the bed then the printing process started .
I checked the first layer that it is okay . less than hour and the design was completed and removed it from the plate.
-During the fabrication time of the robot - laser cutting,
we haven't checked the focus of the machine , so the design wasn't cut . this affected the finishing quality and increased the time.
so we did another run for the cutting job again with the right focus .
-and for the astronaut - 3D fabrication
the old filament was stuck in all the machines and it took many trials to remove it, also we realized that the support for the design wasn't needed at all and it took time to remove it and scratch it out and also it affected the finishing quality.
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