ELEC 391 3D Printing D Printing ECE Lightning Lab. 3D Printing
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1 3D Printing ECE Lightning Lab 3D Printing Fused Deposition Modeling (FDM) Extrusion printing Plastic melted and extruded to create features layer by layer PLA (polylactic acid) ABS (acrylonitrile butadiene styrene) Stereo LithogrAphy (SLA) Layers of photosensitive resin cured by light Laser UV Selective Laser Sintering (SLS) Layers of powder spread over part and sintered by laser Metals 1
2 Tinkerine FDM Printer Tinkerine FDM Advantages Cheap printer You have DIRECT access Cheap material Single Material Adjustable % Infill Durable parts Can make ALMOST anything Short turn around time Low resolution Print it yourself Disadvantages Low Resolution Low Accuracy Design Constraints Wall angles Gap bridges Faked support material Minimum feature size Open Source Driver Software Bugs Features 2
3 Objet SLA Printer SLA : Objet Advantages Can make ANYTHING Impossible to machine Snail shell Very thin / fragile parts Working assemblies Overhangs Different surface finish Glossy Matte Professional Driver Software Reliable Repeatable Disadvantages Expensive printer You don t have DIRECT access Expensive material Build Support 100% Infill Long turn around time High resolution Must place order Brittle Worse in Z direction 3
4 Support Material 37g 4 Hours 24g 2½ Hours 4
5 Material SLA Vero White Hard & brittle White (opaque) Durus Softer Very flexible when thin (1mm) Clear (if polished) Special order Support Gummy FDM PLA Filament Different colour options Consult technician SLS Not Available Resources SolidWorks Design parts Tinkerine Suite Free Download Objet Studio Lab computers ece.ubc.ca/~leos SolidWorks help 3 D Printing help Design guidelines Tutorials / Examples Documentation FAQ 5
6 SolidWorks : Save as STL File Smallest Value 5 deg Assemblies 6
7 Printing an Assembly in Parts Delete Delete Optionally Delete Delete 7
8 #1 #2 17g / 2:27 hours + 28g / 2:27 hours Cost : 28 grams (build + support) Default Print Orientation Build: 39 Support: 30 Time: 4:16 Cost: 69 grams Build: 31 Support: 3 Time: 4:59 Cost: 34 grams 8
9 Hollow Parts Lots of Support Material Difficult to Clean Hollow Parts Make in Multiple Pieces Add Pegs/Holes Crazy Glue Press Fit Minimal Support Material Easy to Clean 9
10 Order Parts Have part files inspected and approved Subject Course / Group / Printer Body # Copies (refer to each part by name) Optional Special Material / Finish STL : Default = VeroWhite / Glossy FDM : Default = Random colour Special Instructions STL : Print orientation FDM : Wall thickness, % Infill Attach all associated.stl files Parts left with TA in MCLD 306 Example SLA Subject ELEC 391 / Grp C7 / SLA Body hexbody.stl : 1 copy lid.stl : 6 copies Please orient hexbody.stl with the large opening facing up to reduce support material. Attachment hexbody.stl lid.stl FDM Subject ELEC 391 / Grp C7 / FDM Body hexbody.stl : 1 copy lid.stl : 6 copies Please use blue material if available. Attachment hexbody.stl lid.stl 10
11 Aesthetic / Functional Design for Printing Fillet Structural & FDM / Waterjet Friendly 11
12 Section View Section View 12
13 Interference Detection & Clearance Verification Specs in SolidWorks Min. feature width : 1mm (flexible) 2mm (sturdy) 5mm OD (shaft) Assemblies Min. joint gap : 0.2mm Shaft = 0.5mm : 0.25mm on each side Press Fit Male OD = Female OD Chamfer male Rotating joint with low backlash Brass shaft / printed bore Bore OD = Shaft OD + 0.1mm 13
14 Caveats Large STL files Spherical features Small angle spec in STL generator Max: 100MB Assemblies not easily freed Large joint surface area Coupled joints Small (fragile) shafts Interferences Glossy welds Caveats Scrape off ALL support material Do not print threads, tap by hand Tap gradually or part will shatter Holes can be expanded but not shrunk FDM holes cannot be expanded more than wall thickness Holes must included in design (do not drill solid FDM) Pressing: Brittle(SLA) or Hollow(FDM) Do not hammer. Use vise Chamfer shafts/holes Drilling: High speed chuck Advance drill VERY SLOWLY If drill bit catches, your part will shatter 14
15 Post Processing Delicate Parts: Ultra Sonic Bath in Machine Shop (40 min) Water Sodium Hydroxide Screws Machine / threaded Sheet metal / self tapping Sex bolts Retaining Rings Internal External E Clip Cotter Pins Rivets Crazy Glue Hole/stud Fasteners 15
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