Stratasys TUTORIAL. For both the dimension bst 1200es and F370

Transcription

1 Stratasys TUTORIAL For both the dimension bst 1200es and F370

2 TABLE OF CONTENTS Simplify or Split parts for improved results FAQs STEP 1: HAVE YOUR.STL FILE READY... 1 STEP 2: TURN ON THE PRINTER... 2 STEP 3: IMPORT YOUR CAD FILE TO GrabCAD Print...3 STEP 4: REVIEW MODEL... 4 STEP 5: FILL OUT AN FDM CONFIRMATION CARD... 9 STEP 6: PREPARE THE PRINTER (Dimension) STEP 6: PREPARE THE PRINTER (F370) STEP 7: PRINT! STEP 8: POST PROCESSING (Dimension) STEP 8: POST PROCESSING (F370)...15 STEP 9: CLEAN UP AND SHUT DOWN APPENDIX A: MACHINE OVERVIEW APPENDIX B: DESIGN CONSIDRATIONS AND LIMITATIONS Minimum Feature Sizes Z-axis Resolution... 19

3 STEP 1: HAVE YOUR.STL FILE READY From CAD You can use any CAD software that creates 3D geometry, including Solidworks, Fusion360, Rhino, SketchUp, etc. In SolidWorks.STL export options, Fine resolution generally gives good results. Check the preview and adjust as necessary. Make sure you check the units! From Scanning: We have two scanning technologies in Room 36. The HP 3D Structured Light Scanner Pro S2 (formerly DAVID SLS-2) is a high-precision projector and dual camera scanning setup. Autodesk ReCap Pro is a photogrammetry program that can convert 2D pictures into a 3D model. *Both will allow you to export/download an.stl file of the scan. Often, scans will have holes or other discontinuities that will affect printing. Programs like Netfabb and MeshMixer can aid in the repair of these errors. From the Web You can find raw CAD models on sites like GrabCAD. You may also find.stl files on sites like Thingiverse and Youmagine. REMEMBER: you should always cite the source for any part you have used or modified! Figure 1: PRL_FDM_TEST.STL file in SolidWorks TUTORIAL Use the PRL_FDM_TEST.STL file on the desktop. 1

4 STEP 2: TURN ON THE PRINTER Dimension bst 1200es ( Dimension ) Press ON/OFF button to turn on the machine. Once the machine has started up from OFF, it will sit in IDLE mode, with Waiting for Part flashing. **If the machine is at room temperature, it will take about 30 minutes before it has come to temperature and can begin building. Figure 2: Dimension bst 1200es power button location and idle screen. Machine is ready when IDLE and Waiting for Part is flashing F370 Press ON/OFF button to turn on the machine. Once the machine has started up from OFF, it will sit in IDLE mode, with Waiting for Part flashing. **If the machine is at room temperature, it will take about 60 minutes before it has come to temperature and can begin building. Figure 3: F370 power button location and idle screen. Machine is ready when IDLE is displayed 2

5 STEP 3: IMPORT YOUR CAD FILE TO GrabCAD Print Open GrabCAD Print When GrabCAD Print opens, it will look like Figure 4. Select the appropriate printer from the pull-down menu in the lower left corner o The Dimension should display a square build platform o The F370 should display a rectangular build platform with a tab in the back right corner Click on the + Add Model button and select your file o You can also drag and drop files into the GrabCAD Print window. o GrabCAD Print accepts many native files (such as.sldprt) as well as.stl o You can add in as many parts/models as you wish as long as the parts all fit in the building area. Figure 4: GrabCAD Print s opening page for the Dimension (top) and F370 (bottom) Figure 5: Click on the + Add Models button to select and add your.stl flies. 3

6 STEP 4: REVIEW MODEL Analysis Mode Model Info Use this mode to repair any small errors in your models. If any errors exist, the analysis mode icon will contain a warning symbol. If this is the case, click the icon and then Repair all Models. Click this icon to view your model(s) and adjust build parameters. Through the Model Info icon, you can adjust the Units and match to the units of the model file being processed. 4

7 Print Settings Support Style: o SMART o Basic o Sparse o Box o Surround Part Fill Style: - Narrows or widens to best support model while using least material - Vertical, closed supports with a consistent spacing between paths - Similar to Basic with much larger spacing between paths - Similar to Sparse with open perimeter; slower to build, easier to remove - Surrounds entire model with support; useful for tall, thin models Part Fill Style Sparse - low density Sparse - high density Solid Fill ~0.080 solid shell and ~30% interior fill ~0.080 solid shell and ~70% interior fill 100% Speed Fastest Moderate Slowest Cost $ $$ $$$ Considerations Parts will be structurally sound, but will not have the strength of a denser build A good compromise of build speed, material usage, and strength Can lead to internal stresses that can cause warping Can you use it? Yes! Yes Advise against Slice Height : Slice Height in (F370 Only) Pros Cons Most accurate approximation of your model Takes longest to build Due to adhesion process, must purchase build plate ($11.50) in (F370 Only) More accurate approximation of your model Takes longer to build in in More accurate approximation of your model Takes longer to build Great for larger, simpler, or rougher models; will build more quickly Will use a bit more material TUTORIAL Support Style: Box Part Fill Style: Sparse low density Slice Height: in 5

8 Arrange On the Dimension, try to avoid the 4 circles indicated in this screen (these circles are not physically present on the black build platform) unless you are unable to locate your part elsewhere. These locations are used by the machine to self-calibrate the build platform. If you have many parts on your build platform, the Arrange tab may help to organize them quickly. Generally, this is unnecessary because most builds are only one or a few parts and you can arrange them manually. On the F370, there are no reserved self-calibration points, so the prints may be positioned anywhere on the substrate 6

9 Orient Press the - or + buttons to rotate your model(s) about the X, Y, or Z axes by the degrees listed in the box. You can change the degree increment by overwriting the box. You can also select a FLAT face on your model to use to orient to Top, Right, or Front. Scale Unless there is a compelling reason, keep this at 100%. If a model is much larger or smaller than expected, it is probably an issue with the units and should be fixed under Model Info rather than Scale. 7

10 Slice Preview When satisfied with repairs and parameters, click here to process your model(s) for print. Here you will be able to check material estimates, view toolpaths, and watch an animation of the build before starting the machine. Once processing is complete, your model will look something like the image below. The DARK GREEN lines indicate where Model material will be extruded, and the ORANGE lines indicate Support material. If needed, you can go back and change your build properties or your part orientation and re-process to incorporate the changes. 8

11 STEP 5: FILL OUT AN FDM CONFIRMATION CARD 1. Fill out project info 2. Fill out Start and End Time estimates Click View Estimates at the bottom of the GrabCAD Print window to check build time and material use estimates. A Tray Estimations table will appear at the top of the screen. You may be surprised at how long the build time is! At this point you can still go back and reconfigure your build parameters to build your part more coarsely/sparsely. Use the Print Time information to fill out the Start Date and Time and End Date and Time estimations on the confirmation card. *You MUST make enough consecutive reservations (ACTUAL reservations, not waitlist) to cover the build time of your part. Figure 6: An FDM Confirmation Card Figure 7: View estimates button in the lower-right corner of GrabCAD Print. Figure 8: Tray Estimations table of the Print Time and Material Usage. 9

12 3. Fill out Material usage In the same Tray Estimations table, use the information to fill out the Model, Support, and Total volumes on the confirmation card. Compare these numbers to the material that is currently in the machine. Click on the dropdown menu at the bottom of the screen next to the Print button, then click on the name of the machine you are using to view machine and material info. If you have a long build that will go overnight or through the weekend, make sure there is enough model and support material to finish your build. If your part will build during a shop session, it is okay for your part to require more material than is loaded. Material cartridges can be swapped mid-build without affecting part quality. It is preferred to run a cartridge to zero so we can prevent material waste. Let the CA on duty know that the material will need to be swapped soon so that we are prepared when it runs out. 4. Pay for part and get CA Sign Off BEFORE building Figure 9: Tray Estimations table of the Print Time and Material Usage. TUTORIAL Figure 10: Machine and Material Info to compare with the material usage of your print. You do not have to pay for the material used in the tutorial print, But do fill out a confirmation card! 10

13 STEP 6: PREPARE THE PRINTER (Dimension) Insert Model Base 1. Press the button next to the flashing Wait for Part 2. Select No and you will be prompted to insert a model 3. Select a Model Base, like above. It s ok if there are markings from previous prints. 4. Slide in the Model Base. 5. Turn the two BLUE tabs vertical to retain the Model Base. 6. Once you ve told the machine that a build base is in place, the machine mode will be Waiting for 11 Part.

14 STEP 6: PREPARE THE PRINTER (F370) Insert Model Base 1. Select a substrate like above. It s ok if there are markings from previous prints. 2. Open the door to access the platen (substrate mounting area) 3. Place the substrate on the platen and slide into the machine 4. Lift the substrate locking handle to retain the substrate 5. After closing the door, press Yes on the touch screen to inform the machine that the substrate is ready for a new print 12

15 STEP 7: PRINT! 1. How to print 2. Post Confirmation Card 3. Auto Powerdown (Optional Dimension bst 1200es only) In the lower right corner of GrabCAD Print, press Print. At the machine, make sure your file is queued o Dimension: press the button next to Start Model o F370: Press the Print touchscreen button Watch it for a couple of minutes to make sure that the build starts without issues. Post your FDM confirmation card on the front of the machine with the clipboard. Most parts built on this machine will require many hours of build time. Auto Powerdown should be used to prevent overheating and excessive wear on the machine. Once your part has begun building successfully, press the button next to Auto Powerdown, and when prompted, turn the machine power switch to OFF. The machine will continue running until it has completed your build and completed its cool down cycle. If you want to get OUT of Auto Power down mode, simply turn the power switch back to ON. 13

16 STEP 8: POST PROCESSING (Dimension) Take Model Base out of the machine 1. Your part is finished when the main LCD reads Completed, Remove Part and Replace Model Base *The surfaces inside the machine will be HOT! Only touch the blue tabs and the model base. 2. Turn the two BLUE tabs vertical to unlock the Model Base. 3. Pull/Slide the Model Base out of the machine. 4. Press Yes once you have removed the Model Base from the Machine. 14

17 STEP 8: POST PROCESSING (F370) Take Model Base out of the machine 1. Your part is finished when the main touch screen says Done *The surfaces inside the machine will be HOT! Only touch the substrate and locking handle. 2. Press the substrate locking handle down to release the substrate 3. Pull/Slide the substrate out of the machine. 15

18 Remove part off of the Model base Remove your part from the black model base by first twisting or bending the platform and/or using a putty knife to scrape your part off the base. If you are having trouble removing your part, ask a TA for help. The CA on duty will remove the first base support layer with a stick blade. Remove Support material You can remove all other support material from your part with various hand tools. (F370 Only) After removing as much of the support material as possible, you may use the SCA3600 to dissolve the remaining QSR supports 16

19 STEP 9: CLEAN UP AND SHUT DOWN 1. Remove trash from purge bucket (Dimension Only) 1. Lift the purge bucket up and out from the back wall. * Remember, all of the machine surfaces will be HOT. 2. Throw out the trash. 3. Place the purge bucket back in place. 2. Turn OFF the machine. 3. Clean up surrounding area, put away tools, and sweep the floor. 17

20 APPENDIX A: MACHINE OVERVIEW This is a Stratasys dimension bst 1200es rapid prototyping machine. This machine uses FDM (Fused Deposition Modeling) technology to build plastic parts from solid models created in CAD programs such as SolidWorks. It is the same process as Fused Filament Fabrication (FFF) which is used by the Ultimaker 2+ and 3 in Room 36. Parts are built up layer by layer by extruding a very small ribbon of molten plastic. Using this method, it is possible to create intricate geometry that would be difficult or impossible to manufacture using traditional subtractive processes. Use it wisely! ABS is the model material used by the dimension bst 1200es and produces parts that are both stable and durable. The Model material color that we use is Ivory, but it can be primed and painted however you d like. The Breakaway Support material is a pale gray color. Realize that hand finishing will likely be required for parts requiring fine surface geometry. For many, however, a part straight from the machine is entirely suitable. Please see a TA for finishing suggestions. 18

21 APPENDIX B: DESIGN CONSIDRATIONS AND LIMITATIONS Minimum Feature Sizes The software requires a minimum of 2 widths of extruded ribbon to build a feature. Z-axis resolution Ribbon width Double ribbon width (appx. min resolvable feature size) (0.25mm) 0.024" (0.60mm) (1.22mm) (0.33mm) (0.71mm) (1.42mm) Z-axis Resolution Because this technology builds a series of flat layers in the X-Y plane (parallel to the floor) curvatures in the Z-axis are approximated. Thinner layers will produce better curvature approximation, but take longer to build. In the images below, you can see how a thicker build layer (on the right) results in more curvature loss. In the examples below, you can see how different build orientations result in drastically different curvature resolution. In the left image, the vertical curved sides of the shape will fully resolve and will be built quite true to the geometry. In the example on the right, the curved sides are lacking a lot of the refinement and detail of the original model. +Z 19

22 Simplify or Split parts for improved results Here is an example of a small part with several lumens through it. To build this part in one piece, these lumens would fill with difficult-to-remove Support material. Instead, the part has been split and small alignment tabs and holes have been added. These tabs and holes will allow the part to selfalign for gluing. 20

23 FAQs What material do these printers use? ABS is the model material used by the Dimension. The model material color that we use is Ivory, but it can be primed and painted however you d like. The breakaway support material is a pale gray color. ABS (gray), PC-ABS (black) or ASA (white) may be used as the model material on by the F370. The QSR support material is soluble in the SCA3600 tank and is an opaque white color. What is Support and how do I remove it from my part? The Dimension uses breakaway support material to allow the machine to build undercut, hollow, or otherwise cantilevered geometry. After the build is complete, this material must be broken, chipped, or pried away from your model. You can use various hand tools to remove the support. The F370 uses soluble QSR support material, which may be removed from the model in the same manner as the breakaway support material. The QSR may also be submerged in the SCA3600 tank to dissolve supports over a period of hours, depending on part size. What is an.stl file? STL originally stood for STereoLithography, although Standard Tessellation Language is a common backronym as stereolithography is only one example of the additive manufacturing processes that use.stl files. How do I convert CAD to.stl? You can export either single parts or assemblies of parts. Depending on the software, you simply need to go to File, then either Save As or Export and make sure to select.stl as the format. CAD programs will provide some options for the export. First, select what units you would like to use, then set the resolution. In SolidWorks, the Fine resolution works great for most models. Here are some general recommended settings: File Encoding: Resolution: Binary (not ASCII) 0.002in OR 0.05mm Deviation Tolerance, 10 Angle Tolerance Setting the resolution too fine will make the file size very large. When unsure, check the display window to see if the resolution looks good for your build. What is the build volume of the printer? 10 x 10 x 12 (Dimension) / 14 x 10 x 14 (F370) Why is my model orienting at a weird angle?.stl files generate a series of flat triangles to approximate your geometry and if you select a CURVED surface here, it will find A flat triangle and tip your part up into a jaunty angle. You may find it easier to adjust your model s coordinate system in SolidWorks if you have a complex geometry that you are struggling to align in the GrabCAD Print window. Note that in SolidWorks the Y axis faces up by default rather than Z, so any parts will be rotated 90deg from the modeled orientation. 21

24 What do the M, S, and E stand for on the Dimension LCD screen? The M and S temperatures indicate the temps at the Model and Support tips. In Idle mode, these will be at about 100C, and will need to heat up to about 300C. The E, or Envelope (space inside the machine) will be at about 70C in Idle mode (or cooler, if you have just turned on the machine), and will heat up to about 75C before beginning to build. 22