Guide for File Prep and Submission 3D Printing 3D Printing Basic Info 3D printing is a type of additive rapid prototyping where material is added one layer at a time to create a 3d object. The Dimension SST 1200 extrudes ABS plastic along a tool path to create an object where-as the Objet 30 lays down a UV-cured resin one layer at a time. The Objet is a higher quality, faster printer where as the Dimension is a lower quality printer. The sources for these models are.stl files, which can be exported from most major 3D modeling applications, including Rhino, Solidworks and Maya. Location Access File Types Max Build Size Build Resolution Material Build Options Pricing Job Turnaround Objet 30 AOC, 1232 Sullivan Technician-run; Files are dropped off at AOC with completed order form; Open to all SAIC community (students, faculty, staff, alumni). Solid STL files. Files must be preprocessed in Objet Studio prior to dropoff. Optional Rhino Export and Analysis Service available; see Setup Services section for details. 11.81 x 7.87 x 5.9 in 0.0011 - ABS-like plastic in solid monochrome color (White, Gray, Black, Blue). Polypropylene-like in white. - Sandable, machinable & durable! Solid interior (stronger but more expensive) Shelled/Support interior (cheaper, interior filled with support) Model Material: $0.40/gram (10% Discount if we choose color!) Support Material: $0.20/gram (Prices can be estimated in Objet Studio) ArtiCard only, payable on job pickup Varies greatly depending on size and shape of model, color choice and queue length. Check with a lab manager for an estimate. Location Access File Types Max Build Size Build Resolution 0.01" Material Build Options Pricing Job Turnaround Dimension SST 1200 AOC, 1232 Sullivan Technician-run; Files are dropped off at AOC with completed order form; Open to all SAIC community (students, faculty, staff, alumni). Solid STL files. Files must be preprocessed in Catalyst prior to dropoff. Optional Rhino Export and Analysis Service available; see Setup Services section for details. 10"x10"x12" - ABS plastic in solid monochrome color (White, Gray, Black, Blue, Red, Yellow, Green). - Sandable, machinable & durable! Solid interior (stronger, more expensive and longer build time) Sparse/honeycomb interior (less strength, cheaper, quicker build time) Model Material: $5.50/in 3 Support Material: $5.50/in 3 Build Base: $0.50/2"x2" square (Prices can be estimated in Catalyst) ArtiCard only, payable on job pickup Varies greatly depending on size and shape of model, color choice and queue length. Check with a lab manager for an estimate. 1 of 8
Model Preparation in Rhino These instructions assume a basic working knowledge of modeling in Rhino. If you are unsure about your modeling skill, we recommend that you work with a faculty member who can guide you through the modeling process. You can also visit the AOC s website for links to helpful tutorials (see the URL at the bottom of this page). Remember, modeling is a skill; it can take months and even years of practice to become proficient! Units We recommend modeling in either inches or millimeters, especially if accuracy of size is important to your part.the units you use during modeling must correspond to the actual units used during output. To set the units, click on File -> Properties then click on Units. Set the Model Units: to either inches or millimeters. Checking for Naked Edges In order to output a correct.stl file for prototyping, NURBS objects in Rhino must be closed solids/polysurfaces (a.k.a watertight objects). This means your object can have no naked or unjoined edges. This is one way to check for naked/unjoined edges during the modeling process (Fig. 1): Type the command ShowEdges into the command line, then hit Enter. You will be prompted to Select surfaces, polysurfaces or meshes for edge display. Select the object(s) you want to check, then hit Enter. This will bring up the Edge Analysis dialog. Select the radio button next to Naked Edges. All naked edges will be displayed highlighted in the color shown. (Fig. 1) Edge Analysis (Fig. 2) What Command This is another way to check for naked/unjoined edges during the modeling process (Fig. 2): Type the command What into the command line, then hit Enter. You will be prompted to Select objects. Select the object(s) you want to check, then hit Enter. This will bring up the What dialog. Look under the heading Geometry ; the object is described as open or closed (closed & valid = good; open &/or invalid = bad). NOTE: We strongly recommend a periodic check of your model for naked edges as you work. Don t wait until you think your model is finished; check often and fix naked edges as you find them. 2 of 8
Repairing Naked Edges To join two naked edges once they have been located: Type the command JoinEdge into the command line, then hit Enter. You will be prompted to Select two unjoined edges. Select the edges you want to join, then hit Enter. Thickness Analysis Solid models can still fail to print correctly if they have parts that are too thin (less than 0.04 /1mm). Rhino s built-in thickness analysis tool can give you a visual representation of parts that may be too thin. 1) Enter ThicknessAnalysis in the command line. 2) Select the object you want to analyze. 3) Upper range: 0.04 lower range: 0.001 Any part highlighted with color is too thin to print. Thickness analysis can take several minutes. 4) It is also recommended to use the Adjust Mesh option to duplicate the mesh settings you plan to use on export. 3 of 8
.STL Export Once your model has been made into a valid closed surface with no thin parts, you can export it to the.stl file format. Select the objectyou want to export.models that will end up being physically separate pieces must be exported as individual STL files. Click on File -> Export Selected Name your file and set the Save as Type: option to Stereolithography [*.STL], then click Save. In the Polygon Mesh Detailed Options dialog, enter the settings for polygon conversion. You can preview the mesh settings, or export directly to an.stl in binary format. NOTE:These settings are recommendations only, and may not be ideal for all parts. These settings may produce extremely large.stl files. Files over 50MB will not be accepted. Checking Meshes Sometimes errors in mesh export occur, even if the original model is a valid, closed polysurface. Bad meshes can lead to output problems including missing parts and the inability of the printer to process the file. Here s how to check for common problems in your exported mesh: Start a new file in Rhino. Make sure to use the same units as your original file. Click on File -> Import and select the.stl you just saved out. The mesh will import. Highlight the mesh by clicking on it, then type CheckMesh into the command line. A message box will appear listing any problems with the mesh. Open the Rhino help file, and search for CheckMesh. Refer to the help file page for specific commands to correct any problems in your mesh. A perfect mesh. Meshes are not always able to be fixed using CheckMesh. Sometimes it is best to go back to the original NURBS model to fix meshing problems. Once your mesh is fixed, save as an.stl and proceed to the Pre-Processing instructions. A good mesh, with problems. NOTE: CheckMesh may report a good mesh with minor problems listed under Important things. Some of these minor problems, such as reversed normals, can prevent the 3D printer from properly processing a file. 4 of 8
Pre-Processing Your File for Objet 30 Once your.stl is exported, you can use the Objet Studio software installed on all AOC computers to ensure that it will process correctly, as well as to estimate the material costs of your file. Click on Start -> All Programs ->Objet ->Objet Studio 1. Right click on the studio space and select Insert 2. Navigate to where you file is located, select your file and make sure Arrange models is checked. Then hit Open. 3. Once the part is imported select Tray Validation on the top menu part. This will make sure your part is able to be 3d Printed. 4. If the part turns purple and says Unclosed contours are detected it means you have a hole in your mesh, or reversed normal and must be fixed. If nothing happens after Tray Validation, that means the part can be printed. 5. Now select "Estimate" on the top menu bar. This will look at all the parts in the pack and figure out how much model and support is used. 6. Select the part that you want to know the cost of and go to the Info tab on the lower left portion of the screen. Use the formula below to figure out your part s cost. COST = Model x $0.40/gram+ Support x $0.20/gram NOTE: Material and cost totals calculated during pre- processing are estimates only. The Time reading under Build Estimates is NOT the turnaround time for your file. Turnaround time depends on the size of your part as well as the number of 3D print jobs ahead of yours. The AOC cannot guarantee any turnaround time less than 1 week; ask a lab monitor for details about turnaround times. 5 of 8
Pre-Processing Your File for Dimension SST 1200 Once your.stl is exported, you can use the Catalyst software installed on all AOC computers to ensure that it will process correctly, as well as to estimate the material costs of your file. Click on Start -> All Programs -> Dimension -> CatalystEX -> Catalyst EX 1. Click on File -> Open STL and navigate to the folder where your.stl file is saved. 2. Adjust printing options: Layer resolution: Set to 0.01 Model interior: Solid for stronger, more expensive parts; Sparse for cheaper, less strong parts. Support fill: Set to Sparse. STL units: Inches or Millimeters (match units used during modeling). STL scale: Always leave on 1. Set scaling in Rhino instead. 3. Click Add to Pack. The file will be processed, with the progress shown at the bottom of the screen. Complex files can sometimes take a long time to process. When the file is done, you will see the message Added part to the pack displayed in the progress bar. 4. Click on the Pack tab at the top of the screen. 5. In the Pack tab, the volumes of model and support material will be displayed in the upper right-hand corner, under the heading Build Estimates. Multiply the total material volume by the material price ($5.50/cubic inch) to get the material cost for your piece. There will also be a cost for the area of support base used to print your model. This cost varies depending on the footprint of your print, however this cost will never be more than $8. COST = Material x $5.50/in 3 + Base Area ($0.50/2 square) NOTE: Material and cost totals calculated during pre- processing are estimates only. The Time reading under Build Estimates is NOT the turnaround time for your file. Turnaround time depends on the size of your part as well as the number of 3D print jobs ahead of yours. The AOC cannot guarantee any turnaround time less than 1 week; ask a lab monitor for details about turnaround times. 6 of 8
File Submission Once your.stl is ready, bring a copy to the AOC on a CD or USB, along with an order form with your contact information, file information, and specifications for output options. If you opt to use the Rhino Export and Analysis Service we will also accept a Rhino (.3dm) file. 3D Printing File Checklist No parts thinner than 0.04 /1mm (see Thickness Analysis section). Solid.STL or.3dm file, with no open edges. One.STL file per physically separate part OR all parts in one.3dm file (service fees apply)..stl file size less than 50MB each..stl file preprocessed in Catalyst to check for errors. Payment and Pickup The AOC will send an email notification as soon as your 3D print job is finished. Payment is due via ArtiCard when your prints are picked up. Properties of a 3D Print: What to Expect 3D printed parts will have a slightly ridged surface due to the way the printer outputs material. Depending on the shape of your parts, this will be more or less apparent. On the Dimension SST 1200 Parts will have a seam, or a slightly raised line where the extruded plastic sometimes layers up on itself. This surface, including the seam, can be left as is or sanded down and/or covered with primer to achieve a smooth finish. ABS machines and sands very easily; solid ABS is durable enough to be used for mechanical parts. We recommend parts that will be sanded or machined be printed with a solid material fill. This seam does not occur on Objet 30 prints. Feel free to ask a lab monitor for sample parts to get an idea of standard resolution and surface quality. Setup Services The AOC offers a setup services to help you prepare your 3D files for prototyping. This service is optional; you can perform the process yourself by following the instructions above. Rhino Export and Analysis We offer a combined file export/check service for Rhino (.3dm) files. Objects for checking must be closed solids. The service includes a thickness analysis to make sure all parts of an object will be thick enough to print, an export to.stl mesh with optimized settings, as well as a check of the.stl file for mesh errors. The service is an export and analysis process only; we cannot edit files, but we will be able to point out problem areas. The Rhino Export and Analysis cost is $5 per physically separate object, billed each time the analysis is run. 7 of 8
Pricing Objet 30 ABS-Like or Polypropylene Model Material FullCure 705 Support Material $0.40/gram 10% Discount if we choose color $0.20/gram Dimension SST 1200 ABS Model Material $5.50/in 3 Soluble Support Material $5.50/in 3 Printing Base (Partial) $0.50/2in 2 Printing Base (Whole) $8.00 Setup Services Rhino Export and Analysis (Fee is charged per physically separate part, each time the export/analysis is run.) $5.00 8 of 8