Advanced Techniques3D Printing

Russell SingerDevelopment Director, MAKEiT Inc.russell@makeit-3d.com

Thinking about 3D printing

Understanding the variables

Application examples

Q & A

Thinking about 3D printing

You can 3D print almost anything.

You can’t 3D print everything, with every material, on every printer.

Tool or fixture making is an excellent use for 3D printing which in turn expands your capability to use other processes.

Understanding the variables

Part DesignFunction

Settings

It’s about balancing variables

Part DesignLayer Height

Temperature Speed

Layer HeightThick layers make stronger partsThick layers perform better with overhangsLayer height affects required temperaturesNot all materials can achieve all layer heightsDoubling your resolution will approximately double print timeJudge appropriate layer resolution against overall scale of part

Small parts require lower temperatures, and the oppositeSmall parts benefit from lower speedsNot all materials are compatible with all geometriesIdeally part designs consider 3D printing from the outsetDifferent print orientations provide different levels of strength

Part Design

Temperature is determined by geometry, layers, and speedsHigh temperatures improve layer bondingLow temperatures improve finish, detail, and overhangsThick layers and large parts require higher temperaturesUse the lowest temperature that achieves layer bonding for best surface finish

Temperature

Lower speeds will improve corner and detail precisionSmall parts may require very low speeds for coolingLarge parts may require high speeds for layer bondingThere is a maximum flow rate at which material can pass through the nozzle, can limit print speed at thicker layers

Speed

Application examples

Two-material printing can be used to combine material properties, but significantly increases complexity of setup

Different material types may not bond effectively, use mechanically interlocking designs for structural integrity

Complex part designs can include flexible and rigid materials, conductive and non-conductive materials, different colors, and more.

Printing with second material support increases capability but also complexity. Print slower (<50mm/s), use higher “z-hop” or “z lift” setting (0.3mm+), and complex shapes may require “raft” feature to improve stability of support.

Prime Pillar

Ooze Shield

Main Part

“Prime Pillar” and “Ooze Shield” can improve two-material printing performance

When printing with two materials, there will always be one nozzle that is hot but not flowing any material. This can cause a clog if it happens over a long period of time. Using a prime pillar will make sure each nozzle prints on each layer to keep material from burning in.

Ooze shield prints a single shell of extra material around the outside of your part, intended to catch excess material that may drip from the non-printing nozzle.

Combining 3D printed parts with specialty materials and traditional methods can create a very advanced end result.

Table grips printed with NinjaFlex brand TPE

Foot caps printed with stainless steel powder-filled PLA from ProtoPasta

Table center printed with basic PLA

Consider tool-making; 3D printing is a great way to create jigs, mounts, guides, and whatever else needed to finish another project

Parts are stronger when designed to take stress along the same plane the layers are printed in.

Motor Torque

Layers oriented to distribute torque

Parts are stronger when layers are printed in line with stress.

Printing in the orientation shown top right will be significantly stronger.

Settings used for M4 screws printed with ABS:Temp: 190 CCooling: 100%

Recommended settings for common ABS materials:Temp: 210 - 240 CCooling: 0%

Settings used for table center, printed in PLA with 1 mm nozzle at 0.4 mm layer height:Temp: 250 CCooling: 100% + extra desk fan

Recommended settings for common PLA materials:Temp: 190 - 225 CCooling: 100%

Parts at the extremes of scale may require experimenting outside of recommended material settings.

Dramatic shifts in part geometry require very different optimizations

Temp: 210 CLayer: 0.05 mmSpeed: 20 mm/s

Temp: 225 CLayer: 0.125 mmSpeed: 60 mm/s

Temp: 235 CLayer: 0.2 mmSpeed: 40 mm/s

Minimum layer time settings can be used to improve evenness of cooling by slowing down in small areas

Cura

Simplify3D

Consider what is appropriate to print and what other hardware options are available

Specialty materials and finishing techniques can create visually compelling results

ABS can be treated with acetone to achieve appearance similar to injection molded parts and improved layer strength

Any questions?Thank you

Russell Singerrussell@makeit-3d.com

Other Resourceshttp://makeit-3d.com/resources

https://www.simplify3d.com/support/print-quality-troubleshooting/

http://www.mcmaster.com

http://www.thingiverse.com

http://www.grabcad.com

http://www.cults3d.com