how to 3d print... right now!
TRANSCRIPT
Calling all Coders, Designers, Makers, Engineers, Hackers, and Thinkers.
Merging innovators from the fashion and tech industries, the result will be awesome!
What is 3D Printing?
Subtractive
manufacturing
Additive
manufacturing
Types of 3D Printing
Fused Deposition Modeling
(FDM)
Stereolithography
(SLA)
Selective Laser Sintering,
Selective Laser Melting
(SLS, SLM, DMLS)
PolyJet (PJ)
Reliable Smooth
Powder
Color
Costs of 3D Printing
FDM
SLA
PJ
SLS, SLM, DMLS
High
Types of 3D Printing
FDM
SLA
PJSLS,
SLM
• Designing FDM parts for Strength
• Designing FDM parts for Fit
• Designing FDM parts for SPEED
What we’ll cover today:
Designing for Strength
FDM print nozzle
Previously printed
layers
X
Y
Z
X
Y
Z
WEAKER
STRONGER
Designing for Strength
X
Y
Z
PULL
PULL
Von
Mises
Stress
Designing for Strength
X
Y
Z
PULL
PULL
Principal Stress Vectors
Designing for Strength
X
Y
Z
PULL
PULL Build Envelope
Designing for Strength
WEAKER
STRONGER
X
Y
Z
PULL
PULL
Designing for Strength
1. Run a static simulation of
your model
2. View stress vectors
3. Print so that largest stress
doesn’t pull LAYERS apart
Designing for Strength: Workflow
• Designing FDM parts for Strength
• Designing FDM parts for Fit
• Designing FDM parts for SPEED
What we’ll cover today:
Designing for FIT
Do you:
A. Design the parts to FIT PERFECTLY together
(because printing tolerances are symmetric)
B. Design the parts with a GAP between them
(to be on the safe side)
C. Design the parts to OVERLAP
(because 3D parts shrink over time)
Designing for FIT
The edge of your CAD model
The beads of FDM
Designing for FIT
Designing for FIT: Crowd participation!
Option 1:
NO Clearance,
NO Draft
Option 2: 0.010” gap
Option 3: 0.020” gap
Option 4: 0.030” gap
Option 4: 0.010” gap
+ sanding
Designing for FIT
0.010”
(0.0254 cm)
Designing for FIT
One bead
thickness gap
Designing for FIT
Wall
0.010”
(0.0254 cm)
0.020” ?
0.010”
thick0.020”
thick0.030”
thick0.040”
thick0.050”
thick
Designing for FIT
One Bead:
Two Bead:
Squish! Z
XX = 2*Z
• Designing FDM parts for Strength
• Designing FDM parts for Fit
• Designing FDM parts for SPEED
What we’ll cover today:
OBZ Design sample partScreen
Nubs
Front
Back
Rubber Button
Designing for FIT
0.003” Clearance for
paper
0.002” Clearance, to let screws have bite
5° of draft, 0.001” clearance5° of
draft,
0.005”
clearance
• Designing FDM parts for Strength
• Designing FDM parts for Fit
• Designing FDM parts for SPEED
What we’ll cover today:
Printing for SPEED
How long does this part take to print?
Printing for SPEED
PrintingPrep the files Post-processing
1hr 54min
• Choosing color/thickness
• Laying out your tray
• Waiting in line
• Operator actually starts
your print!
• Removing from tray
• Removing support materials
• Sanding
• Painting
• Metal inserts
Printing for SPEED
Bad 2: PrintingPrep Post
PrintingPrep PostBad 1:
PrintingPrep Post
PrintingPrep Post
8 hours 8 DAYS
Painting FDM parts
1. Sanding
2. Primer
3. Paint
PrintingPrep Post
8 hours 8 DAYS
PrintingPrep Post
“On some parts, we go through 7, 8 iterations just trying to
get the shape right. Other teams have to try to modify off-
the-shelf parts. Not us- we can custom build for our exact
need!”-Daniel Hoyos Failach, Team Lead
PrintingPrep Post
“That’s not ‘Rapid Prototyping’!”
-Daniel Hoyos Failach, Team Lead
8 hours2 WEEKS
PrintingPrep Post
PrintingPrep Post
“Now we prep and
print ourselves, and
have the parts in the
morning!”
-Daniel Hoyos Failach,
Team Lead
How crazy would it be if only one person in
a building could print Word documents?
Prepare: Schedule:
CAD Input: FREE!
Printing for SPEED
Bad 2: PrintingPrep Post
PrintingPrep PostBad 1:
Bad 3: PrintingPrep Post
Less Support, Less Sanding & Painting
Better Software, Prep part yourself!
Print in Sparse mode, lower density
Bad 3: PrintingPrep Post
Printing for SPEED
Functional Parts
under high stress
Fit or feel
Printing for SPEED
Bad 2: PrintingPrep Post
PrintingPrep PostBad 1:
Bad 3: PrintingPrep Post
EASIEST TO FIX!
• Designing FDM parts for Strength
• Designing FDM parts for Fit
• Designing FDM parts for SPEED
What we’ll cover today:
How to 3D print RIGHT NOW:
If you are a UML student:
One time print:
Makerspace on North Campus
Supervised use:
• Safety training
• Printing & laser cutting training (Mon. 5-7)
Unsupervised use:
• Show lab manager you deserve it
How to 3D print RIGHT NOW:
If you are a UML student: • [email protected]
iHub members get access to
THIS makerspace
• Extra fee
If you are an inventor/start-up:
How to 3D print RIGHT NOW:
If you are a UML student: • [email protected]
Join iHub!If you are an inventor/start-up:
If you already have a Stratasys
Printer:Download GrabCAD Print
for free today!
Printing for Strength:
X
Y
Z
Your print is weakest:
WEAKER
STRONGER
PULLING YOUR
LAYERS APART
Printing for Fit:
For gaps between
moving parts, leave:
(One Bead)
Make your smallest
walls at least:(Two Bead)
(Squish!)Z
X
And horizontially,
account for:
Printing for SPEED:
PrintingPrep the files Post- processing
The easiest section to cut time in is:
PREPARATION!
Design for Manufacturing
(DFM) says:
“Avoid flat-bottom holes. Make sure the
bottom angles of holes conform to
standard drill bits.”
3D Printing
says:
Either way is fine.
“Only design parts that
can be made.”
Design what does
the job best.(Traditional GE Engine Mount Bracket) (Redesigned bracket by GrabCAD user Charlie
Pyott)
3D Printing
says:
Design for Manufacturing
(DFM) says:
● 2 pieces
● Complex, better
fuel mixing built-in
● 10 days
3D Printing
says:
● 150 pieces
● Simple fuel mixing
● 6-9 months to
make
DMLS printed fuel injector nozzle for
NASA’s Marshall Space Flight Center
Design for Manufacturing
(DFM) says:
Design for Additive
Manufacturing (DFAM)
Design for
Manufacturing (DFM)
Optimizing for Speed
Actual
modelSupport
material
Optimizing for Speed
Model material
Support material
Build Time
0.46 cubic inches
0.11 cubic inches
35 min
0.46 cubic inches
0.31 cubic inches
2h 18 min
Optimizing for Speed: Tips
1. Minimize use of Model and Support
material
Optimizing for Speed
Build Time 35 min2h 18 min
Minutes/Cubic Inch 61179
Optimizing for Speed
Build Time 35 min2h 18 min
Minutes/Cubic Inch 61179
FEWMANY Material Changes
Optimizing for Speed: Tips
1. Minimize use of Model and Support
material
2. Minimize times the printer
head has to CHANGE from
Model to Support material
3. TEST, TEST, TEST!
Agenda
● Optimizing for strength
● Optimizing for speed of print
● Optimizing for humans
What if only one person at your company could print
Word documents?
Optimizing for Humans
Optimizing for Humans
CAD Designer/Engineer
CAD Designer/Engineer
CAD Designer/Engineer
Optimizing for Humans
CAD Designer/Engineer
CAD Designer/Engineer
CAD Designer/Engineer
Printer
Operator
15th 16th 17th
Optimizing for Humans
CAD Designer/Engineer
Optimizing for Humans
Prepare: Share:
CAD input
Optimizing for Humans
.STL
Optimizing for Humans
Prepare: Share:
No STLs!
FREE!
What if only one person at your company could print
Word documents?
Optimizing for Humans
Optimizing for Humans
What if EVERYONE at your company could 3D print?
Agenda
● Optimizing for strength
● Optimizing for speed of print
● Optimizing for humans
Optimizing for Humans
Which of these statements is true?
• 3D Printing is faster than
other manufacturing
methods.
• 3D Printing is cheaper than
other manufacturing
methods.
• 3D Printed parts are
stronger than those
made other ways.
• 3D Printing is more
efficient than other
manufacturing methods.
Injection Molding:
CNC Machining:
3D Printed: