3D Printer Tool Training. Gui Cavalcanti 2/3/2012

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1 3D Printer Tool Training Gui Cavalcanti 2/3/2012

2 Training Goals 1. Intro to Additive Manufacturing 2. Intro to the uprint 3. Part Design for 3D Printing 4. Part Layout for 3D Printing 5. Printing and Maintenance 6. Part Cleanup

3 Intro to Additive Manufacturing

4 Additive Manufacturing Most manufacturing is subtractive Common additive manufacturing: welding, sewing Multiple types of additive prototyping FDM: Fused Deposition Modeling SLA: Stereolithography SLS: Selective Laser Sintering Objet, ZCorp, and other proprietary processes

5 Fused Deposition Modeling

6 Stereolithography

7 Selective Laser Sintering

8 Intro to the uprint

9 Intro to uprint Dimension uprint SE Plus Build area of 8 wide x 8 deep x 6 tall Layer thickness of.010 or.013 Alkali-soluble support material Cost of $7.50 per cubic inch of material printed Cost for trays, support material, etc. included Takes *.STL files from most 3D modeling programs and converts them to parts

10 uprint SE Plus

11 uprint Components 1. uprint SE Plus Printer 2. uprint Print Bays 3. Material and Support Spools 4. Print Trays 5. SCA Station

12 Part Design for 3D Printing

13 Part Design for 3D Printing.020 Minimum Feature Size:.010 Bead Cross-Section Z Bead width:.020 Minimum wall size:.040 X or Y Layer thickness:.010 or.013

14 Part Design for 3D Printing Parts shrink after coming out of the printer in a relatively predictable way. Exterior dimensions shrink to 99.7% of their modeled size. Model Reality Interior dimensions (such as holes) shrink to 98.5% of their modeled size. Model Reality Thus, a pin printed the exact same size as a hole will not fit in the hole once it s printed.

15 Part Design Rules of Thumb Minimum structural wall thickness:.0625 No tapping of printed parts; use self-tapping threaded inserts instead Printed cylinders should be between.002 and.005 (in real units, not model units) bigger than holes they need to precisely fit into Wherever possible, include a fillet between.0625 and.125 between all sharp edge transitions.0625 minimum

16 Part Layout for 3D Printing

17 Part Layout for 3D Printing Height often takes 2-3x longer to print than width Multiple prints of single layers of parts will take significantly less time than one print with multiple layers Printing on the X-Y plane is accurate to within.005 across 6 ; along X-Z or Y-Z is much coarser Print cylinders so that they stick out of the printing tray; avoid laying them on their side for printing whenever possible The more support material is laid down, the more manual work and waiting on the bath you ll have to do

18 Printing and Maintenance

19 Printing and Maintenance Use the Catalyst software on the Asylum computer to compile your *.STL files Change model orientation, material density, support density, resolution and more in Catalyst (see documentation) All prints must be logged in the sign-in sheet before printing starts Members will be invoiced via for the price of the print material ($7.50 per cubic inch of material printed) Use the mailing list to coordinate long print jobs, notify others of low consumables, etc. See the Stratasys documentation for more information about maintenance

20 uprint Specifics Only ever turn the printer off with its soft switch, never with its circuit breaker uprint requires its own electrical circuit, shared only with the computer and monitor No SCA station No extension cords uprint is not physically connected to its base, only pick up under the base

21 Part Cleanup

22 Part Cleanup Steps 1. Remove pieces from printing tray 2. Remove as much support material from parts using hand tools as possible Wear safety glasses and vacuum up after you re done 3. Turn the SCA on, set a time that s appropriate (1 hour required to heat up; 1 hour for small parts, 2-4 for larger parts), place parts in the bath 4. Wait the time specified 5. Retrieve parts with tongs, gloves, and safety glasses. Note that you can lift the main tray out of the SCA 6. Wash or dunk parts in clean water 7. Set parts out on wire rack to dry

23 SCA (Support Cleaning Apparatus) On/Off is the upper right hand button Use Set and arrow keys to change the on time Allow 1 hour for warm-up If the Low light is on, fill with hot water from the sink via cup USE GLOVES AND SAFETY GLASSES AT ALL TIMES

24 Wash Station Remove parts from SCA with gloves on Wash parts in water basin thoroughly Leave parts on wire rack to dry

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