Physical Data Visualization and Rapid Prototyping with the Genisys Xs

Transcription

1 Physical Data Visualization and Rapid Prototyping with the Genisys Xs Jo Wozniak Research Programmer Date Issued: May 2001 The Beckman Institute Imaging Technology Group Technical Report Copyright 2001 Board of Trustees of the University of Illinois The Beckman Institute for Advanced Science and Technology Imaging Technology Group 405 N Mathews Urbana, IL [email protected]

2 Physical Data Visualization and Rapid Prototyping with the Genisys Xs Jo Wozniak Imaging Technology Group Beckman Institute for Advanced Science and Technology University of Illinois at Urbana-Champaign Introduction The Genisys Xs 3D printer is a conceptual modeler. It produces high-quality models from a highstrength polyester compound. The models are ready to use right from the printer. However, if you want to finish your model, you can sand it, paint it or drill it to meet your needs. The Genisys Xs is located in the rear left of the VMIL. Files need to be brought into AutoGen, the printer's proprietary software for scaling and orientation. STL files are required. This report details the steps necessary to output a model successfully from the Genisys Xs 3-Dimensional printer. Operating the Genisys Xs 3D printer 1. Before submitting a file to the printer check the material status On the keypad situated at the front of the printer select Menu -> put printer offline (if the printer is online). Use the up or down arrow to scroll through the options. Next select Menu -> Status Menu -> Material Status A series of numbers will appear in a span of 10 columns; each column can have up to 50 wafers The column will look similar to: [ ] Please write down the numbers shown on the display screen as they will be necessary to get a figure for total wafers used later. If wafers need to be added, proceed to step 2. If the amount of wafers is sufficient for the print go to step 3. How many wafers will my model use? One way to obtain an estimate is to take a look at the models in the display case. Below is a table showing several models and the number of wafers used. Whether a print will be completely solid on the inside or filled with a honeycomb structure instead (sparse fill option in AutoGen; see step 9) should also be taken into account when

3 estimating wafers needed for the print. Sparse filled parts will use roughly one third less material than solid filled parts. Model Description Wafers Used Actomyosin protein Measures ~3 in height and ~2.5 in diameter. Model is solid filled. 32 Head of Cyberscan subject Measuers 2.5 in height and head diameter is roughly 2.5 Sparse filled 6 Microtubule Measures 3 in height and 2.25 in diameter. Solid filled. 46

4 Complex Mathematical model of soap bubble. Measures in height and 3.75 in width. Model is skinned To add more wafers, open the top hatch of the machine and check to see if any empty cartridges need to be removed. To do this, squeeze the top and bottom of the empty cartridge, lift up and pull out. Cartridges can be found in the bin to the left of the printer and should be replaced from left to right. To place in a new cartridge, unwrap from the bubble wrap, being careful not to remove the sponge from the cartridge. Slide the cartridge into the slot with the chip towards the rear bottom with the sponge in front. The chip should align easily with the slot. Remove the sponge only after the cartridge is positioned correctly in the machine. Place the empty cartridge in a white box with the other empty cartridges. Close the top hatch of the machine. 3. Open the main hatch of the machine and make sure the platen (stage) is clear of all material. To remove any material from the platen, use the scraper found in the bin to the left of the printer. Discard in waste bin situated nearby. Close the main hatch. 4. Put the printer back online by once again using the keypad on the front of the printer: Menu-> Put Printer Online 5. Submit the part to be printed to the printer using AutoGen (on all VMIL NT workstations). Instructions on using AutoGen begin at step Please check on the printer periodically to make sure it is working correctly. If it is not, please hit the abort button located on the right hand side of the keypad. 7. After a job is completed please remove the part and any extra material off the platen, using the scraper if necessary. Take the printer offline and check for material status. Subtract the number of wafers currently on the display screen from the amount obtained before the print to get the number of wafers used. 8. Please log your name, date, number of wafers used and any comments in the log book kept on top of the printer

5 Autogen is a point-and-click application that greatly simplifies the printing process. The operation can be as simple as opening an STL file, scaling and orienting if necessary and then printing. The software verifies the wireframe and checks for bad edges or open triangles. If the file processes correctly the software will then slice the file on the z plane for the printing process. 9. Using Autogen A. Open AutoGen from Start->Program Files or QuickStart on the computer. The interface will appear: To open your STL (stereolithography format) file go to File->Open STL:

6 B. When the file imports, it may not appear visible in the display window. To correct this, go to the View pull down menu and select Wireframe C. The part will be bright green. The file may also appear quite small. There are several ways to change the scale. Under the Units options, Inches can be selected.

7 Alternately, you can adjust the scale of the part manually in the fit or scale boxes: D. Moving the part in the box can be done in the Translation options box. Even though the part may seem to be stuck in a corner, if this part is to be printed alone, the machine will place it in the center of the stage (platen). You can rotate the part by typing in numbers in the X, Y, and Z selection boxes,

8 respectively. Rotation is necessary only to obtain a larger model, as the build envelope is 8 x12 x8 (depth x width x height). E. To save on material, choose the sparse option under the Fill menu: This will create a honeycomb pattern on the inside of the model (the exterior will become a skin) instead of filling the model completely on the interior. Choosing the sparse fill option may also shorten the time necessary for the build. If the model to be printed is large and does not require a high degree of strength (for drilling, etc.) choosing sparse fill may be a good option as well. F. If the model is particularly fragile or intricate, selecting maximum under the Supports option may be a good idea:

9 G. Once the part is ready for printing, select Print under the File menu. An option box is displayed: If the part is to be printed alone, select that option in the pull down menu. Alternately, parts can be packed to the full extent of the build envelope before being printed. With this option the software will arrange the parts automatically so they fill the stage in the x-y plane and then stack them in the z plane. Several parts can be printed at once using this feature. All but the last part to be built should be packed while the last one should have pack and print selected in this option box. Once the OK button is selected the software slices the file in the Z plane and submits this file to the Genisys printer via the internet. At this time the Estimated Print Time is established. This number is very close to the actual time to print. Go back to step 6.