How to 3D print... right NOW!

How to 3D Print

Right NOW

Shuvom Ghose

Stratasys Software

shuvom@grabcad.com

Calling all Coders, Designers, Makers, Engineers, Hackers, and Thinkers.

Merging innovators from the fashion and tech industries, the result will be awesome!

How to 3D Print

Right NOW

Shuvom Ghose

Stratasys Software

shuvom@grabcad.com

What is 3D Printing?

Subtractive

manufacturing

Additive

manufacturing

Types of 3D Printing

Fused Deposition Modeling

Stereolithography

Selective Laser Sintering,

Selective Laser Melting

(SLS, SLM, DMLS)

PolyJet (PJ)

Reliable Smooth

Powder

Costs of 3D Printing

SLS, SLM, DMLS

Types of 3D Printing

PJSLS,

• 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

WEAKER

STRONGER

Stress

Principal Stress Vectors

PULL Build Envelope

WEAKER

STRONGER

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 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

+ sanding

Designing for FIT

0.010”

(0.0254 cm)

Designing for FIT

One bead

thickness gap

Designing for FIT

0.010”

(0.0254 cm)

0.020” ?

0.010”

thick0.020”

thick0.030”

thick0.040”

thick0.050”

Designing for FIT

One Bead:

Two Bead:

Squish! Z

XX = 2*Z

OBZ Design sample partScreen

Rubber Button

Designing for FIT

0.003” Clearance for

0.002” Clearance, to let screws have bite

5° of draft, 0.001” clearance5° of

draft,

0.005”

clearance

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

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

“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

Less Support, Less Sanding & Painting

Better Software, Prep part yourself!

Print in Sparse mode, lower density

Printing for SPEED

Functional Parts

under high stress

Fit or feel

Printing for SPEED

EASIEST TO FIX!

How to 3D print RIGHT NOW:

If you are a UML student:

One time print:

• 3dprint@uml.edu

Makerspace on North Campus

Supervised use:

• Safety training

• Printing & laser cutting training (Mon. 5-7)

Unsupervised use:

• Show lab manager you deserve it

If you are a UML student: • 3dprint@uml.edu

iHub members get access to

THIS makerspace

• Extra fee

If you are an inventor/start-up:

If you are a UML student: • 3dprint@uml.edu

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:

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

And horizontially,

account for:

Printing for SPEED:

PrintingPrep the files Post- processing

The easiest section to cut time in is:

PREPARATION!

How to 3D Print

Right NOW

Shuvom Ghose

Stratasys Software

shuvom@grabcad.com

Design for Manufacturing

(DFM) says:

“Avoid flat-bottom holes. Make sure the

bottom angles of holes conform to

standard drill bits.”

3D Printing

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

(DFM) says:

● 2 pieces

● Complex, better

fuel mixing built-in

● 10 days

3D Printing

● 150 pieces

● Simple fuel mixing

● 6-9 months to

DMLS printed fuel injector nozzle for

NASA’s Marshall Space Flight Center

(DFM) says:

Design for Additive

Manufacturing (DFAM)

Design for

Manufacturing (DFM)

Optimizing for Speed

Actual

modelSupport

material

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

Build Time 35 min2h 18 min

Minutes/Cubic Inch 61179

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

CAD Designer/Engineer

Printer

Operator

15th 16th 17th

Prepare: Share:

CAD input

Prepare: Share:

No STLs!

What if only one person at your company could print

Word documents?

What if EVERYONE at your company could 3D print?

Agenda

● Optimizing for strength

● Optimizing for speed of print

● 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:

How to 3D print... right NOW!

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