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Design for 3D Printing Hack Chat

Design before you print

Wednesday, May 24, 2023 12:00 pm PDT Local time zone:
Hack Chat
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Eric Utley will host the Hack Chat on Wednesday, May 24 at noon Pacific.

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Like a lot of enabling technologies, 3D printing has had a strange trajectory. It started out as a laboratory oddity, moved on to industrial applications, and finally filtered down to the DIY set, first as scratch-built machines and later as inexpensive commodity printers that can be found almost anywhere. Pretty much everyone who needs a 3D printer now has one.

Not all additive manufacturing technologies are created equal, though, and there are plenty of applications for 3D printed parts where FDM just won't cut it. Luckily, any of us can get access to the latest and greatest manufacturing technologies through job houses that specialize in everything from metal 3D printing to sheet metal fabrication, CNC machining, and even small-run injection molding. We may not be able to afford any of the machines, but in a lot of cases we can afford to rent time of them and get high-quality parts quickly.

But that raises another question: Is my design ready for manufacturing? What works on an Ender on your shop bench might not quite translate to the latest SLS printer, and sending off an iffy design could just end up wasting time and money. Whether you're sending your designs out and running them up on your own printer, you want to know what you're doing will work. That's why we've asked Eric Utley, an applications engineer with Protolabs, to stop by the Hack Chat. With 12 years of additive manufacturing experience, he'll be able to help you tune up your designs and make sure they're ready to print.

  • Hack Chat Transcript, Part 1

    Dan Maloney05/24/2023 at 20:07 0 comments

    Dan Maloney12:00 PM
    OK folks, let's get going! Welcome back to the Hack Chat, sorry for the long absence. I'm Dan, I'll be moderating today along with Dusan as we welcome Eric Utley to talk about design for 3D printing.

    I saw Eric on much earlier today; still out there, Eric?

    eric.utley12:00 PM
    I am still here!

    Dusan Petrovic12:00 PM
    Hi Dan, welcome everyone!

    Dan Maloney12:01 PM
    Hi Eric, welcome aboard! Can you kick things off with a little about yourself and your background?

    Dan Maloney12:01 PM
    Hi Dule!

    eric.utley12:02 PM
    Yes, I have been involved in additive manufacturing (aka 3D printing) for over 15 years now. I work with production technologies primarily like SLA, SLS, and MJF

    eric.utley12:02 PM
    I have a harder time coming up with things I haven't printed than things I have

    Dan Maloney12:02 PM
    I've heard of the others, but help me out with MJF...

    eric.utley12:03 PM
    yes that is Multi Jet Fusion, a tech developed by HP. It uses a series of printer heads that deposits 'fusing agent' into plastic powder and the whole build chamber is hit with heat. The fusing agent heats up from the light and sinters the powder.

    eric.utley12:04 PM
    It prints very fast, we can build hundreds of parts at a time in an overnight print. The material is very general purpose (nylon)

    eric.utley12:05 PM
    The powder acts as support structure, so it requires no scaffolding. If we get really intricate designs like neural networks or tree roots it is the best for shapes like that, but also good at end-use production printed plastic parts

    Dan Maloney12:05 PM
    OK, I think I've seen that before. Also think I've seen DIY versions that spray a thin glue as the binder? Maybe, anyway

    eric.utley12:05 PM
    its not quite the same, what you are referring to is 'binder jetting' where blue/binder is placed on powder to glue it together. The MJF is a heat driven process that actually melts the powder to sinter it

    eric.utley12:07 PM
    We actually do not do any binder jetting, but there are binder jetting printing processes out there that can print in full color plastics or even print metal parts

    Dan Maloney12:07 PM
    Got it. And these are all "big boy" printers, right? Industrial units as opposed to the ones we're more used to, I'd imagine

    eric.utley12:08 PM
    yes correct, these would be industrial printers not seen in home use. Some are specialized for niche parts (like Micro Stereolithography for very small parts) and some like MJF are more general purpose

    eric.utley12:10 PM
    This is our largest printer: It can print metal parts the size of an inline 4 engine block

    Oofda joined  the room.12:10 PM

    Oofda12:11 PM
    what are the kinds of companies primarily printing parts that large?

    Dan Maloney12:12 PM
    Is that actually a use case for a printer like this? IOW, do people need to print something like an engine block for prototyping, etc? Or is it more a case of a huge print bed being used to print multiple items at once?

    eric.utley12:13 PM
    Those are very much aerospace parts. We run both Inconel and aluminum on those large metal printers. Inconel is a nickel based 'superalloy' capable of withstanding very high temperatures. Components for rockets, satellites, and unmanned drones.

    Larry Ascona joined  the room.12:13 PM

    eric.utley12:14 PM
    sometimes it will be something outside of aerospace, like custom manufacturing equipment or prototypes of parts that will eventually be cast

    eric.utley12:15 PM
    We can print heat sinks and other designs in aluminum. The printing allows for internal cooling channels to make for efficient cooling without an extensive assembly of welding multiple parts together.

    Dan Maloney12:17 PM
    We did a story about how rocket nozzles were manufactured with internal cooling channels before AM came along and made that easier. The process was really cool.

    eric.utley12:17 PM
    printing in metal allows aerospace to skeletonize the designs and remove as much weight as possible, they are easily the earliest adopters of printing in metal

    Dan...

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Discussions

trevorholmes5426 wrote 2 days ago point

If you're interested in creating a design for a 3D Printing Hack Chat, one option is to develop a logo or visually captivating graphic that embodies the chat's theme. Here's a step-by-step guide to help you approach the design process:

Conceptualize: Consider the fundamental elements and concepts associated with 3D printing and hack chats. Ponder symbols, icons, or imagery that symbolize these ideas. Brainstorm various design concepts and sketch initial ideas on paper.

Software: Utilize 3D modeling software or graphic design software to craft your design. Depending on the complexity of your vision, options like Autodesk Fusion 360, Blender, Adobe Illustrator, or Canva may be suitable.

Typography: Choose an appropriate font or typography style for the textual elements in your design. Select a font that complements the overall theme and effectively conveys the desired tone, whether it's professional, technical, or playful.

Graphics and Icons: Integrate relevant graphics or icons into your design. You can create your own or find existing 3D printing-related icons or symbols that represent hack chats or collaboration.

Colors: Select a color scheme that aligns with the chat's theme. Opt for a combination of colors that are visually appealing and enhance the overall design. Pay attention to the contrast between the background and foreground elements to ensure readability.

Composition: Arrange the design elements in a visually balanced and aesthetically pleasing manner. Experiment with different layouts and compositions to find the arrangement that best communicates your intended message.

Mockups and Previews: Create mockups or preview renderings of your design to visualize how it would appear in various contexts, such as social media banners, website headers, or promotional materials.

Iteration and Feedback: Seek feedback from others, particularly individuals within the Hack Chat community or those with design experience. Iterate on your design based on their suggestions and refine it until you're satisfied with the final outcome.

Export and Share: Export your design in the appropriate file format, such as PNG or JPEG, at an adequate resolution for online or print use. Share your design with the Hack Chat community or utilize it as a visual representation for the chat.

Remember to honor any branding guidelines or copyright restrictions if you're creating the design for a specific organization or event. Enjoy the creative process and have fun bringing your design to life!

  Are you sure? yes | no

shawnmendes5426 wrote 2 days ago point

If you're looking for a design for a 3D Printing Hack Chat, you might consider creating a logo or a visually appealing graphic that represents the theme of the chat. Here's a step-by-step guide on how you can approach designing it:

Conceptualize: Think about the key elements or concepts related to 3D printing and hack chats. Consider symbols, icons, or imagery that represent these ideas. Brainstorm different design concepts and sketch out rough ideas on paper.

Software: Use 3D modeling software or graphic design software to create your design. Depending on the complexity of your design, you can use software like Autodesk Fusion 360, Blender, Adobe Illustrator, or Canva.

Typography: Choose an appropriate font or typography style for the text elements in your design. Consider a font that complements the overall theme and conveys the desired tone, whether it's professional, technical, or playful.

Graphics and Icons: Incorporate relevant graphics or icons into your design. You can create or find 3D printing-related icons or symbols that represent hack chats or collaboration.

Colors: Select a color scheme that aligns with the theme of the chat. Consider using a combination of colors that are visually appealing and enhance the overall design. Be mindful of the contrast between the background and foreground elements to ensure readability.

Composition: Arrange the elements of your design in a visually balanced and aesthetically pleasing manner. Experiment with different layouts and compositions to find the arrangement that best communicates your intended message.

Mockups and Previews: Create mockups or preview renderings of your design to visualize how it might appear in different contexts, such as social media banners, website headers, or promotional materials.

Iteration and Feedback: Seek feedback from others, especially those who are part of the Hack Chat community or have experience in design. Iterate on your design based on their suggestions and refine it until you're satisfied with the final result.

Export and Share: Export your design in the appropriate file format, such as PNG or JPEG, at a suitable resolution for online or print use. Share your design with the Hack Chat community or use it as a visual representation for the chat.

Remember to respect any branding guidelines or copyright restrictions if you're creating the design for a specific organization or event. Enjoy the creative process and have fun bringing your design to life!

  Are you sure? yes | no

joffdavid5426 wrote 2 days ago point

If you're looking for design tips for 3D printing, here are some general guidelines to consider for a successful 3D printing project:

Design Software: Use a 3D modeling software like Autodesk Fusion 360, Tinkercad, or Blender to create your design. Familiarize yourself with the software's tools and features.

Size and Scale: Determine the desired size and scale of your design. Consider the limitations of your 3D printer's build volume and ensure your design fits within those constraints.

Geometry: Design your model with proper geometry. Ensure your model is manifold (watertight) with no holes or non-manifold edges. This will prevent printing errors and ensure the model is printable.

Wall Thickness: Maintain sufficient wall thickness for structural integrity. Thin walls may result in weak or fragile prints. A wall thickness of at least 1-2 mm is generally recommended, but it may vary depending on the size and purpose of your design.

Support Structures: If your design has overhangs Volume booster up to 600% or unsupported areas, consider adding support structures. These temporary structures help prevent print failures. Many slicing software tools can generate support structures automatically.

Orientation: Consider the orientation of your design on the print bed. Orienting your model optimally can improve print quality and reduce the need for supports. Flat surfaces should be parallel to the print bed whenever possible.

Fillet and Chamfer: Adding fillets or chamfers to sharp edges can enhance the overall aesthetics of your design and reduce the risk of stress concentration points during printing.

File Format: Export your design to a suitable file format such as STL (Standard Tessellation Language) or OBJ (Wavefront Object). These file formats are widely supported by 3D printing software and printers.

Test Print: Before printing your final design, consider doing a test print with a smaller version or a simplified version of your design to check for any potential issues and make necessary adjustments.

Iterate and Refine: 3D printing is an iterative process. Don't be discouraged if your first print doesn't meet your expectations. Learn from each print, refine your design, and make adjustments as needed.

Remember to consult your specific 3D printer's documentation and follow any guidelines provided by the manufacturer. These general tips should help you get started with designing for 3D printing. Enjoy the process and have fun experimenting with your creations!

  Are you sure? yes | no

darazseller2025 wrote 05/22/2023 at 14:10 point

Sure! I can help you with designing for 3D printing. Here are some key points to consider when designing for 3D printing:

Choose the Right File Format: Most 3D printers accept STL (Standard Tessellation Language) files. Ensure that your design is saved in this format, as it represents the geometry of the object using a mesh of triangles.

Keep Geometry in Mind: 3D printers work by adding layer upon layer of material to create an object. Design your model with this layering process in mind. Avoid overhangs and intricate details that may not be supported during printing or may require additional support structures.

Wall Thickness: Ensure that the walls of your design have adequate thickness to maintain structural integrity. Thin walls may result in fragile prints or cause issues during the printing process.

Support Structures: For complex designs with overhangs or unsupported features, consider adding support structures to prevent sagging or deformation during printing. Many 3D modeling software applications have built-in tools to generate support structures automatically.

Orientation and Rafts: Consider the orientation of your design during printing. Certain orientations may yield better results in terms of surface finish and structural strength. Additionally, using a raft—a thin layer of material placed underneath your print—can enhance adhesion to the print bed and prevent warping.

Clearances and Tolerances: When designing assemblies or movable parts, ensure proper clearances and tolerances between components. Factors such as material shrinkage and printer precision should be taken into account.

File Size and Complexity: Large and highly complex designs may require more resources and time to print. It's essential to balance the level of detail and complexity with the capabilities of your printer and available time.

Test and Iterate: 3D printing is an iterative process. Test and evaluate your designs to identify any issues or improvements needed. Make necessary adjustments and reiterate until you achieve the desired results.

Remember that these are general guidelines, and specific considerations may vary based on your 3D printer, material, and design requirements. It's always a good idea to consult the user manual or documentation provided by your printer manufacturer for more detailed instructions and recommendations.

Additionally, there are various 3D modeling software options available, such as Autodesk Fusion 360, Blender, or Tinkercad, which can assist you in creating and preparing your designs for 3D printing.

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