3D PRINTER
PREPARED BY
RAJENDRA R. BANKER(5TH I.T.-502)
RAKESH M. PRAJAPATI(5TH I.T.-549)
CONTENTS
WHY 3D PRINTER?
MANUFACTURERS
PRINTING PROCESS
CHARACTERISTICS
PHOTO GALLERY
CONCLUSION
REFERENCES
MANUFACTURERS
DIMENSION
Z CORPORATION
DIMENSION
Z CORPORATION
PRINTING PROCESS
1. CREATE 3D IMAGE FILE.
STL, DXF, CAD,ZCP,PLY
Dimension printer
• There are three basic steps in printing a
part:
I. Prepare and verify a geometric specification
II. Setup the printer for printing
III. Preprocess and dispatch the file
1. Preparing a geometric specification
Using a CAD system (most popular method)
Using a modeling library
Directly
Verifying the specification
It is strongly advised that the geometry be inspected using a
third party software before printing. Although the Printer’s
software does verify and display the STL file, it is often hard
to see details, and impossible to perform measurements or see
internal/hidden geometries. There are several STL viewers
around, e.g. Solid Concepts' Solid View. This is an excellent
viewer (free for academic use) that not only renders the part
from STL, but also allows making various measurements,
changing transparency setting to make hidden parts visible, as
well as cross sectioning. It also has an option for computing
volume – this option is useful for estimating print time (about
2 hours per cubic inch) and for checking for “leaks” in the
boundary definition.
Important considerations
Accuracy
Scale
Strength
Moving parts
Support material removal
Cost
Print time
Part orientation
Testing
2. Setting up the printer
Routine Setup
1) The printer is typically always on - do not turn it off, because then material cools
off and absorbs moisture.
2) When idle, the temperature settings should be 70 (Model), 70 (Support), 40
(Chamber). Before printing, set up the temperatures to 270 (Model), 235 (Support),
70 (Chamber). Wait until the actual temperature has reached these settings.
3) Clear the print area. If the foam base needs replacement, open the machine door
(press pause if necessary), then unlock and remove the printing plate that holds the
foam base; replace the foam and insert the base back into the machine and lock it in
place.
4) Clear the nozzle skirt if necessary using the metal brush.
5) Press the "Load" button, and then toggle "Model/Support" to make sure material
flows consistently.
6) If either material does not flow, open the print head and manually feed the strands
until material starts flowing. Then close the print head gently, and go to step 5.
Loading Material
1. Roll out the machine and open the back door
2. Remove the empty reel (model or support) and insert a new reel (watch
the orientation so that strand feeds in easily)
3. Replace the exiting moisture-absorbing packets with those that came
with the new reel.
4. Press the "Load" button on the front panel, and select "Model/Support"
appropriately.
5. Feed in the strand into the conic insertion point; feel the strand being
pulled in.
6. Toggle "Model/Support" to make sure material flows consistently.
7. If the material does not flow, open the print head and manually feed the
strands until material starts flowing. Then close the print head gently,
and go to step 6.
PRINTING PROCESS
2. PROCESSING
PRINTING PROCESS
3. PRINTING (DIMENSION PRINTER)
Completing the print
Reduce the temperature settings back to idle
temperatures: 70 (Model), 70 (Support), 40
(Chamber). If the Support temperature does not
want to change, hit "Enter" on the panel, and try
again. Do not turn off the machine.
Remove the foam base, and remove the models
from the foam. (You might need to use a knife -
caution)
Clear the print chamber from excess strands and
dirt.
Removing support material
1. Break off large pieces if support material from the model if possible
(Caution: The support material shatters off into sharp pieces - use eye
protection).
2. Replace water every time in small bath, or every 1-2 weeks in large
bath. Add one full container of waterworks detergent to large bath, or
10th of container to small bath.
3. Submerge the part in the ultrasonic bath - large or small, depending on
part size.
4. Set temperature to 150 Deg F
5. Set timer to no more than 2.5 hours. If submerged longer, part will warp.
6. Do not operate large ultrasonic cleaner when people are in the room -
noise hazard.
7. Repeat from step 3 until all support material is gone.
8. If support material does not completely dissolve after 2-3 trials, consider
redesigning your model so that water can seep in more easily into
cavities with support material.
Z Corporation printer
1. Build Process
The print carriage spreads a layer of powder from the feed
box to cover the surface of the build piston.
The print heads then spray binder solution onto the loose
powder, "printing" the first cross-sectional view. The
remaining powder is loose and supports the part as it is
being printed.
When the cross-section is printed, the build piston is
lowered slightly, a new layer of powder spread over its
surface and the next cross sectional view is printed.
The process is repeated until the build is complete.
PRINTING PROCESS
3. PRINTING (Z CORP.)
2. De-powdering Process
The completed model is encased in unbound
powder and requires de-powdering prior to any
post processing work. The method used to de-
powder is to brush and vacuum excess
powder in the build box, then transfer the
model to an enclosed unit where compressed
air is used to blow the residual powder from the
model.
3. Post Processing
Epoxy resin
CA resin
Elastomer
Wax
Painting
CHARACTERISTICS
Build Size
8*8*12 & 8*10*8 inches
Layer Size
0.010-0.013 inch & 0.004-0.007 inch
Accuracy
0.05 mm
Print Time
2 hours/cubic inch
CHARACTERISTICS
Size
6.4 feet & 4.6 feet
Weight
136 kg. & 120 kg.
Power Requirement
110-120 V
Material
CARTRIDGE
PHOTO GALLERY
PHOTO GALLERY
PHOTO GALLERY
CONCLUSION
Now 3D Printers are efficient, cheap and
easy to use.
REFERENCES
WWW.DIMENSIONPRINTING.COM
WWW.ZCORP.COM
WWW.STRATASYS.COM
WWW.SDSC.EDU
WWW.UALBERTA.CA
