Introduction

3D Printing
 Activity
Let’s make 3D object

1 Give blank Thermocol sheet to a group of participants

2 Ask them to cut the three sets of 2 different shapes from it. (Circle & Rectangle).

3 Ask them to paste the same shape on each other;

4 Inform them to write the Q1 in the Worksheet.

Ask them to color the objects (Optional)

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 ANALYSIS
3D printer uses the same technique. When the circles were placed over one another it formed a
Cylinder similarly when a rectangles were placed on top of one another it formed a cuboid. This
process of adding layer by layer is known as “additive manufacturing process, which is used by all
the 3D printers.
What is 3D Printing

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Process involves to develop a 3D model

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 3D PRINTING
The 3D printing process builds a three-dimensional
object using a computer-aided design (CAD)
model, usually by successively adding material
layer by layer, which is why it is also called additive
manufacturing.

Father of 3D printing: Chuck Hull

While all 3D printers create objects using additive

methods (the opposite of a CNC machine)

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 Method of 3D printing
1. Fused Deposition Modelling- A common approach in which the
part is printed by extruding molten stings of material that melt
together to create the part.

2. Selective Laser Sintering -More common in industrial style prototyping

settings, a laser melts together powdered plastic, ceramic, or other material,
then spreads more powder on top, repeating the process to build the part
layer by layer.

3. Powder Bed and Binder- Similar to Laser Sintering, an inkjet

head distributes binder to the correct location on a bed of powder.
 Method of 3D printing
4. Stereolithography- Here, an ultraviolet laser hardens resin in a vat
layer by layer until the part is built. It can quickly create high
definition parts that can be machined.

In our lab, we have an FDM (Fused Deposition Modelling) 3D Printer.

Let’s Have a look at it

a) A filament of plastic material is fed through a heated moving head b) that

melts and extrudes it depositing it, layer after layer, in the desired shape c). A
moving platform e) lowers after each layer is deposited. For this kind of
technology additional vertical support d), structures are needed to sustain
overhanging parts.
Worksheet
Time

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 Did You Know ?

We can print five different colors We can convert our 3D printer

from a single nozzle at once into a interactive printer using
without changing the filament. Octa-print.
3D Printing
3D Modelling

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 Open source CAD software
The 3D modelling process builds a three-dimensional object using a computer-aided design (CAD) Software.

1 Tinker CAD 6 Sculptris

2 CollabCAD 7 FreeCAD

3 Blender 8 123D

4 Sketch-UP 9 Makehuman

3D Builder
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 CollabCAD
➢It is a collaborative network, computer enabled software system, providing a total
engineering solution from 2D drafting & detailing to 3D product design.

➢The aim of this initiative is to provide a great platform to students of Atal Tinkering
Labs (ATLs) across country to create and modify 3d designs with free flow of
creativity and imagination.

➢CollabCAD provides facilities to build and edit entities in virtual 3D space using
basic geometry such as lines, arcs, and conic sections. 2D profile and free hand
sketching is also available. In addition there is detailed dimensioning, tolerances,
symbols etc.

➢Besides the conventional CAD/CAM features, CollabCAD also provides a

collaborative framework for CAD/CAM professionals to work across a network and
concurrently access the same design for viewing and modification.
Download and Install CollabCAD

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3D Modelling Software –
TinkerCAD

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3D Printing
3D Slicing

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3D Slicing Software

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 Definition
The slicer, also called slicing software, is computer software used in the majority of 3D printing processes for the conversion of a
3D object model to specific instructions for the printer.
In previous lesson we have learnt that the model is saved in “.stl” format , CURA software converts it into G-code so that the
printer can understand the file. We will use Ultimaker CURA 15.04.6

Installation Process:
Please follow these steps to Install CURA on your PC.
1. Install the CURA & you will see a screen as shown in figure Click on Next.
2. On the second Dialog, please select all the Components to install
3. Then Click on Next until you get a screen as shown in the figure. Now Click on
Finish.
4. You will see a dialog box asking you to download a new version, Click on NO, otherwise Cura will be updated to the latest version.

5. Now you will see a wizard, labelled as the First time run Wizard or Add your Machine. Click on Next

6.Now it’s an important step to select your machine or you can say to define your machine to adjust its
settings according to it.

7. Now select your machine from the list if your machine is not listed then please Choose Other & click on Next.

8. Now again you will see a few more machines if still your machine is not listed then choose
Custom & click Next now you will have a screen shown in the image.
9. This is a very Critical Step, please ensure you have proper information labelled in the User manual or
provide by the manufacturer.
10. Write the Machine Name, then Machine dimensions provided by the manufacturer.
11. Write the nozzle size label on the user manual.
12. Check for heated bed if it’s available then check the box. Don’t check the Bed center option.
13. Click on Finish.
Now you will see a Screen with Some controls that will help in deciding the quality of the product. Before we start further
look at Filament diameter change it to 1.75mm
Loading a model in CURA
1. You have already designed a model in tinker cad now we need to load that model in CURA.
2. Click on file then select load model from file then browse or locate your file that you saved in .stl file in your
modelling software.
 Basic Set up

01 02 03
Layer height: The height of each layer is Shell Thickness: The thickness of the Enable Retraction:
the crucial parameter that determines outer wall of the side of the model is Recommended
the quality of the print and time. set to an integral multiple of the
a. Setting range is 0.05-0.3, diameter of the nozzle. If the nozzle is
High quality setting is 0.1, 0.4mm, the recommended wall
and the medium quality thickness is 1.2.
setting is 0.2.

04 05 06
Print Speed: The moving speed of the
Fill Density: The filling density inside
Bottom /Top Thickness: This is print head during printing. Set it to
the model can be set to 10%~100%
generally an integral multiple of the low speed for complicated parts &
according to the actual situation. The
layer thickness. It is recommended high speed for simple elements.
larger the value, the denser the
to be the same as the wall thickness Generally set around 30-50, suggested
interior.
and set to 1.2. PLA setting 50, ABS setting 30.

07 08 09
Support Type: support mode when
Bed Temperature: Platform
Printing Temperature: the printing a model with a suspended part,
temperature, recommended PLA
temperature used by the nozzle to 1. “None” - no support,
setting 50 °C, ABS setting 80-110 °C.
melt the consumables. The melting 2. “Touching buildplate” - creating
temperature is varied based on the support that can reach the workbench
material. It is recommended to set part,
the PLA to 190 degrees and the ABS 3. “Everywhere” - create support for
setting to 230. all parts which are suspended.
(Recommended)
 Basic Set up

10 11 12
Platform Adhesion Type: None defaults Diameter: The filament supplied is Flow: Default 100
to print one layer at a minimum, Brim 1.75mm.
refers to a skirt, and Raft refers to a
bottom plate. It is recommended to
select Raft, the PLA first layer Airgap is
set to 0.15, and the ABS first layer Airgap
is set to 0.1 or lower.

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Nozzle Size: Nozzle diameter is generally 0.4mm. If you customize other nozzle
sizes, fill in here.
a. Note - The nozzle size does not affect the accuracy of the layer
thickness and only affects the minimum print detail. The size of the
nozzle and the printing speed are squared, and increasing the nozzle
size dramatically increases the printing speed.
Now insert the SD Card & you will see SD card written on the screen,
now click on that and .gcode will be saved in your SD Card.

To know more about the function of CURA setting 24

please download the guide for the Given QR code
3D Printing
3D Troubleshooting

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Activity

01
Try to level the gap between the nozzle &
bed.

02
Look at automatic levelling and how to
change levelling on one side.
 ANALYSIS
The 3D printer is an important aspect in rapid prototyping, to Maintain the quality of the object & the long life of the machine
we need to take some precaution while printing and some to service our machine.

01 02
Bed Level – Every Printer has a different Nozzle Cleaning – This is a
mechanism to level. The level word significant problem with many 3D
means the gap between the bed & nozzle printers of nozzle clogging. Go
at 5 Points. (4 Corner of bed & 1 center). through your 3D Printer Manual for
The minimum difference between the the process of nozzle cleaning for
nozzle and bed should not more or less your respective printer.
than a 0.05mm (thickness of A4 size
paper).
 PROBLEM AND ITS CAUSES
S.No Problem Image Major Cause

❑ Filament was not loaded into extruder before printing

❑ The distance between nozzle and bed is too close
Not Extruding at
1 ❑ The filament stripped against the drive gear
start of print ❑ The extruder is clogged

❑ Build platform is not level

❑ Nozzle starts too far away from the bed
Print Not Sticking to ❑ First layer is printing too fast
2
the Bed ❑ Temperature or cooling settings
❑ The build platform (tape, glues and materials)
❑ When all else fails: Brims and Rafts

❑ Retraction distance
3 Snoozing or oozing ❑ Retraction speed
❑ Temperature is too high
S.No Problem Image Major Cause

❑ Nozzle moves too fast

Layer Shifting or ❑ Mechanical or Electrical issues
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Misalignment

❑ Increase the extruder temperature

5 Grinding Filament ❑ Print too fast
❑ Check for a nozzle clog

❑ Manually push the filament to extruder

6 Clogged Extruder ❑ Reload the filament
❑ Clean out the nozzle
Worksheet
Time

30
 Did You Know ?

With the help of 3D Printing There are 3D printers which uses The history of 3D printing
technology, people have already Gold, Silver, Titanium, wood etc began in the 1980s.
managed to create artificial for 3D Modelling .
organs.