3D Printing

First, what is 3D printing in general?

It is a process which an object is made through addition of thin layers to become 3D object.

What is Additive Manufacturing and Subtractive Manufacturing?

Additive Manufacturing	Subtractive Manufacturing
It is a process of adding thin layers by layers on the object to make it become 3D shape.	It is a process of which the large material is removed by using machine to come out with a more defined object and become your prototype.

During the vacation, we are tasked to design an object using Fusion 360 and 3D print the object but the object should be small, and we are only given max of 1 hour of printing. Here, I will list down the steps of how I come out with the idea and the procedures of making the product. LET'S GO!!!

Image above shows the proper paths from design in Fusion 360 and sent it to 3D printer in order to create a 3D object.

1. Design a 3D object in Fusion 360

I came out with an idea of instead putting eggs in a bowl, I decided to put the eggs in an egg holder. It is because since I am an orientated person and I like to make the eggs orientated and it will look tidy and fascinating, so I came out with the egg holder, it will be more elegant when the eggs are put in the egg holder just like how the eggs are arranged in the breakfast area in 5-star hotel!

Here are the steps on how I design the egg holder:

1. First, take the example of the shape of an egg as our starter.

2. Then, it will come up with a sphere, and in order to make it oval, I use SCALE function to make the shape to become oval. Take note of the Z-axis as it will affect the overall shape of the object.

3. Next, I want to cut the object into half, so I use SPLIT BODY to do it, and it results that the shape has become half!

4. After that, I use the function SHELL to make the hollow cavity of the head with the walls of a specified thickness so that the head will become more hollow as shown in the images below. I use the thickness of 3mm for the head.

5. Next, to create the base for the egg holder, I will have to use OFFSET PLANE under CONSTRUCT to design the base. What I do is I adjust the EXTENT > TO OBJECT, then select the origin of the construction and the point under the base of the sphere as shown in the image below. This allows me to able to construct the base of the egg holder.

6. Right now, I want to create a circular base for the egg holder, what I do is I choose the plane that I had created from the previous step and not the plane on the top, then I use SKETCH to create a circular plane. In image #2, to make the base of the egg holder to be slanted, the most important key to take note = TAPER ANGLE!!! This aspect will affect the result whether the base is going to become slanted or not, so I make the angle to be 45 deg. As for the distance, I make it to be -20.00mm because I want to connect the half sphere with the base which the half sphere is located above, so that is why I will need the "- " sign or else the design will be ruined!

7. For the final few steps, I use FILLET to make my egg holder to be more detailed, and one of the benefit is that it will allow my design, especially the edges of the body to be more rounded by adding material to interior edges.

The design will look like this when completed.

EMBEDDED VERSION:

2. Convert the Fusion 360 file to STL file.

1. To convert the fusion 360 file, all I have to do is simply click EXPORT...> Save the file in either STL or 3MF, and you are all set!

3. Slicing the 3D representable file (STL or 3MF) into layers using Cura slicer software

1. Open the Cura slicer software, and this is what you will see after open it. Take note that to change the preset printer to Creality Ender-3, as we will sent it for the printer to do its job. In image #2, as you can see in order to import the file to Cura slicer, select the file that has been saved from Fusion 360 in STL or 3MF format. In image #3, after you have selected the file, you will see your design in the simulated version of the printer.

2. Next, you can adjust the settings for your design as you can see in the image below, take note that you must include SUPPORT for all your design, so that after your design has been 3D printed, it will not collapsed and it will be a perfect 3D product. In image #2, to check the slicing time, simply click on SLICE, and the result is out (this practical requires 1 hour max to print your product which my estimated time is slightly more than that, but it is ok...)! If the estimated time is enough for you, you can click on SAVE TO DISK or if you think the time is too short or too long, you can adjust the settings for the design if necessary.

4. Converting the layers into instructions for the 3D printer (gcode)

1. Before that, you must save your file in gcode format as it requires for the 3D printer.

5. The 3D printer creates the 3D object

1. While waiting for my product to be 3D printed, one of the senior told me that always choose DISABLE STEPPER or else the machine will be spoiled. I noticed that when the object is in the process of 3D printing, the stepper will always move towards and backwards during the process, so that is the reasons why we need to choose DISABLE STEPPER.

Safety precautions:

1. Do not put your bare hands on the stepper during 3D printing is in progress as it will burn your hands due to the hot surface.

2. Wait for a few minutes to let the stepper to cool down, then take the 3D printed object from the stepper carefully.

Here is the product that I have made, YAY!!!

Reflection:

This practical is about 3D printing, as it requires my creativity to create an object from Fusion 360, then 3D printed out. This practical is important as it helps me to understand the basic knowledges on how 3D printing works and the skills. Furthermore, I will also need to apply the 3D printing skills for our group's prototype in the coming semester, or even FYP. Overall, I find the practical interesting because I can learn how the 3D printer work and what we have to take note during the process. If there is a chance, I would like to create designs with more complex in the future. Before that, I used to think that 3D printing is quite easy and straightforward, as the 3D printer will help us to settle the job. Now, I realize that to 3D print your design, there are some precautions to take note, such as safety on using 3D printer, and the properties of your design in Cura (especially to enable SUPPORT) before sent it to the printer. So next, I will make use of the knowledges and skills of using the 3D printer for the prototype for the coming semester, and also Final Year Project.