DIY 3D Printing

Hardware & Software

Ed Nisley • KE4ZNU
softsolder.com
~
ACM Poughkeepsie Chapter
May 2012

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 Upcoming Events
Tchotchkes!
3D Printer Hardware Overview
3D Printer Action Movie
Solid Modeling: OpenSCAD
CAD & CAM Process
Design → CSG → Plastic
3D Modeling Gotchas
Why I Have a 3D Printer
Q&A + Touchy-Feely
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 Tchotchkes
Simple examples
Quick printing
Mixed plastic colors
These are test pieces
Numbers = parameters
Some All have defects!
Understand the limits
Share nicely...

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 Threads
Object “Skirt”
Test/verify extrusion
0.33 or 0.25 mm
±0.1 mm or so
Width = 2 x thickness
All layers identical
Depends on software
Data! Data! Data!

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 DIY 3D Printing

Building things with a hot-melt glue gun

A very small glue gun: nozzle 0.2 to 0.6 mm dia
A very hot glue gun: 190 to 230 °C = 350 to 450 °F
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http://www.thingiverse.com/thing:2064
 Cartesian Coordinates
Z Axis
+Up -Down
X Axis
+Right -Left
Y Axis
+Back -Front
A Axis http://www.thingiverse.com/thing:2064

Filament drive motor

Nozzle vs. platform?
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https://en.wikipedia.org/wiki/Cartesian_coordinates
 3D Printing Mechanics
Z Axis stage
Filament drive = A Axis
Extruder “Hot End”
Nozzle
X and Y Axis Stages
Build platform (heat?)
Leveling
Build Chamber
LED strip lighting!
Coordinate Origin? 7
 Thermal Isolation

Molten plastic vs. plastic structure...

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http://softsolder.com/2011/02/27/mk5-extruder-head-external-temperatures/
RepRap Mendel

http://reprap.org/wiki/RepRap_Options
RepRap Prusa Mendel

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http://reprap.org/wiki/RepRap_Options
 NopHead Mendel90

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http://hydraraptor.blogspot.com/2011/12/mendel90.html
Printrbot

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http://printrbot.com/
 PrintrBot Kickstarter

Backers: 1,808

Goal: $25,000

Pledged: $830,827

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http://www.kickstarter.com/projects/printrbot/printrbot-your-first-3d-printer
Makerbot Replicator

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http://store.makerbot.com/replicator-404.html
 Makergear M2

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http://www.makergear.com/products/m-series-3d-printers
3D Systems Cubify

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http://cubify.com
 3D Printing Up Close

Tux Cookie Cutter

The Movie

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http://softsolder.com/2011/09/07/tux-cookie-cutter/
 Solid Model
Define shape & size
Geometric primitives
Cube, cylinder, sphere
Transform objects
Scale, move ...
Boolean combinations
Union, difference ...
Draw it or program it?
Art vs. Engineering
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http://softsolder.com/2012/04/10/kindle-fire-power-button-protector/
 OpenSCAD Source Code
union() {
translate([PlugOffset,0,0])
cylinder(r=PlugDia/2,
h=(PlugLength + PlateThick),$fn=8);
translate([0,USBOffset,(PlateThick + USBLength)/2])
cube([USBWidth,USBThick,(PlateThick + USBLength)],
center=true);
difference() {
translate([0,0,PlateThick/2])
roundedBox([PlateLength,PlateWidth,PlateThick],
PlateRadius,true,$fn=4*4);
translate([ButtonOffset,0,-Protrusion])
rotate(360/(2*8))
PolyCyl(ButtonDia,(PlateThick + 2*Protrusion));
}
}
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OpenSCAD – The Programmer’s Solid 3D CAD Modeler

 Amateur Radio GPS+Voice

Acrylic sheet machined on my Sherline CNC mill

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http://softsolder.com/2010/06/17/gps-audio-interface-for-icom-z-1a-ht/
 Subtractive Machining

Sherline CNC milling machine

running LinuxCNC (née EMC2)

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http://softsolder.com/2010/06/27/ht-gps-audio-case-dimensions/
 Why I Have a 3D Printer

http://softsolder.com/2012/04/13/wouxun-kg-uv3d-gps-interface-functional-case/ 22
http://softsolder.com/2012/03/01/gpsvoice-interface-for-wouxun-kg-uv3d-brassboard/
http://softsolder.com/2011/10/05/gpsvoice-interface-for-wouxun-kg-uv3d-circuit-hackage/
 How It Starts

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http://softsolder.com/2009/01/01/geek-scratch-paper/
CAD Solid Model

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3D Printed Parts

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Base Plate - Solid Model

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Base Plate - Solid Plastic

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 CAD = Numbers!

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http://softsolder.com/2012/04/05/kg-uv3d-gpsvoice-battery-pack-alignment-lugs/
Radio Base Shape

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Constructive Solid Geometry

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CSG = By the Numbers

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Negative Volumes

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 Constructing Solid Plastic

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http://softsolder.com/2012/04/04/kg-uv3d-gpsvoice-interface-battery-case-latch/
 CAD = Design
Measurements / Style
Geometric Shapes
Min/max width & thickness
Support structures
Auto vs. manual
Printing orientation
Surface finish!
Multiple parts per run?

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 CAM = Manufacturing Process
Given valid CAD geometry
Slice into layers
Thickness & width
Infill density
Hole size adjustment?
Emit G-Code program
Which RS-274 dialect?
Speed(s) & acceleration
Temperature(s)

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Printed Plastic!

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“Given Valid CAD Geometry...”

Gray face = external surface of object

Purple face = adjacent to subtracted object
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http://softsolder.com/2011/08/23/nema-17-stepper-motor-mount/
What’s Wrong With This Picture?

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 Solid Model → G-Code

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http://fabmetheus.crsndoo.com/wiki/index.php/Skeinforge_Skeinlayer
http://softsolder.com/2011/09/05/openscad-vs-skeinforge-40-bogus-g-code/
 Geometric Requirements
Closed surface
“Watertight” objects
Consistent Normals
All aimed outward
2-Manifold
Exactly 2 faces / edge

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http://reprap.org/wiki/Separate_page_on_the_question
https://en.wikipedia.org/wiki/File:Acme_klein_bottle.jpg
Exactly Two Faces / Edge

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http://softsolder.com/2011/08/23/nema-17-stepper-motor-mount/
 What’s Wrong With This Picture?
Closed surface
Consistent Normals
Easy to see?
In this model...
Book version is OK
CSG = 3D volumes
Mesh = 2D surfaces

Beginning Google SketchUp for 3D Printing http://www.apress.com/9781430233619 42

http://reprap.org/wiki/Sketchup_Modeling_for_3d_Printing
http://reprap.org/wiki/Art_of_illusion
 SketchUp Concepts Guide
Designing in SketchUp

SketchUp is not the same as Computer Assisted

Design or CAD. CAD applications are designed
specifically for representing concrete information,
while SketchUp is for exploration and design of
concepts and ideas (though you are not prohibited
from designing models that are as concrete or
accurate as those designed in CAD).
[That’s my emphasis...]

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Google SketchUp Support Answer

 Mostly, It Just Works
Feature size
≥ 2 * Thread Width
n * Thread Thickness
Aspect ratio
Squat = good
Build plate adhesion
Square = good
Always preview G-Code
Catch problems early!
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http://softsolder.com/2012/04/10/kindle-fire-power-button-protector/
 If You Want It ...

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http://softsolder.com/2011/07/01/helmet-mirror-mount-first-light/
 ... And You Can Draw It ...
Multiple components
Fasteners?
Rotating joints
Adhesives
Design style
Rounded edges!
Projecting snout
Can’t be built that way
Can’t be reoriented

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http://softsolder.com/2011/06/29/helmet-mirror-mount-solid-model/
... You Can Probably Build It

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 DIY Support

Canon SX230HS Lens Cap Replacement Clamp Handle

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Dishwasher Rack Protector Superflash Mount
Support Structures

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Why I Have a DIY 3D Printer

Digital Caliper Repair Thing-O-Matic X Axis Rod Follower

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Why I Have a DIY 3D Printer

Tour Easy Superflash Mount

Tour Easy Zzipper Fairing Mount

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Why I Have a DIY 3D Printer

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Camera Macro Adapter and Microscope Mount
Microscope LED Ring Illuminator
Should You Have A DIY 3D Printer?
Are you an engineer?
Do you know one?
Willing to DIY?
Have parts / tools?
Have time?
Willing to learn?
Imperfections OK?
Even ugly ones?
Go for it!
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http://softsolder.com/2011/03/05/thing-o-matic-measuring-build-plate-alignment/
 Q&A + Touchy-Feely
Ask questions
Mill around
Examine stuff
Ask questions
Iterate ...

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 Other Places To Go
Wikipedia: 3D Printing
RepRap: Useful Software List
OpenSCAD: 3D CAD for Programmers
Slic3r: STL-to-GCODE translator / slicer
Pronterface: GCODE-to-printer interface
Thingiverse: A Universe of Things
Search the InterWebs for the obvious terms
Click on the links in the PDF version!

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 Copyright-ish Stuff

Some web images probably copyrighted, but

shown & attributed here under “fair use”
[whatever that is]

The rest is my own work

This work is licensed under the

Creative Commons Attribution-Noncommercial-Share Alike 3.0 United States License.
To view a copy of this license, visit
http://creativecommons.org/licenses/by-nc-sa/3.0/us/
or send a letter to
Creative Commons, 543 Howard Street, 5th Floor
San Francisco, California, 94105, USA.

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 Ed Nisley
Say “NISS-lee”, although we're on the half-essed branch of the tree

Engineer (ex PE), Hardware Hacker, Programmer, Author

The Embedded PC's ISAÂ Bus:Â Firmware, Gadgets, Practical Tricks

Circuit Cellar www.circuitcellar.com

Firmware Furnace (1988-1996) - Nasty, grubby hardware bashing
Above the Ground Plane (2001 ...) - Analog and RF stuff

Digital Machinist www.homeshopmachinist.net

Along the G-Code Way (2008 ...) - G-Code, math, 3D printing

Dr. Dobb’s Journal www.ddj.com

Embedded Space (2001-2006) - All things embedded
Nisley’s Notebook (2006-2007) - Hardware & software collisions

The Smell of Molten Projects in the Morning September 1962

softsolder.com

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 If you
can’t read this
then
make a new friend
‘way up front

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