3D Printing

3D Printing Seminar

Applications
Types of 3d printers
Overview of machines and prices
Online printing services
In depth on FDM printing
Common FDM problems
OSU 3d Printing
Repetier Host Process

Types of 3d Printing

FDM (Finite Deposition Manufacturing)

SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
DMLS (Direct Metal Laser Sintering)
DIW (Direct Ink Writing)
EBM (Electron Beam Manufacturing)
LOM (Laminated Object Manufacturing)

Cost of 3d Printing Machines

Stratasys SLS $846,000
Stratasys Jet Printer $330,000
Cheap SLS printers $30,000
Note: SLS patents expired in 2014

FDM printers $250 to ~$3500

Online Printing Services

Solid concepts
Shapeways
Proto labs
Low cost
Low Time Investment

Image Credit
Shapeways

Early home 3d printing machines

Prusa Mendel 3d printer

Early model
Nearly self replicating
Structure made of all-thread hardware store rod
Joints and mounts made from 3d printed parts

Immediately use 3d printer to make more

3d printers
Low Strength Parts
Need a Metal Option!

Metal FDM Printer?

FDM depends on raising the filament above its glass
transition temperature
The machines do not liquefy the filament
Desired alloys would flow
well during transition
Liquids perform poorly
due to surface tension

http://blog.reprap.org/2011/06/new-approach-to-printing-metals.html

ColorFabbs Metal Filament

BronzeFill and CopperFill

80% by weight Metal
PLA/PFA plastic binder
Printed part can be polished, treated, etc. as metal.
Aesthetic result only.

Lost wax casting with 3d printing

Lost PLA instead of lost wax
3d part encased in sand or
ceramic mold
Heated to melt the 3d part out of
mold
Void filled with molten metal
Mold broken away revealing
higher strengh part.

FDM Filament

Common Diameters
1.75mm Diameter
3.00mm Diameter

ABS Acrylonitrile Butadine Styrene

PLA - Polyacitic Acid
Flexible PLA
*1.75 most common
Laywood sawdust infused plastic
(Your printer head is made for one
Laybrick chalk infused plastic
or the other)
Nylon
PVA polyvinyl acetate support material dissolves in water)
Bendlay translucent 91%
TPE bendable rubber-like material.
PC - polycarbonate
HIPS high impact polystyrene
Conductive ABS 1200 Ohm/cm
LAYFOMM sponge-like once soaked

Information and pictures from: http://www.matterhackers.com/3d-printer-filament-compare

OSUs FDM printers

Low cost High Quantity
Single Filament
Open Source Software
Solidoodle version of Repetier
Host
Has settings automatically
loaded in for Solidoodle
printers.

USB (serial) connection to

drive printer.
No SD card printing option

Common Problems with FDM

Warping of thin parts (ABS)
Getting part to stick to printbed
Heated bed with kapton tape helps ABS
Cold bed with masking tape helps PLA
Many home remedies for the problem
Elmer's glue
Hairspray (gums up machine mechanisms)

Rough surface from support structure

Tangled filament roll
Non-uniform diameter filament roll
Hot filament buckling in printer feed.

So far all these errors have been easily

recoverable!

OSU 3D Printing Rules

1. Computers re-image themselves on reboot. Dont save anything you
plan on keeping!
2. Printing area is not a lab space Therefore safety glasses are not
required. Keep the lids closed, watch for hair and loose clothing
around stepper motors.
3. Machines must be babysat by at least 1 person at all times. 1 person
can watch as many running machines as he/she likes.
4. Provide your own filament for parts. Generally 35 dollars for a 1 Kg
spool.
5. Clean the machine and area of filament scrap after use
6. No post processing of parts on the tables. Please keep them looking
nice
7. OSU owned machines are for school projects, research, and OSU
related activities.
8. All prints must be PG. Do not print weapons of any type,
projectiles, firearms, or components of firearms. *discussed in
detail next

The Medias favorite side of 3d printing

Solid Concepts 1911 pistol
Created with DMLS
Remember that $850,000+ machine?
Inconel and Stainless Steel

Hand finished and assembled.

1. Manufacture of personal firearms
possible since the bronze age
(1288AD)
2. Easier and cheaper to make
hardware store zip guns
3. Many more troubling DIY
creations that dont benefit from 3d
printing.
please avoid gun theology questions and keep them
referenced to the manufacturing technology

Solid Concepts
All 3d printed 1911

Questions / Discussion

Next:
Repetier Host Live Demo