Lecture on Additive Manufacturing Process

Introduction

• Speaker: Alex, Lab Technician from the Digital Manufacturing Lab
• Focus: Pipeline of the additive manufacturing process, specifically post-design steps in 3D printing.

Digital Design Representation

• Two main methods to create a digital model for 3D printing:
  1. CAD Software
  2. 3D Scanning Technology
  • High-definition 3D scanner using infrared technology available at the lab
  • Best for matte parts, convex geometry
  • Limitations with detailed, shiny, or hole-rich geometries (e.g., chess pieces)

File Export

• STL File Format:
  • Stands for Standard Triangle Language
  • Represents geometry surfaces with connected triangles (shell only, no color/material info)
  • Two formats: Text (human-readable) and Binary (compact)

Pre-Printing Considerations

• Model Integrity:

  • STL file must be error-free, closed, and watertight
  • Tools for checking: Netfabb, Meshmixer, online services
  • Volume calculation can help identify errors

• Unit Verification:

  • Ensure correct units by checking bounding box dimensions
  • Helps position model within printer capacity

Printing Technology

• FDM (Fused Deposition Modeling):
  • Uses heated printhead to extrude melted plastic
  • Layer-by-layer construction from bottom to top

Slicing Software

• Converts STL file to machine instructions (G-code)
• Software Used: GrabCAD Print
  • Optimizes model orientation and position
  • Generates necessary support structures
  • Displays model and support material visually

Support Material

• Required for overhangs or internal details
• Support Material Management:
  • Can sometimes avoid by adjusting orientation or separating parts
  • Use of water-soluble support material (e.g., in uPrint and Mojo printers)

Post-Processing

• Process:
  • Removing support material after printing
  • Uses hot bath with water and support removal agent
  • May take several hours to overnight

Digital Manufacturing Lab

• Part of UB Science and Engineering Shared Facilities
• Provides 3D printing, scanning, and other services
• Services are mostly free for students, with some cost for 3D printing to cover expenses
• More information available on their website

Conclusion

• Thank you note and encouragement to visit the lab's website for further details.