ElectiveMMM2016-1

Schedule

Week	Group	Time	Location	Subject
1	1	8:30 - 10:10	Prototyping space	Intro & 3D Printing
1	2	10:30 - 12:10	Prototyping space	Intro & 3D Printing
2	1 & 2	8:30 - 12:10 (Teacher presence between 9:30 - 12:00)	Prototyping space	Work on assignment 1
3	1	9:30 - 11:00	Prototyping space	The Mill and Lasercutter
3	2	11:00 - 12:30	Prototyping space	The Mill and Lasercutter
4	1 & 2	8:30 - 12:10 (Teacher presence between 9:30 - 12:00)	Prototyping space	Work on assignment 2
5	1	9:30 - 11:00	Prototyping space	Printing and Plotting
5	2	11:00 - 12:30	Prototyping space	Printing and Plotting
6	1 & 2	8:30 - 12:10 (Teacher presence between 9:30 - 12:00)	Prototyping space	Work on assignment 3
7	1	9:30 - 11:00	Prototyping space	Human powered machine project
7	2	11:00 - 12:30	Prototyping space	Human powered machine project
8	1 & 2	8:30 - 12:10 (Teacher presence between 9:30 - 12:00)	Prototyping space	Work Human powered machine project
9	1 & 2	8:30 - 12:10 (Teacher presence between 9:30 - 12:00)	Prototyping space	Work on Human powered machine project
10	1	9:30 - 11:00	Prototyping space	Judgement day
10	2	11:00 - 12:30	Prototyping space	Judgement day

3D printing

3D printing is a widely used additive manufacturing technique. In this block you learn about the different 3D printing techniques, the advantages and disadvantages. We will also look at the language used to control many 3D printing (and many other computer controlled machines). You will see this is actually a very simple technique, however making a good 3D print is not necessarily easy. As for all techniques, experimenting is key in learning how get the most out of 3D printing

Techniques

Fused Deposition Modeling (FDM)

FDM is, due to the consumer 3D printers of this type, the most widely known 3D printing technique. With FDM a layers of material are stacked on top of each other. In this way the object is build up layer by layer. This technique can be used with almost any material that can be extruded. This holds for most plastics when heated to just below the melting point. But also other materials like clay, chocolate, bee wax etc. can be used.

* FDM example
* Daniel de Bruin: Analog 3D printer
* Dirk Vander Kooij: Creating an Endless Chair, Dirk Vander Kooij
* Interview Unfold about their installation L'Artisan Electronique featuring ceramic 3d printing
* DUS Architects: Kamermaker II
* RooieJoris: Real 3D printing

Stereo Litography (SLA)

SLA uses a UV laser to harden a special resin at specific points. The 3D object, in a way, grows out of the resin.

* Formlabs Form2

Selective Laser Sintering (SLS)

Laser sintering uses a laser to melt/sinter particles together. This technique can be used to print in metals.

* How metal 3D printing works
* Markus Kayser: Solar Sinter

Powder bed and inkjet 3D printing (binder-jetting)

Inkjet 3D printing is a technique very similar to SLS where a laser melts small particles of material together. With inkjet 3D printing a binder is used instead of a laser. The material can be metal particles but also some type of plaster. The printer uses standard inkjet printing cardridges for printing in full colour. After printing the part is very brittle and usually needs to be impregnated with a solidifying material like epoxy or cyanoacrylate.

* 3D Systems printing process
* Print iPhone in full colour

GCode

From Wikipedia on G-Code:

G-code (also RS-274), which has many variants, is the common name for the most widely used numerical control (NC) programming language. It is used mainly in computer-aided manufacturing to control automated machine tools. G-code is sometimes called G programming language, not to be confused with LabVIEW's G programming language.

G-code is a language in which people tell computerized machine tools how to make something. The "how" is defined by instructions on where to move, how fast to move, and what path to move. The most common situation is that, within a machine tool, a cutting tool is moved according to these instructions through a toolpath and cuts away material to leave only the finished workpiece. The same concept also extends to noncutting tools such as forming or burnishing tools, photoplotting, additive methods such as 3D printing, and measuring instruments.

Simply put, G-Code is the language that tells the machine what to do, which movements to make, when to deposit material, when to stop etc. etc.. For example, a simple G-Code line that tells the machine to move to position X:10mm, Y:10mm could be:

G1 X10 Y10

Here the code G1 is the code for move to. To draw a square with the 3D printer would require four such movements. Assuming we start from location X0 Y0 Z0 and want to draw a square of 10 by 10 mm:

G1 X0 Y10
G1 X10 Y10
G1 X10 Y0
G1 X0 Y0

For a list of G-Code commands an Ultimaker 3D printer understands (or a printer running Marlin) see: https://github.com/ErikZalm/Marlin/blob/Stable/Marlin/Marlin_main.cpp Scrolling down will reveal the G-Code list.

An easy way to manually control your printer and send G-Codes by hand is Pronterface/Printrun: http://www.pronterface.com

Assignments

After each subject you need to conduct experiments with the technique / machine covered. These experiments are very valuable for learning to master the technique or machine. Most assignments ask you to find and perhaps go over the bounderies

Assignment 1: 3D printing experiments

For this assignment you will need to experiment with a 3D printer/technique.

* Find or make a 3D object and print it using one of the conventional 3D printing techniques. Try to get the print as clean as possible. Don't use an object too large, you will need to print it several times. As the school only has FDM printers this will most likely be on an Ultimaker. ProtoSpace in Utrecht has a 3D systems inkjet printer and Fablabl Breda has a Formlabs SLA printer (ask Charlotte from the digital lab).
* Print at least 3 other versions changing settings drastically. For example print a version with a temperature much higher than normal, or with a speed very low or high. Adjust settings on the fly and see what happens. Document your process!
* Adjust the G-Code of the object (e.g. make it stop somewhere so you can insert something into the object and continue again, or make the Z wobble). You may also make a G-Code yourself and try to print it. Remember to save the new G-Code!

After this assignment you will have (at least) 5 printed objects and a lot of experience with 3D printing and what different settings do for the specific printing. Playing with extreme settings shows you what happens when a setting is not good and help you recognize and solve faults in your prints. Try not to just change settings but think about what will happen and why.