PLEASE WEAR GLOVES. NEVER TOUCH THE RESIN (EVEN WITH GLOVED HANDS). BE CAREFUL: RESIN GETS EVERYWHERE.

Transcription

1 FORM 2 TUTORIAL

2 PLEASE KEEP THE FORM 2 AREA CLEAN. PLEASE WEAR GLOVES. NEVER TOUCH THE RESIN (EVEN WITH GLOVED HANDS). BE CAREFUL: RESIN GETS EVERYWHERE.

3 TABLE OF CONTENTS STEP 1: HAVE YOUR.STL or.obj FILE READY... 1 STEP 2: IMPORT YOUR.STL/.OBJ FILE TO PreForm... 2 STEP 3: ORIENT YOUR PART and GENERATE SUPPORTS... 3 STEP 4: CONFIRMATION CARD & PAYMENT... 4 STEP 5: PRINT... 4 STEP 6: REMOVING PART... 4 STEP 7: POST PROCESSING: FORM WASH & FORM CURE... 5 APPENDIX: IN CASE OF RESIN SPILL... 6 APPENDIX: CHOOSING YOUR RESIN... 6

4 STEP 1: HAVE YOUR.STL or.obj FILE READY From CAD You may use any CAD software that creates 3D geometry, including Solidworks, OnShape, Fusion360, Rhino, SketchUp, etc. In SolidWorks.STL export options, Fine resolution generally gives good results. Check the preview and adjust as necessary. Make sure to check the units! From Scanning We have two scanning technologies in Room 36: o HP 3D Structured Light Scanner Pro S2 (formerly DAVID SLS-2) is a high-precision projector and dual camera scanning setup. o Autodesk ReCap Pro is a photogrammetry program that can convert 2D pictures into a 3D model. Both will allow you to export/download an.stl file of the scan. Often, scans will have holes or other discontinuities that will affect printing. Programs like Netfabb and MeshMixer can aid in the repair of these errors. From the Web You may find raw CAD models on sites like GrabCAD. Alternatively, you may find.stl files on sites like Thingiverse and Youmagine. REMEMBER: always cite the source for any part you have used or modified! Image credit: sculpteo.com 1

5 STEP 2: IMPORT YOUR.STL/.OBJ FILE TO PreForm When PreForm opens, it should look like this: Image credit: formlabs.com Confirm the correct printer is connected in the Printer menu. Select the resin type. o See: Appendix: Choosing Your Resin for resin choice considerations. o Look for the version number on the top of the resin cartridge. If no version number is visible, select 01. Select the layer thickness. o 0.1mm is a good enough resolution for most projects. o Thinner layers significantly increase print time (0.1mm prints finish ~4x as fast as 0.25mm prints). Click Apply. Open your.stl file(s). o Go to File, Open, and search for your.stl file. o Alternatively, you may drag and drop files into the PreForm window. o You can add in as many parts/models as you wish as long as the parts all fit on the grid platform (after generating supports). The PreForm will shade a part red if it exceeds the size of the build platform. For larger parts, consider converting them to a multi-part assembly. We recommend inspecting your model for internal features that may affect printability (e.g. unsupported areas or cups). You may do so using the Slicer Tool a vertical slider located below the view menu on the right side of the PreForm screen. 2

6 STEP 3: ORIENT YOUR PART and GENERATE SUPPORTS Before printing a part, one must orient it and generate supports. PreForm offers a One Button Print button, which you may use at your own risk. It will automatically orient your part, generate supports, and send the file to the printer. For more control over part size, orientation, and supports, we recommend going through these manually. First, ensure the part(s) is scaled as expected. Select a part by clicking on it (it should turn blue). You may size or scale it using the Size button (top left), as shown: Image credit: formlabs.com To generate supports automatically, click the magic wand button and the software will suggest an orientation and generate supports. o If the orientation or support locations are suboptimal (say, because it generated supports on an important, high tolerance surface), click the wand again to generate a new orientation. If still no good, read below for manual orientation/support adjustment. Image credit: formlabs.com 3

7 To manually orient and generate supports: o Use the tools at left to manually edit supports and orientation. BE CAREFUL. An insufficient amount of supports or flat orientation will cause the print to fail. o Flat surfaces with support structures print much more successfully when oriented at an angle of 10 20º minimum. Form Labs recommends 45º. o You may adjust the density of supports, but be careful: too few supports will cause print failure. What is too few depends on your part geometry and material. o Note: the grid on the bottom of the displayed cube is the build platform (the top of the Form 2 printer). COMMON PRINT FAILURES: o Not enough supports. o Poor part orientation (e.g. flat surfaces in print orientation). o Part design not appropriate for stereolithography (the type of 3D printing employed by the Form 2). STEP 4: CONFIRMATION CARD & PAYMENT Fill out a FORM 2 CONFIRMATION CARD. The Print Time and Volume are estimated by the software (at the bottom of the main window). Confirm that the print will not run into a session for which you don t have the printer reserved. Give the confirmation card to a TA and pay for the print. Please do not start your print before paying for it. STEP 5: PRINT Confirm that the build platform is clear and the correct resin is loaded. If the resin is not as desired, ask a TA to change the resin cartridge and tray. Click the Print button and then Send to Printer. Once it appears on the printer s screen, press the button on the FORM 2 to start the print. Post the Confirmation Card on the front of the printer. STEP 6: REMOVING PRINT PUT ON GLOVES. DON T TOUCH RESIN WITH BARE OR GLOVED HANDS. If touched, resin tends to drip everywhere and make a mess. Please avoid this. Lift lever to unlock the build platform. Grip the top to slide it off the machine. Do NOT grip the sides or any other surface covered in resin. Place build platform and part into the FORM WASH (as shown in image below). 4

8 Build platform placed into FORM WASH. Isopropanol fill line. Image credit: formlabs.com STEP 7: POST PROCESSING: FORM WASH & FORM CURE Follow the directions posted next to the FORM WASH and FORM CURE station. Set the FORM WASH timer as specified; run wash cycle; and allow to dry for at least 30 mins. Ensure that part is no longer wet before placing into FORM CURE. Carefully remove part(s) from build platform using prying tools and/or snips. Place parts into FORM CURE. Set length of curing cycle using guidelines posted next to FORM CURE machine. Run curing cycle. Claim your finished parts! STEP 8: CLEAN UP Ensure that: o The area around the FORM 2, post-processing stations, and all tools are clean and dry. o All machines are closed. o There is a clean and dry build platform in the FORM 2. o There is enough isopropanol in the FORM WASH. See fill line on outside of FORM WASH (and in image above). Clean up any spills. See Appendix: In Case of Spill. 5

9 APPENDIX: IN CASE OF RESIN SPILL If on surface other than Orange Cover or Resin Tray of Printer -> Dissolve with IPA. If on Orange Cover or Resin Tray of Printer > Ask a TA to clean with acrylic cleaner and microfiber cloth. If skin contact: do NOT use IPA. Instead wash with soap and water. APPENDIX: CHOOSING YOUR RESIN STANDARD RESINS Clear: Transparent; polishes to near optical clarity. Great for internal channels and working with light. White: Neutral and matte tone, slight translucency when thin. Works well for sanding, and provides a great base color for painting. Grey: Neutral and matte tone, great for showing off surface finish and for printing small, accurate features. Photographs nicely. Black: Highly pigmented with matte surfaces our most opaque, high detail resin. Great for printing small, intricate features. ENGINEERING RESINS Flexible: Simulates an 80A durometer rubber. Choose for impact resistance and compression, great for ergonomic soft-touch grips. This material is flexible but not designed to stretch. Tough: Simulates ABS plastic. Choose for applications that will undergo high stress and strain. Great for functional prototyping of assemblies, machining, snap-fits and living hinges. High Temp: Has an HDT of MPa. Choose for static applications that will experience high temperatures, including moldmaking processes such as thermoforming, vulcanization, and electronics encapsulation. Durable: Simulates polypropylene (PP) or high density polyethylene (HDPE). Choose for applications when high elongation, deformation, and/or impact resistance are required. Castable: Choose for direct investment casting (transform your printed part into metal!). Often used to fabricate small, intricate cast parts (e.g. fine jewelry). Resin is designed for clean burn out and high detail. Careful, resin is slightly softer than standard resins before curing. 6