An Introduction to 3D Printing and Ryerson’s Digital Media Experience Lab
The Digital Media Experience (located at Room 308 at the Student Learning Centre), also known as the DME, is a makerspace, fabrication lab, and digital media production facility at Ryerson University. It is a hub for learning and using emerging technology ranging from Virtual Reality, the Adobe Creative Suite, SketchUp, AutoCAD, and so much more. Any Ryerson student has access to their workshops, technology, and resources. I attended a 3D Printing Introduction drop in workshop (which they host daily) to learn the wonders of 3D printing, a technology I have no knowledge about.
3D printing is using a computer to map out and layer material to join/solidify into a three dimensional object. The printer interprets the files in a layer by layer process based on three planes 3 planes: x-axis (horizontal), y-axis (vertical), and z-axis (extrusion). The 3D printer then takes the information of these three axis and interprets when it should place and layer material based on the file. Filament is fed into the 3D printer and heated to a melting point. The nozzle then “prints” the melted material according to the file. The magic of 3D printing is the material’s fast cooling rate, which allows the filament to become a solid and withstand the heat of melted filament layered on top of it. This allows for multiple layers of filament to be stacked and fused together, hence creating a three dimensional object from multiple two dimensional planes. The DME instructor used an analogy of pouring liquid honey that can quickly solidify.
Before 3D printing, I learned about the computer software available to design an object, and the software that drives the printer. There are multiple ways to design 3D printable objects, ranging from complex software for precise and commercial applications to prepackaged minimal effort software that snuck its way onto your Windows update. The type of software you use may affect your model quality as it can have more precision when designing. Either way, the CAD software must export to a .stl file, as this is the only file type the DME will accept.
The DME instructor showed two useful websites to get started with 3D printing. Thingiverse is a free database of various 3D printable files. You can find files from elaborate coasters to toys to spare parts. Whether you wish to print something without the pressure of designing, or modify existing models, Thingiverse is a great resource for .stl files.
Tinkercad is an application to design 3D printable files without any CAD knowledge. It is an accessible 3D model software that within minutes you can begin modeling and shaping your design and have it prepared for printing to bring your design to reality.
As for the software that drives the printer’s themselves, they are hosted on the physical hardware and available through a web browser. Usually this means plugging the printer into a router or directly into your computer via an Ethernet port. Fortunately, the DME has their printers accessible on a private network, so accessing the 3D Printer’s software is simply done by going to your Network and Devices, and clicking on the printer you wish to use to open a web browser (the DME recommends Google Chrome to access it). The software for the 3D Printer allows you to monitor your print, remotely shut down the printer, remotely cancel the print, move the nozzle, and many other functions.
The main window for the software allows you to import .stl files, which are then interpreted by the printer and allows a preview render of the object on a virtual printer bed. Within the software you are able to orientate, scale, rotate, and make simple modifications to the object. It is important to note that the 3D Printer software is for setting up the print, not for editing the file (much like how you edit your document in a word processor, and then tweak the settings in the printing dialog before finalizing your print).
There are many parameters to be adjusted, for printing at the DME there are four main parameters to be mindful of: Fill density, supports, adhesion, and temperature. These parameters are crucial for both efficiency (less physical and time waste), and an optimal 3D print success.
Fill density is an interpretation of how hollow the object is. 0% would give a completely hollow shape. 100% would print the object completely solid. The DME wants to be responsible about saving resources, so they put a cap on fill density at 20%. I initially thought 20% must not be strong, but the object is sturdy enough to be stepped on without bending, let alone break. The DME recommends a minimum of 10% fill density for structural integrity, and a maximum of 20% to save time and material. They also note that 15–20% fill density is quite rigid.
Supports are used in printing applications where a part of the object may collapse under its own weight before the printing is completed. These areas are known as overhangs in the structure, and there are two main types of supports that the printer can develop while producing an object.
Buildplate supports only external overhangs. This means that if the 3D printer determines there is an overhang that needs a support, it will put it on the outside of the structure. Everywhere supports any type of overhang, regardless if it internal or external.
Thankfully, the 3D printer analyzes the object and determines any overhangs (the printer at the DME highlights these areas in brown). This means that you can design your object without worrying about the object collapsing mid-print as the printing software determines where overhangs and supports are needed when the .stl file is imported.
Overhangs are made thin enough to easily be torn off the object, yet strong enough to support it. The maximum thickness of the support is predetermined by the thickness of the overhang, which the 3D printing software will not exceed.
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Adhesion in 3D printing is not to be confused with using an adhesive such as glue to join two objects together. It is an option to create a bed for your object to prevent it from warping while printing, especially at the bottom of the object as the first layers may curl when printed. It also prevents the object from shifting ever so slightly on the bed so the print does not misalign after the first few layers are created.
Brim adhesions place a flat single layer thick area around the object creating a larger bed surface. When the object is completed, you can simply remove the brim with ease.
Raft is a 3d printed insulated bed where the object is printed on. It is a relatively thick grid structure which helps prevent material from loosening or going lost on the printer bed. Because of the nature of raft adhesions, it will take longer, and so the DME recommends using a brim adhesion instead.
The Temperature to set the 3D printer on depends on the type of filament used. This information, along with the diameter of the filament, can be found on its spool. The DME uses two types of filament — PETG and PLA. PETG is slightly more impact resistant and durable than PLA, but they are both user friendly and offer similar benefits in the realm of 3D printing. The filament available is up to what the DME has that day, rest assured the diameter will always be 1.75 mm. PETG has a working temperature range of 240 C to 260 C, whereas PLA’s working temperature range is 180 C to 210 C. The DME recommends that PLA is printed at 210 C and PETG is printed at 245 C.
Once these parameters are applied, the 3D printer’s software will give you an estimated time of printing to produce your object. With this knowledge, the DME instructor went over some 3D printing practises and safety tips:
- Never touch or put your body near the printing nozzle, as they can get upwards of 180 C minimum. If you need to clear any debris from the nozzle, use the tweezers that are at the DME. If a print fails, hit cancel. Raise the nozzle in the 3D Printer’s software. Get help immediately from a DME Staff member
- If there is a fire or the printer emits smoke, turn off the printer (from software or unplugging its power) and get help immediately from a DME staff member
- You may book a maximum of 6 hours per day, every other day
- To make a printer booking, the estimated time to print is needed. This can be accessed by importing your .stl file into the printer, and adjusting the parameters to your print’s need (following the DME guidelines of course). With this knowledge in hand, you can make your booking by contacting the DME
- Don’t hit print until the beginning of your actual booking
- Always check the spool before printing to ensure you use the correct filament temperature
- You must be present within the first 15 minutes of your booking, or the booking is forfeited
- You must be present in the first 20 minutes of your print, as this tends to be the timeframe when a print may fail
- Print one part at a time when possible, this saves time and resources.
- No printing of offensive materials, phone cases, or weapons are permitted!
3D printing clearly has it’s applications in prototyping devices. However, the medical field has found a better use for the technology. Prosthetics and limb replacements have become more accessible due to the low cost of 3D printing. This can allow for doctors to have an exact replica of an organ to analyze before a patient undergoes surgery, which can increase the success rate of the operation. It has also allowed non-medical professionals to contribute to the field by prototyping custom prosthetics and making them accessible due to the low cost of 3D printing. This technology allows for precise replicas and fittings for the human body that would usually be a barrier due to cost.
Before we go about changing the world with our products, here is a quick recap of the DME’s recommendations when applying the four main parameters in your 3D print setup:
- 3D CAD software must export .stl files to be imported into the 3D printer
- 1.75 mm is the filament diameter of material to use
- Fill Density: 10% minimum, 20% maximum
- Supports: Everywhere is for external and internal overhangs. Buildplate is for external overhangs only
- Adhesions: Brim is recommended and prevents warping. Raft provides a sturdy filament bed for your object to be printed on
- Temperature: PLA recommended temperature is 210 C. The printer’s bed can reach 70 C during these conditions. PETG recommended temperature is 245 C. The printer’s bed can reach 90 C during these conditions
- Always check the spool before printing to ensure you are using the correct temperature setting
The introduction to 3D printing workshop did teach me a lot about the technology in a concise and exciting manner. Once completed, I was approved to use the printer and given a cute sticker as recognition. The DME offers advanced workshops for 3D printing, as well as guidance for learning CAD software if you wish to go more in depth into the technology.
