3D Printer Tutorial

1. Create model using TrueSpace or similar 3D modeling package. When model is complete, put a base on the object. (just a note for later in the tutorial, don't make the base too thick, for it will take a very long time to print. A 1/8" base should suffice. A design that is 1 1/2" by 1 1/2" should print in about an hour depending on how much of the volume is filled.)

2. This instruction assumes you are using TrueSpace. Glue the different components of the scene so that they are one object. Then, under the file menu, save the object as a dxf file. This option will not be easily apparent; you must scroll down the panel to find it. The basic idea with most packages is to group all the components into one object and export as a dxf.

(the following instructions use utilities that are available on the machine near the 3d printer in 022)

3. Now we need to convert the dxf file into an stl (stereo lithography format) file. To do this, we use the utility STL_Util. This can be found in the start menu. When you load the dxf file, you will see a blue and white wireframe model of your model. Click on the axis buttons to check the different views and make sure they are correct. Look at the bounding box values to make sure they are not negative. To make sure all the values are positive, click on the button.

4. From within the file menu, save the resulting file as an stl file. (note: this program may not allow long program names; if it will not save the file, choose a shorter filename.) When prompted, save as ascii file format.

5. We now need to create the individual slices for the printer. This is done using QuickSlice. This can be found from the start men under QuickSlice V6.6-qsla -> QuickSlice. Select your stl file. (note: there is no undo in this program; you might want to save versions along the way.)

6. You will see the wireframe on the screen. Check the bounding box values in the lower right hand corner. (note again: for your piece to print in about an hour or less, make the piece within a 1 1/2" by 1 1/2" bounding box.) There are several procedures you can perform on your object prior to slicing such as scaling and moving. Many of these are found in the Orient stl tab in the right portion of the gui.

If you wish to scale: Check the scale option. Enter a scale value in the XYZ box. Click ok. (note: the new scaled bounding box is not shown in the lower right window. To view the new dimensions select portions of the model using the mouse and read the size of the box below. It helps to use different view modes .)

7. Click on ToOrigin within the Orient stl tab to move a corner of the object to the origin.

8. Click on the button to view the object in shaded mode. If the normals seem wrong,, click on the Reverse Normals button within the Orient stl tab. Result:

9. Now it is time to slice the object. Within the same program, go to the Slices tab. The defaults here should be fine. (The slice interval should be .01 for the head on this machine.) Click the Create Slices button . Can save as ssl file.

(note: if any portion of the image appears yellow, this indicates that there are gaps in the slices. You can either go back and fix the model in a modeling program and repeat to here. Or you may try using the advanded features within the Close>> button in the Edit Curves tab to complete the gaps.)

10. You will see one slice. Can toggle between viewing Current or All using the buttons on the top menu. In Current mode, you can also click on the Z Level up and down arrow keys to traverse the slices.

11. If you need to edit your base to make is smaller, click here.

12. The next step is to build the supports and the base. Click on the Supports tab. Click on the button. The supports show up in green. To create a base, within the same tab, click on the button.

13. The next step is to make the roads. Click on the Roads tab. For simple geometries, the default parameters should be fine. Click on the button. View up and down in Z to view the filled in roads.

14. Save as an sml (solid model file) using the button. Note the build time in the lower right hand corner.

15. Now we move to the 3D printer. You need to open the back of the machine and make sure there is enough material on the spools. The front, or first spool you see, holds build material. The next in, the second spool you see, holds support material. If the spools are empty, find someone in phm to replace one of the spools -DO NOT DO THIS YOURSELF. Looking at the front of the machine, the left head spews build material, the right head spews support material. In summary,

Front spool = Build material = Left Head
back spool = support material = Right Head.

Purging: If the machine has not been used for a while, you may need to unclog the print and support heads. Push the MODEL/SUPPORT button on the 3D printer until MODEL appears in the lcd display. Push the LOAD button. This will let the material stream. Will shut itself off after 2 minutes. Can do the same with the support material.

16. Take the small metal brush and wipe the excess material off the heads so that if falls to the bottom. Be careful not to touch the heads or the sides of the printer with your hands. The temperature is about 270 C. Only the brush should touch the heads of the printer. Use the larger soft brush to clean the platform. These should be located in the box above or to the side of the machine.

(note: when the door is open, the envelope temperature (air temperature) drops. After opening the door, wait until the green temperature (current temp) is within at least one degree of the desired temp (red).)

17. Now we need to send this file to the 3D printer. Use Shortcut to ssend.bat from the machine desktop. Choose your sml file. A dos window pops up that states start sending...

18. The pause button should be blinking. There are two steps here that are both indicative of the Pause blinking.

A. To let the machine orient itself: press Pause to let the machine know you are ready. Wait for it to move and calibrate itself.

B. To set the x,y of the print head at (0,0), and the z of the base.

(1)x,y: Press Z-axis button until the LED goes off. Use the buttons in the image below to position the x and y coordinates of the print head. Pressing the center button moves the heads faster. The (0,0) position of the print head corresponds to the lower left hand corner of the foam pad (according to the sml models). For example, if you are printing a model of the media lab, the building will print back and to the right of where the heads are. Find a clear foam location and set the zero.

(2)z: Pres the Z-axis button until the LED is lit. Press the up and down arrow keys to move the base so that the tip of the print head is just slightly into the foam base. If there is no room left on the pink foam base, click here.

19. Press Pause. You should be ready to go. The machine begins by moving the print heads to the metal brushes for cleaning.

20. When the model is complete, carefully pry the model from the foam base. There are some dentist tools in a box above the printer to help remove the supports and excess material.