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TDPT280 - 3D Prototyping

Primary Notes for Monday, January 9, 2017 - Laser Machining


Teacher: Mr. Cale Rauch
Office: AT 166 & AT 141
Office Hours: Monday from 3:30pm-6:30pm
Primary Assignment at hand:
- Use the link provided in Blackboard to access the laser-assignment demonstration: SPECIFIC
ASSIGNMENT INSTRUCTIONS: http://techweb.bsu.edu/jcflowers1/rlo/rpLaser.htm
RUBRIC/GRADING: Blackboard> Submit Demo Reports Here> Demo Laser Machining> View Rubric
DUE DATES LOCATED HERE: Blackboard> Assignments> Major Assignments and Due Dates
- Follow the instructions carefully!
- Use the designated software - Adobe Illustrator - to design your product/demonstration piece
before accessing the laser machine.
- Once finished, have it checked by the teacher or lab-assistant to assure it can be made. This is based
on Design- and Material-choice.
- LOG EVERYTHING
o Log your work on the machine using the binder next
o Log your experimental settings; there is a sheet next the machine to help you with that!
Lab hours
See lab-hours posted on door of lab or on the lab-time handout from class.
Quick history
L.A.S.E.R: Light Amplification by Stimulated Emission of Radiation
AS per-usual, Einstein first theorized about lights physical abilities with enough power in 1917.
In 1965: Adding Nitrogen to the CO2 allowed lasers to become much stronger than when first
developed. Z
Our lasers use a mirror and lens system.
Remember the Right-Hand-Rule! Y

X
Types of Machining:
- Vector-Cut: Cuts all the way through
- Vector-Engrave: Line, but does not cut all the way through
- Raster: Creates a full embedded picture or otherwise embossed-look. Think of it as a printer-
like function.

Vector cut Vector Engrave Raster (Creates a picture)


(Square in pic will be removed (Just lines)
from the material)

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Generally - About the machines mechanics and safety - Dont forget there is a step-by-step manual
next to each machine!
- Use CorelDRAW-X6 or Adobe Illustrator to design your product
- Before using the machine, turn on the vent switch on the wall by the administration-desk and flip
the yellow handle above the laser-machines down to be horizontal.
- Check the lens as demonstrated in class.
- Check the material with the administrator (Especially if you bring your own in)
o NO PVC!! It creates hydrogen chloride gas when heated!
o Class Materials located in brown cabinet towards the back of the lab
Wood, Paper, Leather, Glass, Ceramic, plastic, and Fabric are all acceptable.
o Limit of one-two square-feet of material per-student if you do not bring your own.
o No metals! It is possible, just not for these machines, at this time.
o The No-Nos
No Weapons
No Drug Paraphernalia
No Alcohol Related Items
No Food Items (Just do not use it)
No Reflective Materials (Except on the Lathe)
No Metals (Except on the Lathe)
- Check the thickness of the material which corresponds to the Z-Axis on the machines settings.
- Remember: The two laser machines have different ways of setting Z.
o Larger Machine uses the thickness of your material as a Z-setting
o Small machine uses the small leveling device located in the machine (demoed in class).
- The settings you control are the POWER, SPEED, POINTS PER INCH, and IMAGE DENSITY
o The two you worry about for this class are the POWER, SPEED, and PPI (if you are
working with something that burns easily).
- Generally - keep power at 100% and change the speed only. Power/Speed can (and should) be
experimentally tested before working on the actual demo.
o Less speed means more heat!

- Blackboard:
o Blackboard has been updated with Examples of what reports look like. Check the
Examples, PowerPoints, and Notes Tab.
o Blackboard has a copy of this note-sheet for download.
- Safety:
o Get a pair of safety glasses if you do not want to use the class-pairs.
o No open-toed shoes or stringy clothing.
o Follow instructions carefully. When in doubt, ask for help.
o Log EVERYTHING.
o No food/Drinks in lab.
- Problems
o Watch for cracking, burning, chipping, shattering, and melting.
o Personal time/personal scheduling and working with the lab - talk to teacher or lab
attendants!
o Nervous - Dont be! Have fun! This is a learning experience! If a machine breaks - it is ok!

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TDPT280 - 3D Prototyping Teacher: Mr. Cale Rauch
Primary Notes for Monday, Feb 20, 2017 - 3D Printing - FDM Office: AT 166 AND 144
Office-Hours - Mon 3:30pm-630pm
Primary Assignment at hand:
- Use the link provided in Blackboard to access the FDM-assignment demonstration:
http://techweb.bsu.edu/jcflowers1/rlo/rpFDM.htm SPECIFIC INSTRUCTIONS
http://techweb.bsu.edu/jcflowers1/rlo/280DemoFormat.docx RUBRIC/GRADING
http://techweb.bsu.edu/jcflowers1/rlo/280sylsp2017.htm Course Guide / Syllabus
- Follow the instructions carefully - Binder located next to all machines for instructions and logs!
- Use the designated software - Rhinoceros 5, AutoCAD, Inventor, GoogleSketchUp, and Others - to
design your product/demonstration piece before accessing the 3D printers. Dont know how? Check
out many online tutorials and YouTube videos!
- Save as .STL
- Once finished, have it checked by the teacher or lab-assistant to assure it can be made. This is based
on Design- and Material-choice.
- LOG EVERYTHING - Log your work for the machine-use using the binder next to each machine
Lab hours
See lab-hours posted on door of lab or on the lab-time handout from class.
Quick Vocabulary and Terminology
Fused Deposition Modeling (FDM) or Additive Layer Manufacturing and general 3D-printing as typically known in
current context works by laying down material (usually plastic) in laters. Note that 3D-Printers act as a device which
utilizes FDM as a technique.
o Note that each means layer-by-later manufacturing
STL - Stereolithography - .stl is Used as a file-type for all 3D printers in this course.
SLA - Stereolithography Apparatus - focus on additive layer manufacturing through photopolymerization - a process
by which light causes chains of molecules to link together, forming polymers which result in the 3D object.
SCA - Support Cleaning Apparatus - A bath which is comprised of sodium hydroxide, sodium carbonate, sodium
lauryl sulfate, and sodium Metasilicate; also known (together) as Lye. A Base which is used to dissolve support
material for models generated by UPrint Fred, UPrint Wilma, and the SE-Plus 3D printers by Stratasys.
The Right-hand-rule still applies!
Extruder - Hot-End - Nozzle - Area in a 3D Printer which heats up and extrudes the material.
Stepper Motor - Special DC motor that divides full rotations into equal finite steps which can be positioned and
controlled using sensors, settings, and other controllers. Feeds material in machine.
Ooze - Melted material still coming from the extruder-nozzle which flows even when the stepper motor has stopped.
Mostly an issue with dual extrusion. Help prevent with Ooze Shield and Skirt settings.
Retraction - Distance the stepper motor retracts before switching to a new color to prevent ooze.
Hygroscopic - Ability of a material to absorb humidity/water from the air.
Hydrophobic - Ability to repel water.
Materials
- PLA - Polylactic Acid: Not very Hygroscopic but not Hydrophobic, degrades in water over time
- ABS - Acrylonitrile Butadiene Styrene: Hygroscopic, strong, water-proof
- Nylon: very Hygroscopic, very strong but difficult to print with
- Polyurethane - NinjaFlex: very strong, water-proof, flexible
Machines + Materials + Supports
- Stratasys - UPrint Wilma, UPrint Fred, and the SE-Plus
o ABS
o Supports are great but may need dissolved
- MakerBot - Replicator 2, Replicator 2X (Dual Extrusion); Flashforge - Creator Pro (2014), Creator Pro
(2015) - Both Dual Extrude
o ABS, PLA, Nylon, Polyurethane

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o Supports will need to be either PVA - Polyvinyl Acetate - most associated/used-with PLA - or
otherwise same material as printing with
o Supports can be iffy and will not always work

- ORD Solutions - Rova-3D - Quintuple(5) Extrusion - in its Development Stages


o ABS, PLA
o Supports will need to be either PVA - Polyvinyl Acetate - most associated/used-with PLA - or
otherwise same material as printing with
o Supports can be iffy and will not always work
Material Limitations
- Stratasys Machines: ~2 Cubic Inches of material - see me if you would like to use more!
- Other Machines: Generally no limit - lets talk if you wish to do a considerably larger print
- Each material uses different temperature settings (in Celsius) for the extruder, build-table, and the
ambiance of the build
- Build-Tables heat, size, stickiness, and general ability may limit the materials ability to stick
o Try to build to a NEW or CLEAN part of build-trays!
o Use supplied adhesion-helpers such as:
Printing on a Raft PVA+Water for PLA Kapton Tape
Printing with a skirt or ABS+Acetone for ABS Painters Tape
ooze-shield
Changing Bed Temp Settings Lab-Recommended Temperature Settings in Celsius
- Feel free to experiment on what works best for
Other Limitations (The No-Nos) you! Experiments can only be done on non-
- No Copyrighted products Stratasys machines.
- No Products from Thingiverse Polyurethane
- No Weapons ABS
- Extruder: 230 - Extruder: 230-240
- No Drug Paraphernalia
- No Alcohol Related Items - Build-Tray: 110 - Build-Tray: 0-30
- No Food Items (Just do not use it) - Ambient: Closed - Ambient: Open or Closed
PLA: Nylon:
- Blackboard:
- Extruder: 190-220 - Extruder: 240
o Blackboard has been updated with - Build-Tray: ~60 - Build-Tray: 80
Examples of what reports look like. - Ambient: Closed - Ambient: Closed
Check the Examples, PowerPoints,
Notes, and Practice Problem Answers
tab.
o Blackboard has a copy of this note-sheet for download.
- Safety and Key Notes:
o Use Auto-Power-down features when available - this will shut
the machine down when finished printing.
o Get a pair of safety glasses if you do not want to use the class-pairs - safety glasses are
mainly needed when removing a model from the build-tray; therefore those around you
must be wearing them as well.
o No open-toed shoes or stringy clothing.
o Follow instructions carefully. When in doubt, ask for help.
o Log EVERYTHING - including information for your report
o No food/Drinks in lab.
- Problems
o Problems and failures will occur before, during, and after Prints!
o Feel free to print another if your model break - but try to add or subtract something from
the model which will help it stay together the second time. 4