Tips for 3D Printing Accuracy

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Before We Start

http://www.designworldonline.com/

Moderator

Leslie Langnau Design World

Presenters

Ben Klein Objet Ltd.

Bonnie Meyer Stratasys

Stacie Hoche 3D Systems

ProJet 6000 Accuracy

Stacie Hoche April 2012

ProJet™ 6000 Accuracy • Digital self calibration

• Print accuracy rivaling CNC

Accurate

• Digital motion control • Closed loop monitoring

Precise

• <10 m resolution • Features as small as .3mm

High resolution

ProJet™ 6000 Accuracy

0

5

10

15

20

25

30

35-1

00 -90

-80

-70

-60

-50

-40

-30

-20

-10 0 10 20 30 40 50 60 70 80 90 100

Freq

uenc

y

Difference from nominal in microns

Accuracy is a combination of: -- System capability -- Material properties -- Compared to an absolute

-- 3 x 3 matrix of test parts -- 12 measurements per part -- 108 measurements -- 1mm to 32mm range -- Standard Deviation of <15 microns

ProJet™ 6000 Accuracy Thin walls that get progressively thicker in 10um increments

10 microns = 0.00039 inches

Result=1450 Dpi; 17.5m

1000m

1010m

How small of a increment can the system print?


• Machine Build Modes o HD - Fastest

o UHD – General purpose build mode

o XHD – Fine feature detail


• User adjustment to fine tune

part accuracy

o Shrink Compensation

o Line Width Compensation

ProJet™ 6000 Accuracy • Shrink Compensation

o X, Y and Z adjustments for material shrinkage due to the material cure process

o Values specified in the machine User Interface software

ProJet™ 6000 Accuracy • LineWidth Compensation

o Adjusts for the material cured line width

o Values very due to

• Print Head Characteristics

• Material

• Build Mode

o Values specified in the 3DManage setup Software


Line-Width Compensation Off Line-Width Compensation On

How to Obtain the Most Out of Your

Objet Printer: Quick Tips

Faceted STL file

translated

with coarse

tolerance

• When creating an STL file, the goal is to achieve a balance between file

size and a fully-defined model with smooth curved geometries.

• You cannot build the model any better or smoother than the STL. So if

the STL is coarse and faceted, you will see it in the model.

File translated with

fine tolerance

CAD to STL - Maintain the Proper Resolution

• Divide the CAD files into shells early in the design process

Non-Connex:

Monolithic part, one material

Connex: Assure a distinct separation between the solid bodies:

Create an assembly of one or more parts

“Connexify” a Part

“Connexify” a Part

Uncheck this to allow separate STL files

(For Connex)

In order to support fine features, an auxiliary part can be

printed and removed later

Supporting Delicate Parts with Auxiliary Structures

+ =

Matte mode is intended to generate uniform surfaces. Ensure your model is

suitable for this mode.

Matte Vs. Glossy

The visual differences between Matte and Glossy Parts

Objet Studio – Other Considerations

To truly appreciate fine details on the surface, use VeroBlue or VeroGray

materials in the glossy orientation

Accuracy in Appearance

To imitate final material performance, use Connex for complex applications

Accuracy in Performance

Fitting surfaces should be positioned facing up

No support material needs to be removed

Fitting Surfaces

End part Shore value needs to be determined

Print Several Materials on a Single Piece

Connex Technology enables testing of different values on

a single print


Accurate Parts with

FDM Systems Bonnie Meyer, Sr. Applications Engineer

Stratasys, Inc.

All FDM Systems

Thermoplastics are stable over days, months or years ABS

Polycarbonate (PC)

Polyphenylsulfone (PPSF)

ULTEM

FDM – thorough analysis

27 measurements

12 parts per build

3 runs per machine

Repeated on 3 machines

108 sample parts 2916 measurements

FDM Repeatability Results:

σ: 0.0027 in. (0.07 mm)

Mean: 0.00034 in. (0.009 mm)

Width

Nominal (3.000”,

76.2 mm)

Apr-2008

Actual

Aug-2011

Actual

Change over time

Sample 1 2.997” 2.997” 0.000” (0.00 mm)

Sample 2 3.001” 3.000” -0.001” (0.03 mm)

Sample 3 2.999” 2.998” -0.001” (0.03 mm)

Average 2.999” 2.998” -0.001” (0.03 mm)

Length

Nominal (5.000”,

127 mm)

Apr-2008

Actual

Aug-2011

Actual

Change over time

Sample 1 4.999” 4.998” -0.001” (0.03 mm)

Sample 2 4.998” 4.998” -0.000” (0.00 mm)

Sample 3 4.998” 4.996” -0.002” (0.05 mm)

Average 4.998” 4.997” -0.001” (0.03 mm)

Accuracy Over Time

Maintenance • Routine User Maintenance

o Keep System Clean

• Purge Area

• Build Envelope

o Replace Worn Components

• Tips – Odometer

• Tip Brush/Flicker

• Preventative Maintenance o 1-year and 2-year

Orientation

• Critical Features

• Rounds

Calibration

• Tip Changes

• Periodically

Custom Scaling • Fine Tune in X and Y if Needed

• Quantities of Parts

Recap • All FDM Systems

o Stability and Repeatability

o Routine User and Preventative Maintenance

o Part Orientation

• Fortus 3D Production Systems o Tip-to-Tip Calibration

o Custom Scaling

More Information • www.stratasys.com/accuracy

o Download “Accuracy Myth” white paper

o Benchmark the process with your part

• Contact Stratasys Application Engineering • 855-693-0073 (U.S. toll free)

• +1 952-294-3888 (local/international)

• [email protected]

Questions? Design World Leslie Langnau [email protected] Phone: 440.234.4531 Twitter: @DW_RapidMFG

Objet Ltd. Ben Klein [email protected] Phone: +1.972.52.889.2292

3D Systems Stacie Hoche [email protected] Phone: 803.326.4613

Stratasys Bonnie Meyer [email protected] Phone: 952.906.2244

mailto:[email protected]




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Tips for 3D Printing Accuracy

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Transcript of Tips for 3D Printing Accuracy