Rescuing a 3D Print

We all have that moment when there is a 3D Print failure.
The Nozzle clogs or jams, we run out of filament, or things just stop [firmware issue].
The print appears to be a total waste of time and effort ūüôĀ
BUT …

This situation is a repairable:

In this example we are already using an STL file that we have halved* by positioning it lower into the 3D Print Bed.

This solution is just an extra process of that repositioning method.

We at IDM Imagineering 3D Design and 3D Print prototypes and models in-house for ourselves and our 3D Print Clients so we do not always need a perfect one-off whole print, therefore we can use glue and fillers to finish a model before undercoating and spray painting; you will never see the join.

So, all is not lost. You can simply carry on where the 3D Print stopped.

In other words; reposition your model again lower into the 3D Printing Bed and only leave the required extra amount of the model visible for 3D Printing.

1/ Measure how far you have 3D Printed so far …

2/ Subtract that amount from the Z offset in your 3D Slicing Software [we use Simplify3D].


3/
3D Print the missing piece(s).

Written by: James [Maker] at IDM Imagineering – Equipment for SuperHEROs

*To save print time, as we have multiple 3D Printers, we often print objects as multiple pieces. Waiting for a 30 hour print is a worry; leaving it unsupervised, power cuts, heat for health & safety, noise at night … We would  rather divide and conquer and get a model 3D Printed within normal working hours.

Printers: Flash Forge Creator Pro’s 2014, 2015, 2016, 2017
Software: Simplify3D v3.x
Filament: 3DPrintWorks PLA
Beds: Aluminium or Glass using Masking Tape or HairSpray

FDM 3D Printing Processes, Supports and Truths

It is truly a challenging task to produce an item using FDM 3D Printing.
3D Printers¬†(SLA or¬†FDM 3D Printing) have¬†unexpected time impacts … cleanup; smoothing, harding, drying and support removal (pulling, splitting, cutting, sanding, filing).

Space: 1999 COMM LOCK & STUN GUN KITs 3D Printing Service by IDM Imagineering

I get so excited when a nice print comes out, then I am faced with having to spend another 10% to 50% more time cleaning the prints up (removing support) for our customers.
No matter how hard I¬†try, there are always parts of a 3D Model KIT that requires¬†support layers, somewhere …

As soon as you conquer the issues of bed adhesion, layer separation, curling, rafts, support¬†density, surface finish or resolution another issue pops it’s head up; temperatures, filament properties, mechanical changes on the printers, power-cuts or just gremlins who clog your nozzles or tie knots in your filament reels.

So without whining too much ūüôā and honestly for information, support and discussion¬†… here is one facet of FDM 3D¬†Printing that I¬†would like to illustrate: Upper and Lower Support Layers

Printers: Flash Forge Creator Pro’s 2014, 2015, 2016
Software: Simplify3D v3.x
Filament: 3DPrintWorks PLA
Beds: Aluminium or Glass using Masking Tape or HairSpray

3D Print Support Layers

3D Print Support Layers

s3D Printer Supports and Layers in layman terms:
Upper and Lower Support Layers are to aid in bridging, over gaps, holes and spaces. Essentially the 3D printer lays down filament like scaffolding, then puts boards over these spaces to make a more solid and supporting surface platform, and then lays down the models main body of filament an air-gap thickness over the top of these boards, thereby letting that air gap cool the filament as it is laid down so the 3D Printer filament does not stick to the boards and thereby allowing easy removal of the scaffold and boards when all is cooled down.

Note: Support Spacing is important.

  • Too much scaffold space and the boards sag.
  • Too many boards and it’s harder work to deconstruct all this.
  • Too few boards and they warp, up or down.

Note: Support Removal.

  • Let your prints cool way down.
  • The cooler they are the more brittle and slightly retract, contracted, shrunk the supports become making them a bit easier to remove from the more solid, harder and less effected body.
  • It may take a few days to get the best coolness, dryness brittleness … after the heat and fusion¬†and catalysing effect of 3D Printing in the Filament.

You will find that the Upper sky-wards facing¬†Vertical Separation layer¬†setup¬†will work quite well¬†based on your experiments (keep a good record of all your prototype settings tests) until you find a setting that suits your 3D Printer, your Filament make and your Workshop environment… everyones may be different! so copy settings and improve.

Our challenge was the Lower ground-facing Vertical Separation layer.
Here I¬†found that less layers worked best … about 50% less. I think gravity on the filament due to the filaments softness from heat, sag, movement, etc was the impact/issue… the filament fell onto the body thereby reducing any air-gap and the filament then fused on more-so that the¬†Upper sky-wards facing¬†Vertical Separation layer. ?

Here are some photo’s to illustrate the above theory¬†and processes.

3D Print Support material - before removal

3D Print Support material – before removal

3D Print Support material - Step 1, pliers to pull out the 'scaffold' 3D Printed supports.

3D Print Support material – Step 1, pliers to pull out the ‘scaffold’ 3D Printed supports.

3D Print Support material - Step 2, pushing out any remaining 'scaffold' 3D Print support material.

3D Print Support material – Step 2, pushing out any remaining ‘scaffold’ 3D Print support material.

3D Print Support material - Step 3, slicing and trimming with a craft knife to separate the 3D Print support upper and lower support layers. 'scaffold' 3D Printed supports.

3D Print Support material – Step 3, slicing and trimming with a craft knife to separate the 3D Print support upper and lower support layers. ‘scaffold’ 3D Printed supports.

3D Print Support material - Step 4, using files to cleanup the lower [ground-facing] support layers of 3D Print support.

3D Print Support material – Step 4, using files to cleanup the lower [ground-facing] support layers of 3D Print support.

3D Print Support material - the 3D Print support material removed from this particular single part of a KIT ... and the tools used in the process.

3D Print Support material – the 3D Print support material removed from this particular single part of a KIT … and the tools used in the process.

3D Print Support material - removed. And parts acceptable for traditional COSplay model making and build processes.

3D Print Support material – removed. And parts acceptable for traditional COSplay model making and build processes.

Luckily, the need for supports is usually to do with internal or side-facing¬†surfaces¬†that are not (so) visible. The occasional external or downward facing surface that requires 3D Print Support (even after lengthy consideration of the 3d Print Model creation i9n CAD or the best 3D Print orientation) come out fine for the traditional Prop, COSplay or Model Making processes¬†of filling or even are good enough to be covered by a¬†few coats of primer filler undercoat paint ūüôā

Space 1999 STUN GUN vIDM

Space 1999 STUN GUN vIDM 3D Print Service

Space 1999 COMM LOCK vIDM 3D Print Service

Space 1999 COMM LOCK vIDM 3D Print Service

It is always good to get another viewpoint, more technical or just visual, so read these too:
Simplify3D: Tip of the Day 21 РSupport tab, a technical analysis
Richard Gain: Simplify3D Support Removal

James [maker] IDM Imagineering

Red Dwarf – Lister’s Jacket STAR [COMISSION]

Red Dwarf – Lister’s Jacket STAR [COMMISSION]

12650586_10208810188070829_985159114_n copy

SMEG! : Where‚Äôs the Point in this one? …
We might be 6 Million years away from Reality, but it happened at IDM now!
https://www.facebook.com/IDMimagineering/photos_stream?tab=photos_albums

This is the making-of a 3D Print Commission from a Client; a styled replica of the Star (15cm wide) on the back of Lister’s Jacket from the Cult TV program Red Dwarf [Series 10, EP.1, Trojan]

The Process to work with IDM on a Commission went like this …

00a
First it started with a Facebook Message on the IDM Facebook Page here:
https://www.facebook.com/IDMimagineering/

00b
This screenshot outlines the conversation, feedback and review with the Client as we develop their commissioned work…

01
Research ‚Ķ that thing we all hated at School. Now it all makes sense …

02
We Sketch, Design, Consult and work our way through various 3D Computer Aided design Prototype designs …

03
We test print (many times) and then often return to 3D CAD and refine, refine, refine … then when it’s good we 3D Print, again.

04
After 3D Printing there is some cleanup and aesthetic considerations for weight, strength and mechanical fixing, glueing, more testing, testing, testing

05
And then it’s MADE !
The project can go on from here to Painting or Mass Production Casting or multiple 3D Prints.

IDM can take your Concept from Start to Finish.
IDM Imagineering have been producing Custom Built Props and Special Effects for 4 years using a broad range of Technologies and Materials and supplying these to the UK and Internationally.
For a full outline of how we bring Ideas to Reality visit our website: https://www.idmimagineering.co.uk/3d-services/

IDM Imagineering

Professional Equipment for SuperHEROs
London & LEEDS, UK.
#concepts #3dprint #props #prototypes #specialeffects #imagineering #reddwarf

If you want to be part of the IDM Team then we are always looking for Entrepreneurial Imagineers: https://www.idmimagineering.co.uk/join-idm/

2050 Judges Tactical HELMET [BUILD]

Judge Dredd 3D

See the Video at: https://www.youtube.com/edit?o=U&video_id=lXT2SlxenqI

Prototyping of our 2050 Judges Tactical Helmet.

The Helmet is 3D Printed in PLA with a good thickness and fill density and will be fibreglass lined for additional strength too.

This is the Fan Modification for cooling the interior of the Helmet whilst on Patrol.

The Badge is hollow and the lines let the air flow in/out.

Follow the development on our Facebook Page ALBUM:
https://www.facebook.com/media/set/?set=a.451393731713688.1073741877.146313488888382&type=3

See the Video at: https://www.youtube.com/watch?v=lXT2SlxenqI

IDM Imagineering
Professional Equipment for COSplay SuperHEROs
https://www.idmimagineering.co.uk

IDM Imagineering w Arizona Judges : COSplay of Judge Dredd

Bringing Law to the Lawless …

IDM Imagineering - Professional Equipment for SuperHEROs

IDM Imagineering – Professional Equipment for SuperHEROs

Be sure to see the Arizona Judges in their Judge Dredd COSplay and other great costume groups from Friday to Sunday evening at Amazing Arizona Comic Con! http://amazingarizonacomiccon.com/

The Judges are suited up with IDM COSplay kit, most notably you can see IDM’s high-resolution 3D Printed and Custom Named (3D CAD produced) Badges on their Vest Armour [image below], available at: https://www.idmimagineering.co.uk/shop/

IDM Imagineering Judge Badges - High-resolution 3D Printed Custom Props

IDM Imagineering Judge Badges – High-resolution 3D Printed Custom Props

IDM can take your Concept from Start to Finish.

IDM Imagineering have been producing Custom Built Props and Special Effects for 4 years using a broad range of Technologies and Materials and supplying these to the UKM and Internationally.
For a full outlines of how we bring Ideas to Reality visit our website: https://www.idmimagineering.co.uk/3d-services/

IDM Imagineering
Professional Equipment for SuperHEROs
London & LEEDS, UK.

#concepts #3dprint #props #prototypes #specialeffects #imagineering

If you want to be part of the IDM Team then we are always looking for Entrepreneurial Imagineers: https://www.idmimagineering.co.uk/join-idm/

Concept Mk3 LawGiver

Judge Dredd LawGiver Mk3 concept design by James Murphy

We are proud to offer James Murphy’s Concept Mk3 LawGiver Gun as a 3D Print Service, on Sale until this Friday 5th June 2015. #cosplay #dredd
Available here: Judge Dredd LawGiver Mk3 Concept design by James Murphy

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

Concept Mk3 LawGiver

2012 Badge(s) [DIY – Budget]

Taking our BUDGET [DIY] Badge(s) to the Next Level:
This is a Tutorial for painting our Basic [DIY] Badge range of products.

Straight out of the Mould.
To keep costs down we leave it ‚Äėas-is‚Äô from the Mould, but …tutorial-03-00

We Trim it before sending it on to you ūüôā
There may be small air Bubbles or Imperfections .. all part of the following Fun!tutorial-03-01

Firstly; give it a light sanding, then a coat of UnderCoat…
… and let that UnderCoat harden for a few hours too!
Light sand, inspect, another coat of UnderCoat.
Light sand again.
tutorial-03-02

Fill any remaining small imperfections with Car Body Filler.
Let it harden for a few hours.
Then Trim with a Sharp Knife or Scalpel Blade and also use some Sand Paper again.tutorial-03-04

Another UnderCoat, sand very lightly.
tutorial-03-05

I’ve used a coat of Hammerite Gold here … it’s what I had to-hand #budgets.
tutorial-03-06

Dry brushed with Dwarf Bronze from Games Workshop (or anything similar, mix your own?).
tutorial-03-07
Wait for it to almost dry, rub off with a paper towel.

Do the Dwarf Bronze dry coat it again, rub off in the other direction.tutorial-03-07a
Let it all dry hard.

A wet wash here of Matte Black Acrylic.
tutorial-03-08
Wait for it to almost dry, rub off with a paper towel

Again:
Wait for it to almost dry, rub off with a paper towel
Repeat, until happy.
tutorial-03-08a
Let it all dry.

Rub with a clean Rag… it’s quite durable now.
tutorial-03-09

And here we have BEFORE and AFTER side by side.tutorial-03-10

In the Sunlight ūüôā
tutorial-03-11

Now go put it on your Car, Bike, Kit Box, Lunch Box …
tutorial-03-12

Available in our IDM Imagineering Shop here:
http://www.idmimagineering.co.uk/shop/

2012 Vest Armour Plates [DIY – Budget] SET

If you have bought one of our¬†[DIY – Budget] SETs of Dredd Armour then it’s a simple process with only a few Tools to take it onwards to the next stage of detailing…

1/ Mark Out for Trimming:
BUDGET ARMOUR 01-marking-out

2/ Cut with a Stanley or Craft Knife:

BUDGET ARMOUR 02-cutout

3/ Mark a line for your Stitch Hole drilling:

BUDGET ARMOUR  03-hole-line-marking

4/ Bend the Side Rib:

05-bending

5 Drill your Holes:

BUDGET ARMOUR  04-hole-drilling

6/ Buy your 2012 Vest Armour Plates [DIY РBudget] SET here:

7/ Reference Sizes for Vest building.
Here are some Reference Images (using our Seconds Armour) to give you an indication of the Armour Size for when you come to make your Vest.

Please Note: Everyone is a different size, and the placement and spacing of our Armour is a totally personal choice.

2012 Vest Armour Plates [DIY - Budget] Measured FRONT

2012 Vest Armour Plates [DIY – Budget] Measured FRONT

2012 Vest Armour Plates [DIY - Budget] Measured BACK

2012 Vest Armour Plates [DIY – Budget] Measured BACK

8/ Enjoy!

First on our list of Large Investments – 3D Printer(s)

Part of our list of Large Investments … 3D Printer(s) for COSplay Prop Making.

IDM Imagineering 3D Printing Mass Production

IDM Imagineering 3D Printing Mass Production

Our open sourced 3D Printers are perfectly compatible with different slicing softwares and firmwares to access more functions and materials from PLA  and ABS to Wood and Rubber.

One as not enough, so now we have access to 10 in-house and more remotely at 3D Print Works, the company that supplies us with our custom mixed filaments and advanced 3D Print engineering support.

We use these 3D Printers to Prototype Master Props for moulding and casting and we also use them to mass-produce COSplay props, badges, guns, toys and gadgets for all areas of COSplay costuming, armour and weapons.