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 🙁
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].
Extra pieces position
3/ 3D Print the missing piece(s).
STL lowered into Print Bed further.
The resulting and remaining pieces to be 3D Printed
3D Printing completed
A complete 3D Print … alongside a part Print plus the additional pieces.
All the Pieces compared
Success!, the 3D Printed extra parts matchup perfectly to make a whole 3D Print.
*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 wouldrather divide and conquer and get a model 3D Printed within normal working hours.
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).
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 🙂 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
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.
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 – 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 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 – 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.
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 🙂
This screenshot outlines the conversation, feedback and review with the Client as we develop their commissioned work…
Research … that thing we all hated at School. Now it all makes sense …
We Sketch, Design, Consult and work our way through various 3D Computer Aided design Prototype designs …
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.
After 3D Printing there is some cleanup and aesthetic considerations for weight, strength and mechanical fixing, glueing, more testing, testing, testing …
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/
Professional Equipment for SuperHEROs
London & LEEDS, UK.
#concepts #3dprint #props #prototypes #specialeffects #imagineering #reddwarf
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 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.
Part of our list of Large Investments … 3D Printer(s) for COSplay Prop Making.
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.