Module 1 - Introduction, 3D Printing Hardware, 3D Printing Software
Module 1 - Introduction, 3D Printing Hardware, 3D Printing Software
Instructors
Bernd Bickel, IST Austria
Michael Wimmer, TU Wien
Przem Musialski, TU Wien
3D Printing
3D Printing – Why?
Arabic Icosahedron 3D Printed Gown Cabin bracket for the Airbus A350 XWB made of Ti
(Carlo H. Séquin) (Materialise) (manufactured by Concept Laser GmbH)
«Game Changer» 3D Printer
[Objet]
3D Printers
«Game Changer» 3D Printer
Transparent
Standard Plastics
Rubber-like
Medical
An old concept
3D Printers
3D Printing – Why now?
Democratizing 3D Printing
Desktop printers
Online services
Democratizing 3D Printing
m nm
Speed
[carbon3d.com]
World’s First 3D Electronics Printer
3D Printing – What is it good for?
Implants Prosthetics
Source: Envisiontec, on3dprinting.com
Applications: Architecture & Design
3D printed fuel injection nozzle for a jet engine Airbus wing brackets
Source: Shapeways
Applications: Toys & Gadgets
who knows…
About This Course
• Slow
– Printing even small objects usually takes hours
• Expensive
• Limited print volume
• Unreliable
Software Challenges: Data Requirements
Base Materials
Acquistion Fabrication
Search & Output
Simulation
Target Object
Challenges: Modeling Interfaces
Main goal
Friday, March 04– 1:45- Overview 3D printing. Available materials, material IST Austria; Lab Building West, Big
3:00pm and 3:15-4:30pm modeling, current printer pipeline, shortcomings. Seminar Room, ground floor
Visiting IST machine shop.
Friday, March 18- 1:45- Geometry processing and geometry modelling in TU Wien; Favoritenstr. 9-11,
3:00pm and 3:15-4:30pm the context of 3D printing. meeting room (HA0509), 5th floor
Friday, April 15- 1:45- From 3D Scanning to a printable model. TU Wien; Favoritenstr. 9-11,
3:00pm and 3:15-4:30pm meeting room (HA0509), 5th floor
Friday, April 29- 1:45- Basics of appearance, appearance fabrication. TU Wien; Favoritenstr. 9-11,
3:00pm and 3:15-4:30pm meeting room (HA0509), 5th floor
Friday, May 13- 1:45- Basics of FEM. IST Austria; Lab Building West, Big
3:00pm and 3:15-4:30pm Seminar Room, ground floor
Friday, May 27- 1:45- Stability optimization and design of deformable IST Austria; Lab Building West, Big
3:00pm and 3:15-4:30pm materials. Seminar Room, ground floor
Lecturers
• Bernd Bickel
– Institute of Science and Technology, Austria
– http://visualcomputing.ist.ac.at
• Michael Wimmer
– TU Wien
– https://www.cg.tuwien.ac.at/
• Przem Musialski
– TU Wien
– https://users.cg.tuwien.ac.at/pm/
Prerequisites
• No strict prerequisites
• Computer Graphics background desired
• All assignments require some programming
C++, Matlab, …
• Calculus, linear algebra
– solving equations, derivatives, integrals
– vectors, matrices, basis, systems of equations
Grading Structure
• No exam
• Grading based on assignments
Assignments
• Collaboration policy
– Assignments should be done individually
Communication
• https://courses.app.ist.ac.at/index.php?id=127
Includes the course material
• Teaching assistant
Ruslan Guseinov
[email protected]
• Lecturers
Bernd Bickel [email protected]
Michael Wimmer [email protected]
Przem Musialski [email protected]
Overview Today
3D Printing Hardware and Materials
Support Structures
Slicing
Path Planning
Machine Instructions
3D Printing Basics
Hardware
3D Printing = Additive Manufacturing
https://commons.wikimedia.org/wiki/File:3D_printing_on_replicator_2.webm
3D Printing Process
Source: https://commons.wikimedia.org
Subtractive Manufacturing
Source: https://commons.wikimedia.org
Additive Manufacturing Technologies
Source: http://reprap.org
Stereolithography (SLA)
• Typical ingredients:
– Monomers: small molecules, lower viscosity
– Oligomers: relatively high molecular weight, e.g., acrylates,
epoxies, etc.
– Photoinitiators: generate reactive species (free radicals)
under light exposure to initiate the polymerization
– Additives: binders, surfactants, stabilizers, etc.
How Photopolymers Work
Source: http://www.additive3d.com/photo.htm
Stereolithography Process
Digital Light Projector (DLP) 3D Printing
• Simple design
– laser+mirror are replaced by a projector
– only one degree of freedom
• Faster than SLA
– exposes one layer at a time
• Materials
– The same as SLA
• No additional support material
– Lattice structure similar to SLA
Source: Nicholas Fang, MIT
DLP 3D Printing Process
Selective Laser Sintering (SLS)
Direct Metal Laser Sintering (DMLS)
• SLS and DMLS use a bed of small
particles (made of plastic, metal,
ceramic, or glass)
• High-power laser traces one layer
on the surface of the powder bed
melting/fusing the particles
• The platform descends by one
layer and more material is added
Source: http://en.wikipedia.org/wiki/Selective_laser_sintering
Single- and Two-Component Powders
Source: https://www.youtube.com/watch?v=BZLGLzyMKn4
Sample Fabricated Parts
Source: https://www.youtube.com/watch?v=GnFxujCyD70
Photopolymer Phase Change Inkjets
Source: http://www.engatech.com/Objet-3D-Printing-Technology.asp
Materials
• Bio-compatible
• High-temperature
• ABS-like
• Transparent
• Opaque
• Rigid
• Polypropylene-like
• Rubber-like
Source: Objet Geometries
Photopolymer Phase Change Inkjet 3D Printing
Source: https://www.youtube.com/watch?v=XLLq9SwSTpM
Sample Fabricated Objects
Source: http://www.youtube.com/watch?v=Z1WNA6tdfWM
Source: http://blog.nus.edu.sg/u0804594/common-rp-techniques/laminated-object-manufacturing-lom
3D Printing Software Pipeline
3D Printing Software Pipeline
Input Model
Support Structures
Slicing
Path Planning
Machine Instructions
Input File Formats
• STL (Stereolithography)
– Triangle “soup” – an unordered list of triangular facets
– Vertices ordered by the right hand rule
ASCII binary
solid name UINT8[80] – Header
}
UINT32 – Number of triangles
facet normal ni nj nk
outer loop foreach triangle
vertex v1x v1y v1z repeat
REAL32[3] – Normal vector
vertex v2x v2y v2z for each
REAL32[3] – Vertex 1
vertex v3x v3y v3z triangle
REAL32[3] – Vertex 2
endloop REAL32[3] – Vertex 3
endfacet UINT16 – Attribute byte count (0)
end
endsolid name
STL (Stereolithography) File Format
Support Structures
Slicing
Path Planning
Machine Instructions
Model Orientation
strong weak
printing
direction
Model Orientation: Mechanical Properties
max load: 0.22kg
weak
printing
direction
strong
printing
direction
Model Orientation: Build Time
support support z
support
• Manual placement
– User is responsible for placing parts on the build tray
• Semi-automated placement
– User places parts on the build tray
– System provides feedback on build time, support volume, support
contact area, mechanical properties
• Automated placement
– orientation is computed using optimization according to one or
more objectives (build time, support volume, support area,
mechanical properties)
3D Printing Software Pipeline
Input Model
Support Structures
Slicing
Path Planning
Machine Instructions
Support Structure Generation
support
inkjet FDM
Simple Conservative Algorithm
Source: http://www.youtube.com/watch?v=aFTyTV3wwsE
Advanced Algorithms: Bridging the Gap
Support Structures
Slicing
Path Planning
Machine Instructions
Slicing
Epsilons
Slicing Algorithms: Direct Plane-Triangle Intersection
Support Structures
Slicing
Path Planning
Machine Instructions
What Does Path Planning Influence?
• Build time
– repositioning the tool at the start of a new path
– accelerating and decelerating for direction changes
• Surface accuracy
– the filament size
• Distortion
– materials with a high coefficient of thermal expansion
– the top layer shrinks when it hardens and it distorts since it is tied to the bottom layer
• Stiffness and strength
– fill pattern
– the area and strength of bonds depends on spacing and the time interval between the
tool traversal
Path Planning for Raster-based 3D Printing
• Contour
• Contour + solid interior
• Contour + interior fill pattern
Path Planning for Vector-based 3D Printing: Contour
• Allows manufacturing
hollow objects, some
overhangs, some tilted
surfaces
• Reduces frequency of tool
repositioning
• Reduces support structures
Source: http://www.3ders.org
Path Planning for Vector-based 3D Printing: Contour
Horton et al 1993
Han et al 2002
Path Planning for Vector-based 3D Printing: Interior
TriHatch QuickCast
Horton et al 1993
Path Planning for Vector-based 3D Printing: Interior
Support Structures
Slicing
Path Planning
Machine Instructions
Machine Instructions
Support Structures
Slicing
Path Planning
Machine Instructions
Representation of Multi-material Objects
• Input
– A separate boundary representation for
each material (e.g. an STL file)
• The rest of the pipeline is similar
+ + +…+
Voxel Representation of Multi-material Objects
• Voxel-based modeling
– Each voxel maintains
information about its
composition
1 Voxel
50% A
25% B
25% C
Voxel Representation of Multi-material Objects
• Voxel-based modeling
– Each voxel maintains
information about its
composition
– When printing this
A A
volume is dithered to
obtain a halftoned
representation B C
4 Voxels
Software Architecture Challenges
textures materia
ls
Applications/Interactive Design
Functional Specification
Direct Specification
Hardware/Materials
Questions?
Tell us about yourself
• Name / affiliation
• Background
• What do you want to learn? What are your expectations?
• Have you ever taken a lecture about
– Geometry processing
– Physics-based simulation
– FEM
• Programming skills
– What language(s) do you know?