Practical 3D Printing: Printing

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Printing

06.28

00:00	As we'll be outsourcing the manufacturer of our design for SLS 3D printing, this module will be focused on the considerations around arranging this, rather than the practical steps of using the SLS printer itself.
00:13	After we finished our 3D model at the end of the previous module, we exported a STEP file, which we'll be sending to the manufacturer.
00:20	There are plenty of file formats we could use, but wherever possible it's best to stick to STEP files as they're a more accurate representation of our design, especially when curves are involved.
00:32	However, I've found that due to the finer details of how some CAD software exports STEP files, this doesn't always play well with all manufacturer's websites, and when they're uploaded there might be faces of the model missing.
00:45	Using a trusty STL mesh file does tend to make this a relatively trouble-free process, so keep that in mind if you ever run into problems.
00:54	We'll continue with our intake manifold example, and use Prototech as the manufacturer, which will show a relatively representative process of getting a part made by a real manufacturer for a real application, so let's crack on.
01:08	We'll naturally start by opening Prototech's website and selecting get a quote.
01:13	From here we have two options, additive instant quote or engineer assisted quote.
01:18	Since we don't have any special requirements like meeting standards or high quantities for our design, we can move forward with the more convenient instant quote.
01:27	After setting up some account details, we're greeted by a page where we can upload our model.
01:33	This is as simple as locating the file on your computer, the important thing is checking the correct units, be it millimetres or inches, that matches what we designed our part in, so the scale is correct.
01:45	We worked in millimetres, so that's our choice.
01:49	Once uploaded, the program will analyse the design and bring us to our 3D project page.
01:54	The first thing we need to do is apply the material and post processes from under the tab on the right side of the page.
02:01	We can filter the materials by the 3D printing technology used.
02:05	Hopefully it's not surprising that the two of interest to us for this project are MJF and SLS.
02:12	Here we can see that the MJF option throws up some printability warnings.
02:16	In this case, that's due to the size of the part, which basically means it has to be printed on an angle across the build volume and will result in compromises to the geometry of the part.
02:27	Put simply, there's potential for some warpage.
02:30	The SLS options don't show this, other than for the TPU material, which we're not interested in for this project anyway.
02:38	Prototech also has a capabilities page, which shows the maximum build volume for each 3D printing technology and process.
02:46	Here we can clearly see that the MJF machines are smaller, hence the warnings.
02:52	As we know, this is a DFM consideration to keep in mind when we're designing our parts.
02:57	For this project, we'll choose PA12 glass felt.
03:01	Reviewing the technical datasheet for this option, under the thermal properties, we can see that this should be able to handle around 150-170 degrees Celsius.
03:11	As our part is an adapter for ITBs on a naturally aspirated car and mounts to a rubber isolator, this will be fine.
03:19	Next, up we have the post processing options, which we're going to be diving a lot deeper into in the next module.
03:25	So, for now, we'll just select, the smooth, sealed and dyed option.
03:29	This involves vapour sealing of the part for a smooth, watertight finish and we'll choose to dye it black.
03:36	We'll also select the tapping and inserts option and then use the attachment tabs to include our technical drawing for the position of these.
03:45	With the smoothed, sealed and dyed option applied, we can see the price for printing our parts and start to get an idea of what it might cost us.
03:53	However, the threaded inserts require a manual quote, due to the almost endless amount of options for the inserts themselves.
04:00	We can also see the little dot near the viewer go green, which naturally is a good sign.
04:06	From here we just need to open the viewer so we can review our model to make sure it has all the features and everything looks correct.
04:14	The printability analysis is all looking positive in this case, with the model successfully optimised, not containing any thin walls, containing one shell and fitting into the build chamber.
04:26	The last part we need to discuss is the send request button that we can use to communicate any concerns or questions with the manufacturer.
04:33	This is important if we have any doubts about the suitability of our design for a manufacturer.
04:39	In our case we need to use the send request function to obtain our manual quote, at which point the Prototech team will review our order and then provide an accurate quote and invoice.
04:50	Had we not used threaded inserts however, from here it's just as simple as finishing the check out and paying for the service, following which Prototech will complete the print and send it to us.
05:02	We'll discuss the post processes that follow the printing, including the threaded inserts in the next module.
05:08	For now though, let's jump forward a few steps to when we have our part in hand.
05:13	This is the time to thoroughly review the print and ensure that we're happy with the results.
05:18	This includes the surface finish, geometry and dimensional accuracy.
05:22	For our part we can take some physical measurements with a ruler or verniers, as well as test fit it to the engine and the throttle bodies to check everything lines up as it should.
05:32	Our manifold looks great and the initial fit up looks promising.
05:36	In the following modules we'll put this part to use on the car.
05:39	But let's summarise what we've covered so far, looking at the Prototech website, which again is a fairly representative of a good and easy to use on demand 3D printing service.
05:51	This process starts by uploading our model file that the part was designed in to ensure the scale is correct.
05:59	We can then choose the specific material we need and the corresponding 3D printing technology as well as any post processes or finishing touches.
06:09	Following this we can review the pricing and warnings, include any relevant attachments like technical drawings or raise any DFM concerns.
06:17	Once we're happy it's just a matter of confirming the order, providing a delivery address and making the payment.