Tips for 3D Printing Accuracy

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In this webinar you will learn specific tips on how to obtain the best accuracy from 3D printing machines for your parts from 3D Systems, Objet, and Stratasys. Each manufacturer will give you 5 tips that will ensure accurate dimensions in your built parts. These tips will cover various design, material, and machine factors that can influence the final outcome of your part.
All registrants will also receive free copies of these white papers following the webinar:
- Top Five Reasons to Integrate 3D Printing into your Product Development Lifecycle
- How 3D Printing works: The Vision, Innovation and Technologies Behind Inkjet 3D Printing

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Tips for 3D Printing Accuracy

  1. 1. Tips for 3D Printing Accuracy
  2. 2. Thank You to our Sponsors
  3. 3. Before We Start This webinar will be available afterwards at designworldonline.com & email Q&A at the end of the presentation Hashtag for this webinar: #DWwebinar
  4. 4. Moderator Presenters Leslie Langnau Stacie Hoche Ben Klein Bonnie Meyer Design World 3D Systems Objet Ltd. Stratasys
  5. 5. ProJet 6000 Accuracy Stacie Hoche April 2012
  6. 6. ProJet™ 6000 Accuracy Accurate Precise High resolution • Digital self calibration • Print accuracy rivaling CNC • Digital motion control • Closed loop monitoring • <10 m resolution • Features as small as .3mm
  7. 7. ProJet™ 6000 Accuracy 35 30 25 -- 3 x 3 matrix of test parts -- 12 measurements per part -- 108 measurements -- 1mm to 32mm range -- Standard Deviation of <15 microns Accuracy is a combination of: -- System capability -- Material properties -- Compared to an absolute Frequency 20 15 10 5 Difference from nominal in microns 100 90 80 70 60 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80 -90 -100 0
  8. 8. ProJet™ 6000 Accuracy Thin walls that get progressively thicker in 10um increments 10 microns = 0.00039 inches 1010 m 1000 m How small of a increment can the system print? Result=1450 Dpi; 17.5m
  9. 9. ProJet™ 6000 Accuracy • Machine Build Modes o HD - Fastest o UHD – General purpose build mode o XHD – Fine feature detail
  10. 10. ProJet™ 6000 Accuracy • User adjustment to fine tune part accuracy o Shrink Compensation o Line Width Compensation
  11. 11. 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
  12. 12. ProJet™ 6000 Accuracy
  13. 13. 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
  14. 14. ProJet™ 6000 Accuracy Line-Width Compensation Off Line-Width Compensation On
  15. 15. ProJet™ 6000 Accuracy
  16. 16. How to Obtain the Most Out of Your Objet Printer: Quick Tips
  17. 17. CAD to STL - Maintain the Proper Resolution • 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. Faceted STL file translated with coarse tolerance File translated with fine tolerance
  18. 18. “Connexify” a Part • 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
  19. 19. “Connexify” a Part Uncheck this to allow separate STL files (For Connex)
  20. 20. Supporting Delicate Parts with Auxiliary Structures In order to support fine features, an auxiliary part can be printed and removed later + =
  21. 21. Matte Vs. Glossy Matte mode is intended to generate uniform surfaces. Ensure your model is suitable for this mode.
  22. 22. Objet Studio – Other Considerations The visual differences between Matte and Glossy Parts
  23. 23. Accuracy in Appearance To truly appreciate fine details on the surface, use VeroBlue or VeroGray materials in the glossy orientation
  24. 24. Accuracy in Performance To imitate final material performance, use Connex for complex applications
  25. 25. Fitting Surfaces Fitting surfaces should be positioned facing up No support material needs to be removed
  26. 26. Print Several Materials on a Single Piece End part Shore value needs to be determined
  27. 27. Print Several Materials on a Single Piece Connex Technology enables testing of different values on a single print
  28. 28. Print Several Materials on a Single Piece
  29. 29. Accurate Parts with FDM Systems Bonnie Meyer, Sr. Applications Engineer Stratasys, Inc.
  30. 30. All FDM Systems  Thermoplastics are stable over days, months or years     ABS Polycarbonate (PC) Polyphenylsulfone (PPSF) ULTEM
  31. 31. FDM – thorough analysis  27 measurements  12 parts per build  3 runs per machine  Repeated on 3 machines 108 sample parts 2916 measurements
  32. 32. FDM Repeatability Results:  σ: 0.0027 in. (0.07 mm)  Mean: 0.00034 in. (0.009 mm)
  33. 33. Accuracy Over Time Width Nominal (3.000”, 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”, 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) 76.2 mm) 127 mm)
  34. 34. 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
  35. 35. Orientation • Critical Features • Rounds
  36. 36. Calibration • Tip Changes • Periodically
  37. 37. Custom Scaling • Fine Tune in X and Y if Needed • Quantities of Parts
  38. 38. 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
  39. 39. 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) • ApplicationSupport@Stratasys.com
  40. 40. Questions? Design World 3D Systems Objet Ltd. Stratasys Leslie Langnau llangnau@wtwhmedia.com Phone: 440.234.4531 Twitter: @DW_RapidMFG Ben Klein Ben.Klein@objet.com Phone: +1.972.52.889.2292 Stacie Hoche Stacie.Hoche@3dsystems.com Phone: 803.326.4613 Bonnie Meyer Bonnie.Meyer@stratasys.com Phone: 952.906.2244
  41. 41. Thank You  This webinar will be available at designworldonline.com & email  Tweet with hashtag #DWwebinar  Connect with  Twitter: @DesignWorld  Facebook: facebook.com/engineeringexchange  LinkedIn: Design World Group  YouTube: youtube.com/designworldvideo  Discuss this on EngineeringExchange.com

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