Tag Archives: 3D printing

BSC 2018: Correcting some too thin errors

As I am fairly new to 3D printing, I am learning a tonne about what not to do. One of the biggest issues I have discovered is that things that look good in CAD can look absolutely terrible once printed, given the resolution of the printing or the limitations of FDM 3D printing. Today I wanted to talk about three different, but similar errors I made: making a part too thin to print correctly.

Back corner of the cab

First up – the back corner of the cab. As the backside of the cab is curved, it thins quite a bit at the very back corners.

Back corner of cab in blue. See the thin joint at the very end

When you bring this into Cura to slice it for printing, the problem becomes obvious.

Back corner of the cab, showig that when printed, it will only be two layers thick (~0.8mm)

The solution to this is to thicken the back wall of the cab, which I did by adding a flat piece to it:

Back corner corrected with additional piece (in red)

Once you bring that into Cura, you see that the narrowest part is now at least 1mm thick, so the piece shouldn’t be so weak.

Thicker corner sliced in Cura
Fenders

The next piece I tackled was the fenders. They were originally 0.25mm thick, which means that they were just over one layer thick when printed at 0.2mm and only two layers thick at 0.1mm. This meant they basically didn’t print at all.

Fender dimensions
Fender sliced, showing no overlap

The solution to this problem is two-fold: thicken the fender up to 0.5mm and also only print at 0.1mm (considered Fine quality).

New fender, now 100% thicker!
New sliced fender, showing overlap
Top of the windshield

This is actually entirely my error. I made the windscreen and frame around it taller than the sides or back of the cab. This meant when I cut up the model to slice, the top of the windscreen disappeared. Oops.

 

Top of the windscreen, showing the height difference

 

Top of the cab when sliced. That grey area is supposed to have yellow lines for printing

BSC 2018: First print of 1956 PANG

The new printer board for my 3D printer finally showed up, so I got to printing the first print of my 1956 PANG. It was less than a full success. As you can see in the pictures below, I have a bunch of work to do.

Printed truck on build plate. Printed without the side compartments. Excuse my messy garage

As can be seen on the build plate, a bunch of details didn’t come out right – the biggest of which was the top of the cab for some reason completely failed to print correctly. I also accidentally selected brim intead of skirt, so I had lots of cleanign to do.

Front & side view. Lledo Model A, Copplestone Chinese and Infinity Ariadna for scale

The sides of the truck aren’t very smooth, and a bunch of the finer details simply didn’t print.

Side rear view of the truck
Side rear view of the truck with Lledo Model A, Infinity Ariadna and Copplestone Chinese for scale
Front and side view of the truck

So what next? First of all,my printer needs some upgrades:

  • A part cooling fan (the Ender 2 lacks it by default)
  • Belt tighteners (and the belts replaced with metal-core of some kind)
  • A more modern Marlin (the firmware that runs the printer)
  • A lot more tuning

On the truck, the first thing I am going to do is shrink it by 25 to 30%. It is too large for what I want. Then I need to some work on the model itself

  • Thicken some of the walls so that they print, especially the fenders, which didn’t print at all
  • Clean up some of the smaller details, possibly removing them for now
  • Re-cut up the cab so it prints correctly

Anyway, I have my work cut out for me!

BSC 2018: PANG print layout

I finally got around to laying out the 1956 PANG for the first printing. As you can see from the pictures below, I am trying to remove the need for supports which will mark the surface of the final print.

Final draft for reference
Final draft for reference
Laid out in TinkerCAD for printing
Laid out in TinkerCAD for printing

I chose not to break out the rear section or the bins for initial printing. I likely will in the final version, as it will speed up print time and make it cleaner.

Cura print layout
Cura layout, with approx. print time. Note that my printer (Ender 2) has a fairly small print bed, so this will fit on it

 

One final note: I am certain that there will be tweaks needs to be this and I am missing things, namely an interior and side mirrors to start.

BSC 2018: 1956 PANG first printable draft

Build Something 2018 continues and I have been pretty quiet for the last week. Part of this is because I am waiting on the warrantied printer board, so motivation is low. Also been busy with other things. But today I kicked myself into gear and go the first printable draft done of the 1956 PANG. Take a look below (the red rectangle is 32mm high and is there for reference):

Front view of 1956 PANG truck
Front View
Front angled view of 1956 PANG
Front angled view
Rear view of the 1956 PANG
Rear view of the 1956 PANG
Side view of the 1956 PANG
Side view of the 1956 PANG
Rear angled view of the 1956 PANG
Rear angled view of the 1956 PANG

 

BSC 2018: 1956 PANG continued

Well, Build Something 2018 is well underway at Lead Adventure. You can follow all the entries, including at least two other 3D printed things, over on the subforum.

And what of our 1956 PANG tricycle truck? Yesterday saw a lot of work on the back end.  As of two days ago it looked like this:

I really didn’t like the aspect ratio of the truck – height, etc. So I completely rebuilt the back end so it was taller and thus looked narrower:

Early work on 1956 Pang

Today I started working on the front end, which is a lot harder. It has a lot of curves with curves, so it going to be a real challenge to do well. I am not overly happy with the look (too wide and squat) so might rebuild the front. Here it is in exploded view.

Front end of 1956 PANG, exploded view on right
Front end of 1956 PANG, exploded view on right

What I love about modelling this way is that if you don’t like something, it is trivial to rebuild it. Play with the ratio, etc.