3D repair _teaching deck

Middle

Design Thinking | Prototype

Simulation & Modeling | Model Development

3D Repair

Overview

Turning Effect of Forces: Have you ever tried placing your hand near the hinge to open a door?

Turning Effect of a Force

When a force is exerted on a pivoted system, it causes a turning effect on the system.

This turning effect is known as moment or torque.

The moment of a force is the product of the force and the perpendicular distance from the pivot to the line of action of the force.

Source

Moment = Force x Perpendicular Distance

Principle of Moments

Principle of Moments

The Principle of Moments states that when a body is in equilibrium, the sum of clockwise moments about a pivot is equal to the sum of anticlockwise moments about the same pivot.

Moment =force F x perpendicular distance from the pivot d.

Moment = Fd

Introduction to 3D Printing

Introduction to 3D Printer

The Makerbot Replicator 2, one of the more popular 3D printers in 2014.

The 3D printer is an additive manufacturing machine in which material is solidified or joined from computer control.

Using Computer Aided Software (CAD), 3D models are created digitally to be transferred to a 3D printer to print it on it’s physical form.

The Fused Deposition modelling Technique relies on melting layers of plastic on the surface.

The most common commercially available printers on the market are FDM (Fused Deposition Modelling) Technology printers.

Uses of 3D Printers

There are many types of use-case scenarios for 3D printers to assist in daily life:

Rapid prototyping

Small scale manufacturing

Replacement & repair

Medical solutions

Understanding 3D Printing

Applications of 3D Printing

Pros & Cons of 3D Printing

Pros

Cons

• Not suitable for large volumes • Limited material types • Not ideal for industrial production

• Rapid prototyping • Freedom of Design • Prints on Demand • Reduced Costs

Hands-on Activity

Fusion 360

Fusion 360 is an industry standard CAD parametric modeling software, used widely by many product designers to create complex prototypes & run simulations. Log into Fusion 360 to get started! Take note of the interface that you’ll be using: • There is a save icon on the top left (Rubik’s cube). It stores the saved files. • Fusion 360 is a cloud-based program so files are saved on Autodesk servers.

Workspace for creation/modification

Data Panel for save file location

View box to keep track of aligned views

Browser to keep track of objects in 3D space

3D space

Check the different outline squares and discover the panel

Basic Navigation

Navigation around 3D space: • Mousewheel: Zoom In/Out camera • MMB: Pan camera • Shift + MMB: Rotate camera Under the workspace, there is the Create and Modify dropdown menu that we will be using to create and edit objects.

Getting Started: Creating a Sketch

2. Create a sketch

1. Create a box

3. Shape your box

Create a box in the 3D space from the top menu, Create → Box, this will be your tutorial object for creating/modifying objects

In order to shape your box, you can create a sketch via Create → Create sketch. You will be tasked to place the sketch either in the 3D space or on one side of the box.

Your workspace will change to allow for shaped sketches. Select the 2-point rectangle to create a square sketch. Afterwards, click on finish result to complete the sketch.

Manipulating the Sketch

You can manipulate the sketch by extruding, revolving, or making a hole. These options are available in the Create menu.

Hole

Revolve

Extrude

Adds depth to a sketch by extruding it into a 3D shape.

Rotates a sketch into a 3D shape.

Adds a hole in the selected sketch/face.

Making a hole

Let’s try making a hole Select File < New design

3. Extrude

2. Make a sketch

1. Create a box

Put a box in the 3D space as shown previously.

Create sketch > Circle (place it on the top face)> Finish sketch.

Use the extrude option to create a hole.

Modify

The Modify option allows you to refine the object with various editing tools:

Press/Pull

Draft

Fillet

Scale

Shell

Move/Copy

Your Task: Find the perfect fit for a broken zipper on an article of clothing.

Find the perfect fit for a broken zipper!

Export the 3D Model

Create the Zipper

Set the 3D Print

1. Ensure that the 3D model is within the print space

1. Open up the 3D repairzippersample.f3d file. The model is a sample zipper base that can be improved upon with your sketch design.

Ensure that the changes are kept small for the 3D printer.

• Dimension limits: Length: 50 mm, width: 15 mm, height: 5 mm

2. Check the preview before printing. Take note of the timing when changing settings

• You will need to export the model to a .STL file.

2. Drag the model into the workspace to edit.

3. Print Settings

3D Printing Troubleshooting

Resolution

Mistakes/Issues

Possible Reasons

▪ Proper calibration of the print bed is required. ▪ Print bed surface is dirty. ▪ Printing temperature is incorrect. ▪ Printing speed is too fast.

▪ Recalibrate & adjust the nozzle to the proper height. ▪ Clean the bed surface before printing. ▪ Change the speed/temperature of the 3D printer nozzle.

3D print does not stick to the surface.

▪ Extruder is clogged/overheated. ▪ Out of filament.

▪ Ensure that filament is clean and without any dust. ▪ Allow 3D printer to cool down from overheating. ▪ Re-load the filament onto the 3D printer.

3D printer stops mid-print.

▪ Print bed is not heated properly. ▪ Printing speed is too fast.

▪ Check temperature around the 3D printer. ▪ Heat up print bed. ▪ Slow down print speed.

3D print is warped/ broken/bent.

Reflection

Assuming that one end of the zipper is fixed, how would you modify your design in order to make it easier to rotate?

Fixed end

Create a 3D model using 3D space to illustrate this.

Could you explain your design using the turning effect of moment?

Summary

• Applied the turning effect of a force. • Created and printed a 3D model using a 3D modeling software.

Do you need to go deeper on the topic?

What have we learnt?

Beginner’s Guide to Fusion 360

Working files

Educator Guide

Working files

Educator Guide

Beginner’s Guide to Fusion 360

Middle

Design Thinking | Prototype

Simulation & Modeling | Model Development

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Print not sticking to bed

3D Printed Rapid Prototype

Replacement and repair tools and components.

Overview

120 min

Physics

• Apply the turning effect of a force.
• Create a prototype using a 3D printer.

Extruder is clogged

3D printing vs Injection Moulding - In the long run, Injection Moulding is more cost effective than 3D printing.

Problem Solving: 3D Hook on a table edge

Warped bottom of 3D printed box

Print Settings: • Higher infill percentage strengthens the model, while lower infill speeds up print time • Add adhesion/rafts to prevent warping

Export the model to a .STL file: • File → Export Change file type from .F3D to .STL and select a location to export the file.

A 3D printed hand aid designed to assist in physiotherapy

Zipper sample dimensions: Length: 35 mm, width: 10 mm, height: 2 mm If you need to measure your model: Use the Measure tool (from Inspect) in the workspace and select the edges of the objects to obtain the dimensions.

Print not sticking to bed

Plastics are the only widely available material for 3D printing

Extruder is clogged

Warped bottom of 3D printed box

3D model is within the print space: • Case: 40.9 mm x 15 mm x 6 mm • Clip: 28.2 mm x 11 mm x 2.8 mm