The article titled “Complex design from start to finish – 3D design for 3D printing pt11” is a tutorial series focused on using a free 3D CAD program for 3D printing. The video demonstrates the step-by-step process of designing a complex part using extrudes, revolves, sweeps, and lofts. The part being designed is a duct with specific measurements and features. The video also covers the use of digital calipers and a fillet gauge for taking accurate measurements. Throughout the design process, the video emphasizes the use of sketches, construction lines, dimensions, and constraints, as well as the application of fillets and other details. It concludes with a discussion on slicing, printing, and post-processing the final part, as well as recommendations on where to purchase quality filaments and resins.

The video, created by Teaching Tech, aims to showcase the complete step-by-step process of designing a complex part for 3D printing using parametric 3D modeling. It begins by introducing the importance of designing one’s own 3D printed parts for optimal results. The video then proceeds to guide viewers through the process of designing a more complex part, illustrating the use of various tools and techniques such as extrudes, revolves, sweeps, lofts, and fillets. The tutorial emphasizes the meticulous process of taking accurate measurements and creating sketches, as well as the importance of post-processing and refinement for achieving the desired end result.

Step 1: Taking Measurements

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Using digital calipers

Taking accurate measurements is crucial when designing parts for 3D printing. To ensure precision, it is recommended to use digital calipers. Digital calipers provide a digital reading of the measurements, which eliminates the chance of human error in reading analog calipers. The calipers should be zeroed before taking measurements to ensure accurate readings.

When measuring a part, it is important to measure all relevant dimensions, such as length, width, and height. Additionally, any specific features or details that need to be replicated in the design should be measured as well.

Using a fillet gauge

In addition to digital calipers, a fillet gauge can be used to measure the radius of fillets on a part. A fillet gauge is a set of small pieces of metal with different radii. By placing the gauge against the fillet, one can determine the appropriate radius to be used in the design.

To use a fillet gauge, simply align the gauge against the fillet and select the piece that matches the curvature best. The radius measurement can then be used when applying fillets in the CAD software.

Step 2: Creating Sketches

Using construction lines

Before starting the design process, it is important to create a sketch of the part. Sketches provide a blueprint for the design and serve as a foundation for applying additional features and measurements.

Construction lines are used to create the basic shape and structure of the part. These lines act as guidelines and can be used to ensure symmetry and alignment. By using construction lines, you can easily modify and adjust the dimensions of the sketch as needed.

Adding dimensions

Once the construction lines are in place, dimensions can be added to define the size and proportions of the part. Dimensions provide precise measurements that ensure accuracy in the design.

Dimensions can be added by selecting the desired lines or points and entering the appropriate measurements. It is important to consider both the overall dimensions of the part as well as any specific measurements needed for features or details.

Applying constraints

Constraints are used to ensure that the sketch remains fully defined and does not contain any ambiguous or conflicting dimensions. Constraints allow for easy modification of the design while maintaining the desired shape and proportions.

Constraints can be applied by selecting certain elements of the sketch and defining their relationships to other elements. For example, you can make two lines parallel or perpendicular to each other by applying appropriate constraints. This helps to maintain the integrity of the design and avoid any unintended changes during the modeling process.

Step 3: Using Extrudes, Revolves, Sweeps, and Lofts

Creating different sections of the part

After the sketch is complete, various operations can be applied to create different sections of the part. Extrudes, revolves, sweeps, and lofts are commonly used operations in CAD software to create complex shapes.

Extrudes are used to create solid bodies by extending the sketch in a specific direction. By selecting the sketch and specifying the distance or depth, you can create a three-dimensional shape.

Revolve is used to create rotational bodies by revolving a sketch around an axis. This is useful for creating symmetrical shapes, such as cylinders or cones.

Sweep is used to create shapes by sweeping a profile along a path. This allows for the creation of complex curves and contours.

Loft is used to create smooth transitions between two or more sketches. This operation allows for the creation of organic shapes and smooth surfaces.

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Highlighting the use of sweeps and lofts

In the design process, sweeps and lofts are particularly useful in creating the duct part. Sweeps can be used to create the curved sections of the duct, while lofts can be used to create smooth transitions between the different sections.

By using the appropriate sketches and specifying the sweep or loft paths, you can achieve the desired shape and curvature of the duct. These operations provide flexibility in creating complex geometries and smooth surfaces.

Finalizing the design with fillets and details

Once the basic shape of the part is created, fillets and other details can be added to enhance the design. Fillets are used to round off sharp edges and corners, providing a more aesthetically pleasing and practical design.

Fillets can be easily added by selecting the edges or corners that need to be filleted and specifying the desired radius. This helps to improve the overall appearance and functionality of the part.

Additional details, such as cutouts, chamfers, or embossed features, can also be added to further enhance the design. These details can add visual interest and functionality to the part.

Step 4: Discussing Slicing and Printing

Overview of slicing process

Once the design is complete, the next step is to prepare the model for 3D printing. This involves slicing the 3D model into layers that can be printed one by one.

Slicing software takes the 3D model and converts it into a series of slices based on the layer height specified. These slices are then sent to the 3D printer, which prints each layer successively to build the final part.

During the slicing process, various settings can be adjusted, such as print speed, layer thickness, infill density, and support structures. These settings can affect the quality, strength, and print time of the final part.

Printing the final part

After the slicing process is complete, the final part can be printed using a 3D printer. The printer heats the filament or resin and deposits it layer by layer according to the instructions provided by the slicing software.

The printing process can take several hours or even days, depending on the complexity and size of the part. It is important to ensure that the printer is properly calibrated and maintained to achieve accurate and high-quality prints.

Post-processing techniques

Once the part is printed, post-processing techniques can be applied to improve its appearance and functionality. These techniques include removing support structures, sanding or polishing the surface, and applying coatings or finishes.

Support structures are used to provide stability during the printing process but are typically not needed in the final part. They can be removed by carefully breaking or cutting them away from the printed part.

Sanding or polishing the surface can help to smooth out any imperfections or layers visible on the printed part. This can be done using sandpaper or specialized sanding tools.

Applying coatings or finishes, such as paint or varnish, can give the final part a more professional and polished look. Different materials and finishes can be used depending on the desired appearance and functionality of the part.

Step 5: Buying Quality Filaments and Resins

Where to purchase filaments

When choosing filaments for 3D printing, it is important to consider factors such as material type, quality, and availability. Filaments are available in various materials, including PLA, ABS, PETG, and more, each with its own characteristics and properties.

Quality filaments can be purchased from reputable suppliers and manufacturers. It is recommended to read reviews and research different brands to ensure that the filaments meet your specific needs and requirements.

Online marketplaces, specialized 3D printing stores, and local suppliers are all good sources for purchasing filaments. It is important to check the specifications and ensure that the filaments are compatible with your 3D printer.

Where to purchase resins

Resins are used in stereolithography (SLA) and digital light processing (DLP) 3D printers. They provide high resolution and detailed prints, making them suitable for various applications such as jewelry, dental models, and engineering prototypes.

Quality resins can be purchased from specialized suppliers and manufacturers. It is important to choose resins that are compatible with your 3D printer and suitable for the specific application.

Similar to filaments, it is recommended to read reviews and research different brands when purchasing resins. Online marketplaces and specialized 3D printing stores are good sources for purchasing resins.

Step 6: Modeling a Part Using CAD Software

Discussing the modeling process

To model a part using CAD software, it is important to have a clear understanding of the design requirements and constraints. CAD software allows for precise modeling of complex geometries, making it ideal for 3D printing applications.

The modeling process typically starts with creating a sketch and adding dimensions to define the basic shape and size of the part. Additional features and details are then added using operations such as extrudes, revolves, sweeps, and lofts.

During the modeling process, it is important to regularly check and adjust the design to ensure that it aligns with the desired measurements and angles. Iterative adjustments may be necessary to fine-tune the design and achieve the desired outcome.

Creating a model with four outer flat surfaces

For the specific part being discussed in the tutorial, the model needs to have four outer flat surfaces. This can be achieved by carefully defining the dimensions and angles of the sketch.

By applying proper constraints and measurements, the sketch can be adjusted and modified to ensure that all four outer surfaces are flat and aligned as intended.

Reversing the direction of the model

In the design process, it may be necessary to reverse the direction of the model to achieve the desired shape or angle. This can be done by flipping or mirroring the sketch or by changing the direction of the extrude, revolve, or loft operation.

By carefully adjusting the parameters and constraints, the model can be reversed to match the intended design.

Making adjustments to achieve desired angle and measurements

Throughout the modeling process, it is important to regularly check the angle and measurements of the part to ensure that they align with the desired outcome.

If adjustments are needed, the sketch can be modified by changing the dimensions or adding additional constraints. By iteratively adjusting and fine-tuning the design, the desired angle and measurements can be achieved.

Step 7: Applying Fillets

Applying fillets to upper corners

Fillets are used to round off sharp edges and corners, providing a smoother and more visually appealing finish. In the case of the part being designed, fillets are applied to the upper corners to improve the overall aesthetics and functionality.

To apply fillets, the appropriate edges or corners are selected, and the desired radius is specified. The fillets help to reduce stress concentrations and improve the durability of the part.

Applying fillets with a radius of one millimeter to front face and junction between upper and lower sections

In addition to the upper corners, fillets with a specific radius can be applied to the front face of the part and the junction between the upper and lower sections.

Fillets with a radius of one millimeter are applied to ensure a smooth transition and eliminate any sharp edges that may cause discomfort or impact the functionality of the part.

By carefully selecting the edges and applying the appropriate fillet radius, the design is enhanced both aesthetically and functionally.

Step 8: Modeling a Mounting Boss

Using 3D extrusion technique

A mounting boss is a raised surface or structure that is used to attach or secure other components. In the design process, a 3D extrusion technique is utilized to create the mounting boss.

The 3D extrusion technique involves selecting the sketch or profile of the mounting boss and extending it in a specific direction to create a three-dimensional shape. The dimensions and parameters of the extrusion are specified to achieve the desired height and thickness of the boss.

By using the extrusion technique, the mounting boss can be accurately modeled and incorporated into the design.

Creating a hollow boss with a thickness of two millimeters

To optimize the design and reduce material usage, the mounting boss can be created as a hollow structure with a specified thickness.

By applying the appropriate parameters and constraints, the interior of the boss is removed, leaving only the outer shell with a thickness of two millimeters. This ensures that the boss retains its structural integrity while minimizing material waste.

The hollow boss design saves on material cost and reduces print time, making it a practical and efficient choice.

Step 9: Modeling a Fitting

Creating a sketch with dimensions

To model a fitting, a sketch is created with the desired dimensions and measurements. The fitting is typically a cylindrical shape with specific diameters and lengths.

By using the appropriate tools, such as circles and lines, the sketch is created on a new plane or surface within the CAD software. It is important to accurately input the dimensions to ensure that the fitting aligns with the intended design.

Using the revolve tool to create the desired shape

Once the sketch is complete, the revolve tool is used to create the desired shape of the fitting. The revolve tool rotates the sketch around an axis, creating a symmetric object.

By selecting the appropriate parameters, such as the angle and axis of rotation, the sketch is transformed into a three-dimensional shape. The revolve tool provides flexibility in creating cylindrical or tapered shapes, depending on the design requirements.

The fitting can be adjusted and fine-tuned using the revolve tool until the desired shape and proportions are achieved.

Conclusion

In conclusion, designing complex parts for 3D printing requires a systematic approach and familiarity with CAD software. By following the step-by-step process outlined in this tutorial series, you can create intricate and precise designs for various applications.

Taking accurate measurements using digital calipers and a fillet gauge is crucial for ensuring precision in the design. Creating sketches with construction lines, dimensions, and constraints establishes a solid foundation for the design process.

Using extrudes, revolves, sweeps, and lofts allows for the creation of different sections and shapes of the part. Applying fillets and other details enhances the aesthetics and functionality of the design.

Understanding the slicing and printing process is essential for preparing the design for 3D printing. Purchasing quality filaments and resins ensures optimal results in terms of print quality and durability.

Modeling a part using CAD software involves careful adjustments and fine-tuning to achieve the desired angle and measurements. Applying fillets and modeling mounting bosses and fittings further enhances the design.

By following this comprehensive tutorial series, you can gain the necessary knowledge and skills to design complex parts for 3D printing. With practice and attention to detail, you can create high-quality and functional designs tailored to your specific needs and requirements.

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