Ambassador Quick Tip: Designing for 3D printing for better results!
2023-08-04 | By Will Siffer
License: Attribution 3D Printing
Looking above, you can see one of the most fascinating 3D prints that was made in the lab a couple of years ago. This serves as an everyday example that 3D printing is not always the proper manufacturing method and is not the catch-all solution so many believe it is. That block was printed as a 25x25cm PLA at about 60% infill, making it a full 1kg of plastic! That's a full roll!
Seeing this block inspired me to write this blog post because I think compiling what I've learned from 3D printing and, more importantly, what I have learned from designing for 3D printing all into one place. So here are my best practices when it comes to 3D printing:
1) Only print a design that cannot be easily purchased as a refined product.
This one may seem a little too broad, but in general, I am referring to printing simple shapes like rods and cylinders that would be stronger and better if a solid rod was purchased from a hardware supplier. Sure, there are some times when load isn't important, but for most projects, it would be better to go for a device that was purpose-built for the application.
Why will simple 3D printed shapes tend to fail? 3D prints are weak along their layer lines, so a rod will be weak when bent if printed upright, or it will be dimensionally inaccurate if printed on its side. This leads me to my next tip!
2) Print devices with consideration to layer line strength and support material minimization.
This is an extreme example, but take a look at that print orientation! This makes no sense, and it will require a crazy amount of support material to print successfully. Other examples that are a bit easier to see what I am talking about.
Here is a model that would need to be printed this way for round dimensional accuracy, but see how when I slice it there will be a lot of support material (light blue)? Also, notice how the model is quite hollow toward the top making this part weak.
3) When printing something for an electrical project, make sure to plan for wire routing and component size!
I am so guilty of this. Sometimes it is easy to forget that wires take up space in a design, and I am using this platform to tell as many people as possible to design for wiring! One of the biggest tips I have in this guide is to use DigiKey to find a good pair of digital calipers and order a new roll of 3D printing filament. I've linked some recommendations to what I like below, but there are lots of other great options too!
Use your tools and make sure to print mindfully. My final bonus tip is to minimize plastic waste by printing intelligently and printing only what you need to minimize plastic waste. Fortunately, DigiKey sells PLA rolls with cardboard spools that are more recyclable than plastic rolls. This is a big step forward in sustainability!
Finally, in case you are looking for a 3D printer for yourself, I am excited to find that DigiKey now sells an incredibly affordable entry printer, the Ender 3 V2. At under $300, this printer will be perfect as a starter printer with loads of support available, and ordering from DigiKey means you get the same shipping benefits you love with all of your components!
I hope you learned something today; these are just the biggest tips that I have and there is so much to learn as you work on designing for 3D printing. I love making 3D printed content on maker.io and Digikey.com because they have really grown their offerings since I first started as an ambassador. There is always something new to find on Digikey.com!
Until next time, I am the Student Ambassador for Purdue University, and I hope you learned something today!
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