What is 3D printing?

How does FFF/FDM work?

(source: https://all3dp.com/2/fused-filament-fabrication-fff-3d-printing-simply-explained/)

http://youtube.com/watch?v=Z70SF4guWKo


(source: How Does The FDM 3D Printing Technology Work? | Manufactur3D)

Important concepts:

  1. Filament is brought in by "cold end" and heat up to molten form at "hot end" and squeeze out through nozzle
  2. Squeezed out molten material (extruded material) get deposited onto the 3D object under construction, layer by layer

(source: Fused Filament Fabrication – Simply Explained | All3DP)

Benefits of FFF

  • Large selection of materials, including many common thermoplastics, wood and metal-infused thermoplastics, and even food (such as chocolate).
  • Least expensive printer technology.
  • Least expensive materials.
  • Easy to switch materials.
  • Possible to print using multiple different materials.
  • Printers and materials offered by many manufacturers.
  • Relatively easy to build your own printer.
  • Fast printing.

Major disadvantages of FFF

  • The detail of finished prints is limited by the size of the nozzle. Other technologies offer higher detail.
  • The strength of finished parts is limited because each layer is joined to the layer below it.
  • Need to waste some support material due to gravity
    Block Image (source: Introduction to Fused Deposition Modeling (FDM) - University of Maryland)
  • Have layer pattern on the side

source: Fused Filament Fabrication – Simply Explained | All3DP

Material

Build material

PLA (Most commonly use)

  • melting point: 180C to 220C
  • soften at 60C (glass transition temperature)

https://www.wevolver.com/article/a-comprehensive-guide-to-pla-melting-point-and-how-it-influences-3d-printing

MaterialProperties
PLA (polylactic acid)Excellent surface quality and detail. Mechanical and heat properties not suitable for some applications
ABS (acrylonitrile butadiene styrene)Strong, ductile material with wear resistance and heat tolerance
Nylon (polyamide)Strong yet flexible, with good chemical, impact, and abrasion resistance
PETG (polyethylene terephthalate glycol-modified)Good toughness and wear resistance, with chemical resistance against many industrial fluids.
CPE (copolyester)Durable and flexible with a glossy finish and good impact and heat resistance
PC (polycarbonate)Strong and tough material with heat resistance up to 110 °C
TPU (thermoplastic polyurethane)Flexible material with rubber-like properties. Provides high impact and wear resistance
PP (polypropylene)Durable, tough, and fatigue resistant. Retains shape after torsion, bending, or flexing
PVA (polyvinyl alcohol)Water-soluble material used to create supports for overhangs and cavities

source: What is FFF 3D printing? - UltiMaker

source: How much should I charge to make prints? Help Center

Support material

Using normal build material for support:

IMG_3313


When your flat overhang don't have support:

(source: Resource Blog — The Mantis 3D Printer)


How to 3D print With Supports | The Factory

Support | Bambu Lab Wiki


The following is some introduction of Bambu support filaments:

Types of support filaments

Support W, i.e.

Support for PLA

Support for PLA/PETG
Support for PLA/PETG | Bambu Lab Global Store

PVA
PVA | Bambu Lab Global Store

Support G, i.e.

Support for PA/PET

Types of body filaments that are compatible

PLA, PLA-CF, etc.

PLA, PLA-CF, PETG, PETG-CF, etc.

PLA, PLA-CF, PETG, PETG-CF, etc.

PA, PA-CF/GF, PA6-CF/GF, PAHT-CF/GF, PET-CF/GF, etc.

Characteristics

1. Easy to remove;

2.  High surface quality;

3. Insensitive to moisture, and not strict with drying and moisture proofing

1. Water-soluble, and suitable for those models that are not convenient to remove with hands and tools;

2. Easy to remove;

3.  High surface quality;

4. Sensitive to moisture, and very strict with drying and moisture proofing.

5. Please refer to this wiki before use: PVA Printing Guide.

1. Easy to remove;

2.  High surface quality;

3. Sensitive to moisture, and very strict with drying and moisture proofing.

Recommended settings

1. In most printing cases, it‘s recommended to print the support interfaces with support filaments, and print the support bases with body filaments, so that a lot printing time can be saved.

2. In some special printing cases, it's able to print both the support interfaces and the support bases, i.e. the whole support structures, with support filaments. However, it may leads to bad printing results when it comes to support structures that are thin and tall and deforming or falling during printing.


*Bambu only have 1 nozzle, the following picture just for showing we can use support material for support part in FDM printing. Bambu is able to switch material on same layer by using AMS.

(source: A Guide to FDM Printale Plastics and 3D Printing Filament | 3devo)

Extra: 

3D Printing Materials Explained: Compare FDM, SLA, and SLS

https://www.youtube.com/watch?v=9B-HGhN_jCk

Common problem affecting printing quality

Bad filament quality (e.g. brittle when filament absorbs moisture over time)

What Effect Does Moisture Have on 3D Printer Filament Storage?

(source: What Effect Does Moisture Have on 3D Printer Filament Storage?)

PETG quality difference with different moisture contamination

https://www.youtube.com/watch?v=Ql1oN3XyrZg&t=19s

Flow Rate and Filament Moisture

Mass flow rate is directly correlated with the moisture content of 3D printed filament. Higher moisture content yields the lowest viscosity and the highest mass flow rate.

While high flow rates are generally desirable, an unregulated flow rate leads to over extrusion.

Indications of Possible Moisture Content in Failed 3D Printing Builds

  • Filament cracks or makes popping noise as the filament is pushed through the extruded
  • Holes in the top of parts
  • Extruder tip bubbles with a tiny burst of steam, stringy or drooly
  • The filament will not adhere to the print bed
  • Repeated builds seem inconsistent or fail no changes in variables
  • Extruder motor stops but filament keeps coming out
  • Extruder motor starts but filament extrusion is delayed
  • Parts become soft, fragile, and break easily
  • Extruder jams

How to quickly check if the PLA filament is wet

https://www.youtube.com/watch?v=koFBnmyTioQ


Unsuitable Temperature

Nozzle temperature (melting point)

Heat bed or build plate temperature (glass transition temperature)

Enclosure temperature

Clogged in extruder

https://youtube.com/shorts/NNLzOippOxo?si=JDqaPiB26ZHYR8q6

Under-Extrusion

(source: Under-Extrusion | Simplify3D Software)

Over-Extrusion

(source: Over-Extrusion | Simplify3D Software)

Overheating

(source: Overheating | Simplify3D Software)

Gaps in Top Layers

Simplify3D - holes or gaps in top layer (source: Gaps in Top Layers | Simplify3D Software)

Weak Infill

Simplify3D - weak or stringy infill (source: Weak Infill | Simplify3D Software)

Gaps Between Infill and Outline

(source: Gaps Between Infill and Outline | Simplify3D Software)


Inconsistent Extrusion

(source: Inconsistent Extrusion | Simplify3D Software)

Stringing or Oozing

(source: Stringing or Oozing | Simplify3D Software)

Layer Shifting

(source: Layer Shifting | Simplify3D Software)

Warping

(source: Warping | Simplify3D Software)

Layer Separation and Splitting

(source: Layer Separation and Splitting | Simplify3D Software)


Vibrations and Ringing

(source: Vibrations and Ringing | Simplify3D Software)

Curling or Rough Corners

(source: Curling or Rough Corners | Simplify3D Software)


More refers to: Print Quality Guide | Simplify3D Software

For Bambu Printer: Common print quality problems and solutions | Bambu Lab Wiki

3D printing works smoothly when ALL the followings are satisfied:

  1. filament is brought by the "cold end" continuously and get into the "hot end" at the appropriate speed
  2. hot end is hot enough to melt the filament so that it can flow out continuously, but NOT too hot to make the material too "runny" or even burn them
  3. extruded material should stick to the heat bed or build plate at the first layer, or to previous layer of the object under construction

Refer to https://3dprinting.stackexchange.com/a/15950/41236 on what happens when "hot end" is too hot or too cold.

Workflow for printing a FFF 3D printing

(source: https://www.researchgate.net/figure/FFF-3D-printing-process_fig1_355853683)

  1. Prepare 3D model using a CAD software (Tinkercad, Blender, Fusion360, Rhino3D, SolidWorks, ....). Make sure the 3D model is "water-tight".
  2. Export 3D model as STL (or STEP in case of Bambu Lab Studio)
  3. Use a slicer software to convert the STL file into G-code file (or .gcode.3mf in case of Bambu Lab Studio). G-code is the language for describing instructions to control operations of a FFF 3D printer while 3D printing.
  4. Send the G-code file to the 3D printer, and execute instructions in the G-code file on the 3D printer
  5. 3D printer operates according to the G-code to complete the printing.

Slicer Software

To slice your 3D model into layers, and convert those layers into print sequence, and generate the G-code file or send it directly to your 3d printer.

Bambu Studio Quick Start Guide | Bambu Lab Wiki

Bambu Slicer Introduction (Bambu Studio)

Installation

  1. Download Bambu Studio according to your PC operating system.
    WindowsOS:
    Bambu_Studio_win_public-v01.10.01.50-20241115162711.exe

    MacOS:
    Bambu_Studio_mac-v01.10.01.50-20241115162711.dmg

    Alternative way:
    Download in https://bambulab.com/en-us/download
  2. Follow the instruction on Installation (No need to follow the version)
    Windows:

    Mac:
    simply open the .dmg file then copy the Bambu Studio app to the Applications folders on your Mac.
    install_bambu_studio_on_mac.png
  3. Open Bambu Studio
  4. Choose Asia-Pacific
  5. You can choose skip or Join the program, it doesn't matter
  6. Clear all selection, only choose Bambu Lab X1 Carbon 0.4mm nozzle
  7. Filament Selection doesn't matter, just click Next
  8. MUST install Network plug-in
  9. Click "Prepare" to switch to build plate view, make sure you choose the "Bambu Lab X1 Carbon 0.4 nozzle" and the plate type is "Smooth PEI Plate"

Slicing Technique

Overhang

Slow Down for Overhangs | Bambu Lab Wiki

https://www.youtube.com/watch?v=SqfJOmYZefg&t=13s

Overhangs | Common print quality problems and solutions | Bambu Lab Wiki

Bridge

Bridge settings | Bambu Lab Wiki

https://www.youtube.com/watch?v=SqfJOmYZefg&t=126s

Bridge | Common print quality problems and solutions | Bambu Lab Wiki

Support

Support | Bambu Lab Wiki

https://www.youtube.com/watch?v=SqfJOmYZefg&t=316s

Seam

Seam settings | Bambu Lab Wiki

The seam is a kind of gap between the start and end points of each perimeter of the layer( Unless you enable the Spiral Vase mode, refer to Spiral Vase | Bambu Lab Wiki). It leaves vertical seams on the surface of the model, which is unavoidable in FDM 3D printing. Seams can be well hidden on irregular surfaces such as those with concave and convex vertices. On the other hand, some models with circular surfaces (such as cylinders) will not be able to hide the seams, which will be very obvious.

Print by object

Print-by-object | Bambu Lab Wiki

When there are multiple print objects in one plate, you can choose to print multiple models at the same time (by layer, the default print sequence), or you can choose to print them one by one. Print-by-object can reduce stringing and oozing caused by traveling between models. And if one model fails, it usually does not affect the printing of the other models when using this mode.

Files for 3D Printer Test 

Ref: 3DP - Design for 3D Printing - Characterization of Filaments - Digital Fab Lab - Design and Make Confluence

General
Overhang angle test
Bridging test
Tolerance test
Temperature test


3D_printer_test.3mf3D_printer_test.3mf

makerworld.com/en/models/973215#profileId-945401

3D printer stress test by der absolute Hammer - MakerWorld

Slicer Control

Interesting 3D printing examples

Bambu Operation process

ams-photo.jpg

AMS (Automatic Material Management System)

  • For switching between multiple materials while printing
  • Auto filament load and change
  • Humidity measurement and control

Introduction to AMS | Bambu Lab Wiki

First layer Inspection

Bambu X1-Carbon inspecting the first layer #thingiverse #3dprinting #bambulab #3dprinter #video

Spaghetti

Self-service Bambu printing system detail step

Preparation

  1. Slice the 3D model
  2. Screen capture the whole window including details of Total printing time, Total Filament, whole view of the sliced model, Bambu Printer type and plate type.
  3. Export plate sliced file to generate .gcode.3mf file
  4. Login to https://sdfablabhub.designandmake.org/.
  5. Click "3D Print"
  6. Click "New Print Job"
  7. "Choose File" → select the screen capture
  8. "Choose File" → select the .gcode.3mf file
  9. Enter the Estimated Print time, Material use amount, Which material (Must choose Matte PLA for now), Purpose for printing.
  10. For "Subject Use", please write down the subject code.
  11. For "Own interest" in purpose for printing, please write down briefly describe what this print job used for.
  12. If you need to make a consultation with our staff to discuss about your print job (maybe you need some slicing advise), you can check the "Request for consultation", and write down what you want to ask, with some files or images for reference.
  13. MUST click "submit" to submit the print job detail form.
  14. Wait for staff to review your print job and update your print job status. You will need to have the approve status for each print job in order to print.
    (We will open your .gcode.3mf file to see if there's any slicing problem that clearly leads to print fail. e.g. no support on the part that MUST need support, wrong Bambu Printer version or plate type selected)
    (We will update the status to "Required Modification from User" if there's any slicing problem)



  15. You can view the detail of the Approval Status by clicking on the icon at the last column.
    Here's an example: 
  16. If your sliced file have some problem, staff may leave comment on your print job page in the "Discussion area with staff". So that you have a more clear guideline on how to fix your file.
  17. It is possible that if you have accumulate some print jobs without any slicing problem, after sometime, your print job will be auto approve by system. However, if you create any mess up situation in 3D Printer due to slicing problem in your future print job, you will need to wait for the approval from staff again.
  18. Make sure you have enough credit for the printing, otherwise you cannot start your print job. Our current rate is 1 gram = 0.1 credit

In front of 3D Printers in V104

  1. Bring your laptop to V104 with Bambu Studio installed.
  2. Bring your phone with Bambu Handy installed and logged in your own Bambu account.
  3. Search for a Bambu that is available to use.
    1. If the Bambu power off (LED light OFF), the print job is finished. You can remove the build plate with print carefully ( (warning)  Don't damage others print ) and put on the table nearby. Then take a empty build plate on the build plate holder and place it inside the Bambu ((warning) careful for the orientation).
  4. Use your phone to scan QR code on top of 3D Printers to access the Fab Lab System.
  5. Login.
  6. Choose the correct print job you are going to print.
  7. Power ON
  8. While waiting for the Bambu to turn on and prepare, you can login your own Bambu account in Bambu Studio of your computer
  9. Open the corresponding .gcode.3mf file
  10. After Bambu finished setting up, logout the Bambu from the touch panel, login your account to the printer by using Bambu Handy QR code scanning
  11. Refresh on the Print plate window, you should see the Printer you just pair
  12. Sent the print job, you MUST UNCHECK the Timelapse, CHECK the Enable AMS checkbox. It is advise to check the Bed Leveling and Flow Dynamics Calibration for better printing quality.
  13. You should receive an email indicating that your print job start successfully
  14. (warning) Please wait until the Bambu Printer finished First layer inspection to ensure your print is successful

Notes for using 3D printer

  1. Please come back to remove your print ASAP, as it occupy a build plate which may disturb others from using the 3D printers.
  2. If there's not enough filament, please scan the QR code for that printer, and click "Request filament refill".
  3. If there's any bizarre situation happen for the 3D printer, or it encounter any operation problem, please click "Issue Report" so that our staff will come to fix the problem, or find out the culprit. slightly smiling face 

Consultation

  1. The consultation will be hold only if both USER and STAFF accept the proposed time.


  2. Please go to V611 to find the staff for consultation.
  3. Please come on time.
  4. You can chat with the staff on the discussion area. You can also submit files or images for references there.


Tasks to do


Group List
SD4410https://docs.google.com/spreadsheets/d/1GFXY7OE9U7fNf6weUNiRGlMWLG_yy-v8uRTmrekdrAA/edit?usp=drive_link
SD5978https://docs.google.com/spreadsheets/d/1RqvxV0AGCVzNH8JdUThcVBd-VcPf0-X1RoEY-Ka7JZ4/edit?usp=sharing
SD5512https://docs.google.com/spreadsheets/d/19cDH9F7tQOr9ROFFqZGQQ6_H2RS8R6_0W1IMYB6Hkyk/edit?usp=sharing
SD1105https://docs.google.com/spreadsheets/d/1cAIEK6l7qH1TU0QOURo5VJoddmgriPKuhgA9jOuesQo/edit?usp=sharing

For how to export a .gcode.3mf file, please refers to the above "Self-service Bambu printing system detail step" → "Preparation" part.

Submission method:

  1. Go to https://sdfablabhub.designandmake.org/, Choose 3D Print > New Print Job
  2. Create a new print Job for each Task 1-3 (each person), Task 4 submit only one for each group.
    i.e. for a group of 4 ppl, I need to see 13 print job submitted for their group account.
  3. Fill in your sliced capture and plate sliced file according to the task requirement. (For Task 3 the sliced capture is different, please pay attention for the requirement)
  4. Fill in the rest of the information. Choose Matte PLA, Subject Use, and fill in your own subject code(May not be SD4410). Click submit.
  5. Go to the detail page of the print job you just submitted
  6. Check the detail, make sure you submitted the correct file. If you need to make changes, click "Edit"
  7. Scroll down to the bottom of the page, reply the text required by each task. e.g. for Task 1, you will need to reply "Task 1, group member no. {Your group member no.}, {Your English Full Name}". It is your group member number, NOT your group number. 


  1. Orientation

    Task1.3mf

    Instruction:

    Submit a Screen capture of the whole window, and a .gcode.3mf file with sliced models in Bambu studio. The orientation MUST need to be fixed so that it doesn't need any support in order to print the objects.

    Submission required:

    a. Reply "Task 1, group member no. {Your group member no.}, {Your English Full Name}".
    b. One modified .gcode.3mf file
    c. One screen capture of the Sliced View showing support option enable but no support generated with correct orientation of the objects (Whole window screen capture in Preview session).
    d. Your printer setting should choose "X1 Carbon 0.4 nozzle", and build plate should choose "Smooth PEI".

  2. Sense of selecting support

    Decide which is the best printing orientation by adding the support.


    Original File:
    Task2.3mf

    Correct answer: (support should be less than 0.5g)

    Instruction:

    Submit a Screen capture of the whole window, and a .gcode.3mf file with sliced models in Bambu studio. Must use tree(auto) support mode, and need to select an extra option for the support (ONLY WITHIN THE Support-Support SECTION, do not modify any option in Support-Advanced), the best orientation should be less than 0.5g support. The surface of the bolt pattern is functional, so it must remain smooth, and must keep the original shape after printing.

    Submission required:

    a. Reply "Task 2, group member no. {Your group member no.}, {Your English Full Name}".
    b. One modified .gcode.3mf file
    c. One screen capture of the Sliced View showing support option enable and selected tree(auto) mode with option selected (Whole window screen capture in Preview session).
    d. Your printer setting should choose "X1 Carbon 0.4 nozzle", and build plate should choose "Smooth PEI".

  3. Spherical print

    Instruction:

    Find a 3d model on the internet, with spherical structure.
    Look at Variable Layer Height | Bambu Lab Wiki for reference, apply variable layer height to your 3d model, you can use either adaptive or smooth. Apply suitable support structure as well (depends on your 3d model).
    Screen capture the sliced view with color scheme as "Layer Height" just like the following picture.


    Submission required:

    a. Reply "Task 3, group member no. {Your group member no.}, {Your English Full Name}".
    b. One modified .gcode.3mf file
    c. One screen capture of the Sliced View showing the color scheme as "layer height", with suitable support structure apply to the sliced 3d model (Whole window screen capture in Preview session).
    d. Your printer setting should choose "X1 Carbon 0.4 nozzle", and build plate should choose "Smooth PEI".

  4. Hole Tightness
    signal-2025-02-02-220739_003.mp4

    You need to print a similar model at the end of this task, and submit it in the Fab Lab system, and also your printed product in the V104 collection box. 

    Provided Material:

    Please choose the corresponding base according to your number of group members (At least 2 ppl in a group)
    Task4Base_4ppl.stpTask4Base_3ppl.stpTask4Base_2ppl.stp

    Instruction:

    Printing file parameter limitation:

    Number of group members4 ppl3ppl2ppl
    Model Total Printing Time
    (including preparation time)    		<1 hr<50 mins<40 mins
    Filament Estimation (grams)<18<12<8

    If you submit a print file that is out of these range, I will request for your modification. 

    You should use the Task4Base_{}ppl.stp as the base, and draw the other missing parts by yourself.

    You need to add hole for different layer:

    First layer (the top prism in the sample):

    The cylinder for first layer have radius of 1.5mm, as the prism should tightly fit to the cylinder, the hole should have 0.1mm extra in radius, which means the hole should have 1.6mm in radius, with 5mm as height.


    Actually it do not needs to be a triangular prism, as long as it have the hole in correct size. This layer is just for preventing the layers fall off. However, please be remind that a complex shape will increase printing time, and use more filament. 

    Second layer to fifth layer:

    Number of group members4 ppl3ppl2ppl
    Number of layers432
    Height per each layer piece10 mm
    Total cylinder height40mm30mm20mm

    The cylinder have radius of 2mm, as the polygon prisms should have a little bit loose in order to make it spinnable, the hole should have 0.2mm extra in radius, which means the hole should have 2.2mm in radius.

    The height for each layer is 10mm.


    Cylinder height for 4 ppl is 10 * 4 = 40mm. (So 3ppl is 30mm... and so on)


    For Each layer:

    Can be any sided polygonal prism, it is formed by a polygonal prism minus a smaller polygonal prism so that it is hollow, and union with a tube with the 2.2mm radius hole.
    The height must be 10mm.
    Sample for forth layer:

    You also need to add 3D letter on top of the side surface.

    The letter should align with the side surface, and must be consist of 5mm in height and 1mm in width in order for it to print clearly.


    The sliced view must look like this in order for the extruded letter to print correctly.

    Required letter for layer except bottom layer:

    First letter is your group member number submitted in the google sheet. If you are the no.1 in group, you should have your first letter as "1". 
    Starting from second letter, it would be your English Full Name initial. e.g. LCM stand for Lau Chiu Ming, and he is the no. 1 in group.


    Bottom layer:

    Include your subject code (e.g. SD1105 should be "1105") at first surface (or first two surface depends on if there's not enough space).
    Then the next surface should be your group number. E.g. group 1 should be "G1", group 2 should be "G2" and so on.
    The next is the same as the other layer, your group member number and your English Full Name initial.
    (For group of 2 ppl, the surface of each side faces may only enough for single letter, you can spread the subject code on the bottom layer, and the group number on the layer above. i.e. second layer: "G" "2" "1" "L" "C" "M", third layer: "1" "1" "0" "5" "2" "H" "C" "F")


    Each group should submit 1 set (assembled), each person should make 1 layer piece.

    Extra (for student who like to challenge):

    You can draw star shape instead of regular polygon, but keep in mind that the extruded letter should not be floating (no empty space between the letter and the intersection area of two surface).


    Submission required:

    a. Reply "Task 4, group member no. 1, {English Full Name}, group member no. 2, {English Full Name}, group member no. 3, {English Full Name}, group member no. 4, {English Full Name}" *according to how many group members you have
    b. Submit the print job for only ONCE per each group. 
    c. Your printer setting should choose "X1 Carbon 0.4 nozzle", and build plate should choose "Smooth PEI".


    Fill in all the required detail. Your modified .gcode.3mf file should have all the parts in one plate, and set the print sequence to "By object", enable "tree(auto)" support.
    Make sure the filament amount and printing time is within the limitation mentioned above.



    d. (In Print job form) One screen capture of the Sliced View WITH Total printing time and Model printing time shown (Whole window screen capture in Preview session). If there's support, capture should show support section.
    e. (In V104) After admin approve your print job, you can then go to V104 to send your print job to the available printers according to your group assigned timeslot.  Assemble your print, and then put it into the corresponding submission box right next to the printer according to your subject code. Admin will add credits to your group account before your assigned printing time slot.
    f. (Extra requirement for SD1105 students) You should submit a powerpoint in blackboard, with 3 or more than 3 captures capturing different angle of your layer piece. 

    Printing time slot, also the deadline for Task 1-4 submission
    Group No. 1 - 1213 - 2425 - 36
    SD4410Feb 10-23 26-
    SD5978Feb 10-23  26--
    SD5512Feb 13- 26  28--
    SD1105Feb 24- Mar  9  12



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