The post 10 Printability Tips for Your 3D Model appeared first on Shapeways Blog.

1. Choose Straightforward Software

There are many different versions of free 3D modeling software available. Depending on project requirements and level of experience, designers often look into and and end up using a variety of different 3D modeling programs; for instance, CAD software like Tinkercad or SketchUp is great for users on every level and easy to use for most design projects, while Blender is a powerful tool and a mesh modeler, offering a variety of add-on tools for intensive customization. 

Other software involves more of a learning curve but is worth it in the end due to the ability to create much more complex 3D models. No matter what type of 3D modeling software is used, it is key to be apprised of specific guidelines; for instance some programs may offer automatic features, while others are manually set.

2. Set Your 3D Model up for Success from the Start

While the modeling process may often be fun and exciting, efficiency is critical for optimizing any product for successful 3D printing–whether the intention is to make high-performing parts for sleek drones, an architectural model for an important client meeting, or a prototype that could serve as one of a hundred iterations during product development. 

Once a customer uploads a 3D model to Shapeways, it is automatically checked for common issues; however, the modeling process should be used to perfect a design as much as possible before analysis, avoiding thickness or strength issues, and compensating for any possible areas of vulnerability ahead of time. Turn in a model that is above the basic requirements for printability, rather than picking up the slack after analysis.  

3. Configure the Basic Layout for Good Adhesion and Support

Creating a successful design for a 3D printable shape means planning for the printing process in terms of successful adhesion. Although layer adhesion can become tricky due to issues with temperature, cooling, or layer height, mistakes in modeling could also be the culprit. Avoid problems ahead of time by designing a 3D model that will stick to the print bed easily, creating a flat surface to build upon layer by layer.

Plan for overhangs too–and try to avoid steep ones–as well as adding support structures if necessary. While this is not required for powder-based technologies like Selective Laser Sintering or Multi Jet Fusion, other 3D printing methods like Stereolithography (SLA) rely on supports to maintain the integrity of the part during manufacturing. 

4. Design 3D Printable Shapes that Can Support Their Own Weight

Rather than facing disappointment after the fact, preliminary considerations for size and weight of the 3D model are imperative to success. If not scaled properly, 3D prints may be surprisingly small–but worse, if they are too heavy it may be impossible to position them upright as intended or they could fail completely during production. 

Refer to bounding box information to avoid these problems; for example, in 3D printing with Nylon 12 [Versatile Plastic], one of the most popular materials at Shapeways, these details are readily available. Models should be scaled within the listed dimensions of the bounding box, a 3D imaginary outline of a box enclosing the smallest area occupied by a 3D model. 

Note: printing orientation will be restricted if the 3D model size is close to the maximum dimensions.

Following is an example of the bounding box dimensions for Nylon 12 [Versatile Plastic]:

• Bounding Box Max
  • 650 × 350 × 550 mm (Natural White)
  • 180 × 230 × 320 mm (Natural Black)
  • 200 × 150 × 150 mm (Processed & Premium)
  • 345 × 375 × 440 mm (Smooth)
  • [Parts over 330 mm long in any direction may have a visible line due to our dual laser printer]
• Bounding Box Min
  • X + Y + Z ≥ 7.5 mm (Natural)
  • X + Y + Z ≥ 25.0 mm and axes must be ≥ 2.5 mm (Processed & Premium)
  • 10 x 10 x 10 mm (Smooth)

5. Choose Suitable Materials and Technology for Your 3D Model

Along with preparing for issues with scaling and size, researching materials and technology ahead of time will also save a lot of time and headaches, especially when designers are working with more complicated geometries. Again, design guidelines should be considered, but stretching the limits of a particular 3D printing material or technology can present obvious problems; for example, a part cast in metal with intricate engraving may be rejected for use with a material like Steel, due to a weak geometry or other specific details. 

Research materials to match models with project requirements whether using metal for fine jewelry or perhaps a more flexible material 3D printed with Nylon 12 [Versatile Plastic] using SLS 3D printing technology for interlocking parts.

6. Pay Attention to All Guidelines

With the inception of a design, or a project involving comprehensive product development, all guidelines should be considered, no matter what level of expertise the designer has achieved. Guidelines begin with software, and should be in line with project requirements. This is why so many designers are proficient in numerous types of 3D modeling software programs, and may find one appealing over the other depending on what they are working on at the time. 

Considering design guidelines is critical while creating a model, as well as moving forward to choose the proper materials and technology for 3D printing. This is why Shapeways offers design guidelines for every material description, whether you are wondering about designing for materials that rely on Multi Jet Fusion technology or Selective Laser Melting. While many designers do need different features such as flexibility or hardness, other factors come into play such as the ability to offer desired textures that may work as well for materials with rougher surface finishes.

7. Design for Suitable Wall and Wire Thickness

Think of walls as the flat surfaces in a model and wires as strands. Issues with wall thickness are extremely common, and usually caused by areas of the 3D model that are too thin, with the potential to break during 3D printing. This can be compensated for in automated slicing programs, but in many cases designers may choose to use customized settings. A common example would be a structure with walls that suddenly become too thin in curved areas, leaving the 3D model open to vulnerability. If the walls are too thick, however, designers and engineers may find that they are using too much material and opening up the potential for cracking. Upon printability analysis at Shapeways, a 3D model must have walls and wires that are sufficient to survive 3D printing, post-processing, and packing and delivery.

8. Create a Compatible File  

Many models emerge from 2D drawings which are then extruded into 3D, or they may be built from basic to more complex 3D structures using a variety of different software programs. Compatible files include the following:

• File types: DAE, OBJ, STL, X3D, X3DB, X3DV, WRL, 3MF, STP, STEP
• Full-color printing: OBJ, MTL, DAE, WRL, X3D, X3DB, X3DV
• Maximum file size for all types: 64 MB and/or 1 million Polygons

9. Prepare for Prototyping, Testing, Iterating

Many designers and engineers rely on Shapeways to help them perfect prototypes and parts during the product development process. This means experimenting with numerous materials and technology, along with editing them along the way for form and fit; in fact, some Shapeways customers may 3D print well over a hundred iterations before they take a product to market. With rapid prototyping, the process is fast–and results in a high-performing, tested product that ultimately enhances the consumer experience. 

Shapeways customers may also work with the User Application team in testing parts for the proper materials, sometimes requesting the PITA (Print It Anyway) method. Although sometimes risky and often working outside material guidelines, PITA allows designers to see what might happen–but without any guarantees! 

10. Prepare for Cost, Printability Analysis, and Customized Feedback 

Once a 3D model is ready for 3D printing, the Shapeways customer uploads their design and receives an instant quote. The model undergoes file analysis to ensure its printability. Sometimes things do not go exactly as planned during the modeling process, despite all efforts, and a design may require customized feedback or more complex file fixing via the User Application team at Shapeways. While they do everything possible to regenerate files which may be problematic, for more challenging issues the UA Team may need to work directly with the customer regarding necessary changes. 

Download our Infographic, 10 Printability Tips for Your 3D Model.

About Shapeways

Working with Shapeways ensures your part will be printed with the highest quality materials in the most efficient manner possible.

Enjoy the benefits of advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post Ten Ways to Ensure Printability of Your 3D Model appeared first on Shapeways Blog.

Printability Checking

Although companies utilizing AM can follow Design For Printability (DFP) standards and practices to help bolster success rates of printing functional 3D parts and products, they can still come out of the process with faults and weaknesses. Printability checking is a process that involves the testing and assessment of a digital file containing any type of 3D model design. This checking process is set up to ensure that 3D model designs are ready and able to be printed.

Shapeways 3D Printing Checklist

Shapeways provides you with a go-to guide for analyzing your digital files to ensure your 3D models are optimally designed for successful printability and manufacturing. Once your model is uploaded, Shapeways will begin to run through a series of auto checks. Checks include whether your uploaded file is in a readable format, checking polygon count, bounding box requirements for your model, and model integrity. To find out more about these checks in detail, you can view this printability checklist.

In addition to these checks, Shapeways provides an informative materials overview on 90+ 3D printing materials that could be used to bring your 3D model to life. To ensure a successful print, take advantage of these resources to help you prepare your 3D file to match printing specifications.

For example, Shapeways offers material information and design guidelines for printing in Nylon 12 plastic. This material is otherwise known as Versatile Plastic, Polyamide, PA 2200, and PA12. Nylon plastic is highly durable and is suited for a range of applications including mechanical parts, tech accessories, prosthetics, fixtures, prototypes and more. With Shapeways, your models can be 3D printed in large quantities using an industrial Selective Laser Sintering (SLS) printer. Following printing, models will go through an intense post-production process that includes extraction from a powder bed, cleaning, polishing, and if desired, a color and/or finish for the most polished look.

Nylon 12 is a white powder and color can be added with the application of dye in a hot color bath. Shapeways offers a range of colors for dyeing your model, including pink, orange, red, green, yellow, purple, blue, and black. Nylon 12 is a porous material and dye can penetrate its surface up to 0.5mm. Concerning material finishes available for this material, you have the option of choosing between Natural, Processed, or Premium. The premium finish by Shapeways is the smoothest finish available and comes with good scratch resistance.

Shapeways guidelines offer practical advice on how to design your Nylon 12 model concerning the appropriate wall thickness and escape hole size. Escape holes are needed to allow emptying of the support material from the model. Small cavities and inadequate geometry can make it difficult to remove. The appropriate escape hole size is essential to factor into pre-print checks. Shapeways recommends two escape holes of adequate size at either end of your Nylon 12 model for optimal removal of support material.

Shapeways also guides checking the balance and weight of product designs, providing the right support for more vulnerable structures. This helps to ensure products can withstand their own weight and stay resilient against collapse or deformation. Other pre-print checks that Shapeways performs include model scale adjustment, smoothing modifier compensation, checking for adequate clearance between parts to avoid potential fusion, and more.

During the checking process, you can click on “View 3D Tools” from within any Material view of your model, and Shapeways will display the results of these auto-checks for you to view. You will also have the option to “View Issues” if your uploaded model failed any checks. This information will enable you to troubleshoot and optimize your model design for successful printing.

Secondary Checks

Once your model has passed the first round of checks, you might think you’re ready for a successful print. However, software and digital technology can only go so far in making the necessary observations to ensure model integrity. Shapeways undertakes secondary manual checks with human inspection to provide an extra eye for issues that automatic computer checks may not pick up on. Whatever issues Shapeways engineers discover, they will send you an email with suggestions for how you could optimize your model for success.

Shapeways engineers will be working with you to ensure that your product is suitable for commercial production, and this means printing at an industrial scale with a high volume if required. Discrepancies may arise from the printing and finishing process, ranging from the way that models are packed and orientated within the printing machine, to how models interact with each other in the polisher. Whatever material you decide to use and whatever level of experience you have with additive manufacturing, Shapeways will guide you toward printing viable parts and products for your business.

If you have more questions concerning the auto-checking process or want to get in touch to discuss your additive manufacturing needs, the Shapeways team is here for you.

The post Make Your 3D Model Design Print Ready appeared first on Shapeways Blog.

Your Pre-Print Checklist

Use this checklist as a tool to prepare your model for 3D printing and put your mind at ease.

1. Design for your material
   Each checklist item applies differently to each material. The material design guidelines are your primary resource for designing 3D printable products.
2. Check wall & wire thickness
   Every part of your model must be thick enough to be 3D printed, survive post-production, and be safely packed and shipped. Learn more about printing strong and sturdy models.
3. Create escape holes for hollow models
   Excess material, such as nylon powder for our Strong & Flexible Plastic, must be able to escape from hollow models. The material guidelines describe the required escape holes for each material—when in doubt, lean towards more and/or larger escape holes.
4. Check balance and weight
   A model must be designed for real-world physics. Be sure to account for weight distribution, and the model’s ability to support its own weight.
5. Protect vulnerable areas
   Outstretched elements, such as wires or appendages on figurines, could snap off during or after printing if the joint is not strong enough. Add extra support to these areas to help prevent breakages in the production process.
6. Adjust model scale
   You likely had to specify the scale of your model (meters, millimeters, inches) before uploading your model, but it’s always smart to check those dimensions one more time to make sure they meet your expectations before you order.
7. Ensure clearance for moving parts
   Moving parts need clearance between one another to function properly. This is especially important when designing for Strong & Flexible Plastic—without enough clearance, the parts will fuse together during the print process.  The Material Guidelines have specific information on clearance requirements for the material you plan to use.
8. Make sure details are large enough
   Embossed and engraved details have minimum requirements to ensure they print clearly. Those specifics are listed in the Material Guidelines.
9. Compensate for smoothing modifiers (if applicable)
   3D printers do not read smoothing modifiers, so instead, sub-divide your mesh to replicate the effect of smoothing.
10. Optimize your colors
    If designing for Full Color Sandstone, check that your Shapeways render matches your expectations. CMYK is best at producing bright, well defined colors.
11. Don’t forget to read our content policy
    We encourage the endless possibilities of your creativity but ask that your designs respect our content policy.

Once your model checks out, you’re ready to bring your design to life!

The post 11 Things to Check Before Sending Your 3D Model for Printing appeared first on Shapeways Blog.

Auto-Checks

Shapeways provides guidelines and auto-checks to ensure that your uploaded models are printable in each material. For example, models created at Shapeways in Versatile Plastic are 3D printed in a durable nylon material in large batches using an industrial Selective Laser Sintering (SLS) printer. Versatile plastic has an intense post production process that includes extraction from powder and other models, cleaning and polishing, and even dying in different colors. Thin or narrow models can be easily broken or separated during post production. You can refer to the Design Guidelines for Versatile Plastic to determine how thin you can make the wires in your model. Here’s what those guidelines say about two success parameters, wall thickness and wire thickness:

In the guidelines above, “walls” are flat surfaces in your model and “wires” are more like strands. Notice that the recommended minimum for supported wires (those that connect to your model nearby on both ends) is 0.8mm. Processed models are put through a polisher, and Premium models are polished even more, so their minimum is higher: 0.9mm. Finally, the minimum for unsupported wires (which don’t inherit as much stability from the rest of the model) is even larger, at 1.0mm.

After you upload your model, Shapeways will perform a series of auto-checks to measure the thickness of walls and wires, among other things. If you click on “View 3D Tools” (or “View Issues”, if your uploaded model failed any checks) from within any Material view of your model, Shapeways will show you the results of these auto-checks. Here’s what that looked like for an early demo version of our Deltoidal Icositetrahedron model:

Although this model passed the Wire Thickness check, it fails the Wall Thickness check. The flattened nodes at the vertices, and even some of the long wires, are considered “walls” here, and they aren’t thick enough to get over the 0.7mm minimum thickness requirement.

Checking and Fixing Thickness Issues

You can check the thickness of your model in whatever design software you used to create it. Or, another easy way to determine the minimum thicknesses of your design is to import your model to Meshmixer and use the Thickness tool in the Analysis menu. You can then use Meshmixer to make your design thicker, if needed, by selecting the model and then using Edit > Extrude (using the Normal Direction) or Edit > Offset to expand your model outwards or inwards. To thicken only selected parts of your model, you can take the more targeted approach described in our previous article Tutorial Tuesday 50: Using Meshmixer to Make 3D Models Thick Enough to 3D Print.

Prototyping

Even if your model passes printability checks, it’s worth printing a demo model to make sure that everything is okay. Sometimes, weak geometry can’t be determined until a model is actually printed and in your hand. Even if the print comes out successfully, it may be too delicate to hold up to its intended use. After our example model failed printability checks, we redesigned it so that it would just barely pass the checks and print successfully. It was a beautiful model, but it wasn’t long before it broke and warped:

I guess the moral of this story is: For best results, don’t try to just *barely* meet the print requirements; rather, make sure you are safely above them.

It’s worth pointing out that the size of the model itself matters as much as the thickness; the two go hand-in-hand. In the image above, the smaller model has the same wire thickness but is actually quite sturdy. The larger model is weaker because the wires are longer and have to hold up to greater stress when the model is handled. This means when prototyping, you can’t always get an accurate impression of the strength of your model by shrinking your model down, or designing a smaller version. Think about it this way: a wireframe model the size of your head will need a larger wire thickness than a model the size of your pinky!

In the end, we decided to thicken up our Deltoidal Icositetrahedron model significantly. The final version looks like the blue model on the right in the image below. It’s much stronger, and the cost of printing was only increased by a few dollars.

Human Checks

Sometimes models pass the online checks at Shapeways, but then fail a secondary check when they are actually ordered for printing. That’s because actual human beings at Shapeways check your model manually while they prepare it for 3D printing. They check for things that require a lot more expertise than the automatic computer checks, like how large your model is, how the different pieces of it fit together, and a lot of things that you or I might not think of. If they notice a problem then they will email you, and try to suggest ways that you can modify your model to increase the likelihood that it will print successfully.

Keep in mind that the printing engineers at Shapeways want to make sure that your model can print correctly not just once, but over and over. A model that passes the auto-checks and listed guidelines may have weak areas that may not break on the first print, but are likely to break the second or third time. This means that even if your print comes out well in a “Print it Anyway” situation, it still might not be stable enough to offer as an item in the Marketplace. Variations in print stability can arise from small differences in the printing and finishing process, like how the models are packed or oriented in the machines, or how it interacts with other models in the polisher.

As an example, consider our Hoop Knot Earring:

According to the Design Guidelines for Silver, we needed to make the wires at least 1mm in diameter. However, it’s best to exceed that significantly; consider that Silver models from Shapeways are 3D printed in wax, cast in Silver using lost wax casting, and then finished and polished. All of those procedures could damage a model with weak geometry. When we uploaded our Hoop Knot Earring for printing, it passed all of the auto-checks. But when we tried to order a print of it in Silver, the kind and knowledgeable human engineers at Shapeways said that the geometry of our model was too weak. They suggested adding connectors and even emailed me this helpful illustration:

Of course, in this case I couldn’t add connectors since that would have ruined the design; instead I had to make the wires thicker to give the model more stability. That resulted in the print shown below on the right. Later I tried to make a larger version, shown on the left, but an interesting thing happened; since the wires had to travel further, they were more prone to bending and becoming misshapen when I opened and closed the earring. Even though the larger model had thicker wires, in the end it didn’t work as well as a functional item.

In the end, you’ll have to use a combination of your own design analysis, automatic printability checks, manual printability checks, and physical prototyping to successfully print delicate or geometrically complex models. If you’ve got your own tips and tricks that help you through this process, let us know!

The post 3D Printing Strong and Sturdy Models appeared first on Shapeways Blog.

Thin Walls

This error will most frequently limit the types of materials your product is printable in. Because our plastics are more forgiving, a model may pass printability in those materials but not in any metals. Whether it’s unprintable in all or only some materials, here’s a helpful resource for breaking down that wall that’s keeping your model from being printable (pun intended).

Floating Shells

Loose shells are pieces of your model that are separate or unconnected from the base portion of the model. In some cases, this may be intentional (like this) because you want the parts separated. If not, try our part count visualization tool to help you identify unconnected parts and catch problems where you had intended to print a single, connected model.

Non-manifold Edges

This means that your model has failed print checks with a “non-manifold” or “mixed normals” error. These can be triggered by a number of things so head on over to this page to find out how you can fix the model.

Now that you’re ready to make it printable, upload your latest model here.

PRINT YOUR DESIGN NOW

The post The Top 3 Reasons Models Aren’t Printable and How To Fix Them appeared first on Shapeways Blog.