Contents

Part 1: What Is 3D Printing?

1 The Goal of 3D Printing

For Businesses

Rapid Prototyping

Manufacturing

For the Hobbyist

The Maker Culture

A Tool in Your Arsenal

Common Misconceptions

Materials You Can Use

A Replicator in Every Home

The Time It Takes

What It Can Print

Finishing

2 The History and Future of 3D Printing

3D Printing Is Born

Hull’s and 3D Systems’ Contributions

The Invention of FDM Printing

The Development of Other 3D Printing Processes

The RepRap Project

Initial Intentions

The Importance of Open Source

Rapid Development

Refinement, Availability, and Your Wallet

Maturation of Technology

Availability of Parts

The Race to the Lowest Price

3 Manufacturing with 3D Printers and CNC Mills

The Simple Principle Behind 3D Printing

Slicing and Creating Layers for Your Model

Extruding Filament

CNC Milling and How It Works

Subtracting with CAM Software

Milling the Material

Pros and Cons of 3D Printers vs. CNC Mills

Cost

Part Geometry

Material Matters

Surface Finish

Using the Right Tool for the Job

4 Types of 3D Printers

Stereolithography

Digital Light Processing

Powder Bed Printing

MultiJet Printing

Selective Laser Sintering

Fused Filament Fabrication

Part 2: All About the Hardware

5 The Frame

Cartesian Layouts

Ways Cartesian 3D Printers Are Constructed

Cartesian Layout Considerations

The Importance of Frame Construction

Rigidity and How It Affects Quality and Reliability

What Makes a Good Frame

Size Matters

6 Movement Components

Components for Smooth Linear Motion

Rails and Smooth Rods

Bearings

Stepper Motors

Belts and Pulleys

Weight-Bearing Components for Converting Motion

Lead Screws

Threaded Rods

Attachment and Connection Components

Couplers

Nuts

7 The Extruder

What Is Extrusion?

The Cold End

Direct Feed

Bowden

Direct Drive vs. Geared

The Hot End

Thermistor

Heating Element

Physical Design and Makeup

The Nozzle

Print Fans

Using Multiple Extruders

For Support Material

For Filaments with Different Properties

8 The Build Platform

Build Platform Materials

Heated Beds

Heated Build Chambers and Enclosures

Surface Treatments

Painter’s Tape

White Glue

Polyimide Film

PET Film

ABS Juice

Hairspray

9 Control Components

End Stops

Mechanical End Stops

Optical End Stops

Other Kinds of End Stops

Control Boards

Arduinos and Proprietary Control Boards

Changing or Upgrading Control Boards

SD Card Support

Using an SD Card

Benefits of SD Cards

LCD Controllers

10 Choosing a 3D Printer

Open or Closed?

What Does It Mean to Be Open Source?

Why It Might Matter to You

Assembled, Kit, or DIY?

Assembled 3D Printers

3D Printer Kits

Building a DIY 3D Printer

Determining Your Needs

Print Volume

Print Resolution

Filament

Prices

Printers with Unusual Designs

Part 3: Setting Up and Printing

11 Software Setup and Printer Control

Firmware Explained

Choosing Host Software

Choosing Slicing Software

Connecting to Your Printer

Controlling Your Printer

G-Code

Printing with G-Code

Performing Functions Manually with G-Code

12 Leveling the Bed and Adjusting the Z Height

Why Does Your Bed Need to Be Leveled?

Manual Leveling

Auto-Leveling

How to Adjust Your Z Height

Setting the Z Height Manually or Automatically

Knowing the “Correct” Z Height

13 Slicing and Printing

Configuring Your Slicing Software

Slicer Settings Explained

Printer Settings

Filament Settings

Print Settings

Preparing for and Running a Print

Host Preparation

Running a Print

14 Troubleshooting Your Prints

What’s the Problem?

Extrusion Problems

Overextrusion

Underextrusion

Jamming

Poor Dimensional Accuracy

Temperature Problems

Hot End Is Too Hot

Hot End Is Too Cold

Cracking of Part Due to Cooling

Discoloration of Filament Due to Heat

Adhesion Problems

Warping

Part Comes Loose

Part Breaks During Removal

Other Printer Problems

Blobs

Stringing

Drooping

Ghosting

Project 1: Carabiner

Preheat the Extruder and Heated Bed

Load the .STL File

Slice the Model

Load the Filament

Extrude Some Filament

Start the Print

Watch the First Layer

Let the Part Cool

Remove the Part

Project 2: Pencil Holder

Load the .STL File and Resize the Model, If Necessary

Preheat the Extruder and Heated Bed, and Load the Filament

Modify the Slicer Settings to Make the Model a Cup

Slice the Model

Start the Print

Watch the First Layer

Remove the Part

Project 3: Robot

Load the .STL File

Preheat the Extruder and Heated Bed, and Load the Filament

Modify the Slicer Settings for Supports

Slice the Model

Start the Print

Watch the First Layer

Remove the Part

Remove the Supports

Project 4: Storage Box with Drawers

Open Your Host Software and Load the Storage Body .STL File

Slice the Storage Body

Print the Storage Body

Load the Drawer .STL File and Slice It

Print the Drawer

Print Two More Drawers

Part 4: 3D Modeling

15 Introduction to CAD

Why CAD Came About

Artistic 3D Modeling vs. CAD Software

CAD Software Options

An Overview of Common CAD Program Commands

Modeling Commands

Sketching Commands

The Importance of Units and Scale

Choosing Units

Scaling in CAD

16 Modeling Techniques and Best Practices

Premodeling

Tricks of the Trade

Assemblies and Fitting Parts

Planning an Assembly

Fitting Parts Together

Modeling Successful 3D Parts

Exporting Files

17 Practical Reverse Engineering

Why You Should Learn Basic Reverse Engineering

Finding the Right Measurement Tools

Digital Calipers: A Necessary Tool

3D Scanners: Not All They’re Cracked Up to Be

Measuring the Part

Inferences

Geometric

Design Intention

Proportions

Modeling the Part

Project 5: Monogrammed Coaster

Open Your CAD Program and Create a New Part

Extrude a Circle

Fillet the Top Edge

Cut the Letter

Export the .STL File and Print

Project 6: Custom Storage Drawer

Open Your CAD Program and Create a New Part

Extrude the Body of the Drawer

Cut an Opening for the Handle

Design the Compartments

Add a Rough Handle

Add Fillets to Handle

Add Ridges for Grip

Export the .STL File and Print

Project 7: Dust Collector

Create a New Part and Revolve the Body

Cut a Groove

Create the Second Part and Revolve the Body

Make the First Clip

Copy the Clip

Export the .STL Files and Print

Project 8: Reverse Engineering a Useful Part

Create a New Part and Extrude the Body

Fillet the Edges

Shell the Cover

Cut One Socket Opening

Mirror the Socket Opening

Create the Screw Hole Support

Add the Screw Hole

Export the .STL File and Print

Part 5: Advanced Usage and Techniques

18 Printing with Other Materials

What Materials Are Available?

Nylon

Polycarbonate

Flexible Filament

Wood Filament

PET

HIPS

Hardware Needed

All-Metal Hot Ends

Print Fans

Heated Beds and Bed Materials

Printing Techniques

Temperature

Speed

Cooling

Layer Thickness

19 Modifying Your Printer

Adding a Fan Shroud

Adding a Heated Bed

Bed Size

Control Board

Power Supply

Switching to All-Metal Hot Ends

Installing Multiple Extruders

Extending Axes

Converting to a PCB Mill

Alterations for Laser Cutting

Finding Parts

Appendixes

A Glossary

B Resources

C Further Uses of 3D Printing

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