Surface Check in Rhino

To create a valid digital 3D model that can be printed, it needs to be checked for inverted surface normals. In
order for the 3D print software to understand which parts are solid and which are void, all surfaces of the model
need to be oriented in the same direction with the positive side facing outwards.

The easiest way to check surface direction in Rhino is through changing the shading settings:
- type 'AdvancedDisplay';
- open the 'Advanced Settings' and click on 'Shaded';
- at the dropdown box for 'Backface settings', choose 'Single Color for all backfaces';
- at the colour field, choose a bright colour such as red, click ok;
- inspect your model in shaded mode, make sure there are no layers with a red colour;
- select some or all red surfaces and use the 'Analyze Direction' tool and 'Flip' + enter to switch the normals.

Alternatively attempt to join as many surfaces as possible. Ideally all surfaces which constitute one single solid
object should be joined into one polysurface.

Exporting as STL file

Select the geometry and use File / Export Selection and choose the extension Stereolithography (*.STL).

A dialogue box appears indicating that the NURBS geometry will be converted to a polygonal mesh (necessary
for the STL format). The number required indicates the distance between the original and the triangulated
surface. Choose '0.001' to generate a highly detailed mesh, with a relatively large file size. If the process takes
too long, the file size becomes too big (>100 Mb) or the program crashes, try again with '0.01' or '0.1' as setting.

At the next option box choose 'binary', 'export open objects' and click OK.

Final Check and Saving in ZPrint

To finish the digital process before sending the file to print, the 3D model needs to be inspected and saved in the
ZPrint software.

Install the ZPrint software and choose the Z310 as printer type.
Open your STL file and visually check for bad surfaces shown in dark grey.
Dark grey spots indicate areas that will not be printed and are possibly generating errors such as holes or extra
geometries in neighbouring parts of the model. The problem is usually a missing surface (hole in the model) or a
surface with a flipped surface normal. The solution is to go back to the original model in Rhino and adjust the
problem there.
Surfaces that appear as flickering surfaces when rotating the view indicate two surfaces at the same place. Go
back to the model in Rhino and delete one of them.
A final check can be done by simulating the actual printing process.
Use '3D View / Switch Layer View / 3D View' and press shift+A and shift+Z to scan up and down through the
layers of your model to check for errors such as rectangular shaped holes in the model or unintended lines
running through.
When the model seems fine it is possible to calculate the cost using the current prices for consumables at the
AA's Digital Prototyping Lab.
- use File / 3D Print Setup... and set up ZP131 as powder type;
- use File / Print Time Estimator to calculate the estimated use of powder and binder;
- the current pricing is 0.15 GBP per ml binder, 0.88 GBP per cubic inch powder;
- for infiltration with cyanoacrylate (superglue) add 5.00 / 7.50 / 10.00 pounds for small / medium / large models.
To submit the model for printing, save the file in the *.zbd format and deliver it at the Digital Prototyping Lab
between 10.00 am and 1.00 pm on weekdays.

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(c) February 2009