RAPID PROTOTYPING

LAB MANUAL

Prepared by
JAYANTH .I
 List of Exercises

1. 3D printing of Shaft Support

2. 3D printing of Spur Gear

3. 3D printing of Helical Gear

4. 3D printing of lock nut

5. 3D printing of ratchet

6. 3D printing of Cam

7. 3D printing of sprocket gear with holes

8. 3D printing of Stub axle

9. 3D printing of M12 nut

10.3D printing of ball fidget

***
Expt. No: 01 Date:

3D PRINTING OF SHAFT SUPPORT

AIM:
To fabricate a Shaft support with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig (a): Shat Support isometric drawing

PREPARING A PART FILE FOR SUBMISSION:

1. Open the Shaft support part file in Solid Works.
2. Open the “Save As” menu dialog.
i) Set the file as a STL file.
ii) Click on “Options...”
iii) Set “Deviation” to the lowest value available
iv) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
v) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
1) Trim unnecessary flanges or wall.
2) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
3) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
1) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
2) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
3) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 02 Date:

3D PRINTING OF SPUR GEAR

AIM:
To fabricate a Spur gear with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Spur gear diagram

PREPARING A PART FILE FOR SUBMISSION:

3. Open the Spur Gear part file in Solid Works.
4. Open the “Save As” menu dialog.
vi) Set the file as a STL file.
vii) Click on “Options...”
viii) Set “Deviation” to the lowest value available
ix) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
x) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
4) Trim unnecessary flanges or wall.
5) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
6) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
4) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
5) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
6) Negligence on the above points can cause Personal Injury and Machine Damage.

RESULT:
Expt. No: 03 Date:

3D PRINTING OF HELICAL GEAR

AIM:
To fabricate a Helical gear with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Helical gear diagram

PREPARING A PART FILE FOR SUBMISSION:

5. Open the Helical Gear part file in Solid Works.
6. Open the “Save As” menu dialog.
xi) Set the file as a STL file.
xii) Click on “Options...”
xiii) Set “Deviation” to the lowest value available
xiv) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xv) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
7) Trim unnecessary flanges or wall.
8) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
 c) Produce the part as an assembly of smaller parts
9) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
7) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
8) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
9) Negligence on the above points can cause Personal Injury and Machine Damage.

RESULT:
Expt. No: 04 Date:

3D PRINTING OF LOCK NUT

AIM:
To fabricate a Lock nut with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Lock nut diagram

PREPARING A PART FILE FOR SUBMISSION:

7. Open the Lock nut part file in Solid Works.
8. Open the “Save As” menu dialog.
xvi) Set the file as a STL file.
xvii) Click on “Options...”
xviii) Set “Deviation” to the lowest value available
xix) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xx) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
10) Trim unnecessary flanges or wall.
11) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
 b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
12) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
10) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
11) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
12) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 05 Date:

3D PRINTING OF RATCHET WHEEL

AIM:
To fabricate a Ratchet wheel with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Ratchet wheel diagram

PREPARING A PART FILE FOR SUBMISSION:

9. Open the Ratchet wheel part file in Solid Works.
10. Open the “Save As” menu dialog.
xxi) Set the file as a STL file.
xxii) Click on “Options...”
xxiii) Set “Deviation” to the lowest value available
xxiv) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xxv) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
13) Trim unnecessary flanges or wall.
14) Minimize support material used:
 a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
15) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
13) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
14) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
15) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 06 Date:

3D PRINTING OF CAM
AIM:
To fabricate a Cam with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Cam profile diagram

PREPARING A PART FILE FOR SUBMISSION:

11. Open the Cam part file in Solid Works.
12. Open the “Save As” menu dialog.
xxvi) Set the file as a STL file.
xxvii) Click on “Options...”
xxviii) Set “Deviation” to the lowest value available
xxix) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xxx) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
16) Trim unnecessary flanges or wall.
17) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
 c) Produce the part as an assembly of smaller parts
18) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
16) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
17) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
18) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 07 Date:

3D PRINTING OF SPROCKET GEAR WITH HOLES

AIM:
To fabricate a Sprocket gear with holes with the give dimensions using uPrint SE Plus 3D
printer.

DRAWING:

Fig: Sprocket gear with holes diagram

PREPARING A PART FILE FOR SUBMISSION:

13. Open the Sprocket gear with holes part file in Solid Works.
14. Open the “Save As” menu dialog.
xxxi) Set the file as a STL file.
xxxii) Click on “Options...”
xxxiii) Set “Deviation” to the lowest value available
xxxiv) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xxxv) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
19) Trim unnecessary flanges or wall.
20) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
21) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
19) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
20) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
21) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 08 Date:

3D PRINTING OF STUB AXLE

AIM:
To fabricate a Stub axle with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Stub axle diagram

PREPARING A PART FILE FOR SUBMISSION:

15. Open the Stub axle part file in Solid Works.
16. Open the “Save As” menu dialog.
xxxvi) Set the file as a STL file.
xxxvii) Click on “Options...”
xxxviii) Set “Deviation” to the lowest value available
xxxix) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xl) Save the file

DESIGNING COST & TIME EFFICIENT PARTS:

22) Trim unnecessary flanges or wall.
23) Minimize support material used:
 a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
24) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
22) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
23) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
24) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 09 Date:

3D PRINTING OF M12 NUT

AIM:
To fabricate a M12 nut with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: M12 nut diagram

PREPARING A PART FILE FOR SUBMISSION:

17. Open the M12 nut part file in Solid Works.
18. Open the “Save As” menu dialog.
xli) Set the file as a STL file.
xlii) Click on “Options...”
xliii) Set “Deviation” to the lowest value available
xliv) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
xlv) Save the file

DESIGNING COST & TIME EFFICIENT PARTS:

25) Trim unnecessary flanges or wall.
26) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
27) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
25) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
26) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
27) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
Expt. No: 10 Date:

3D PRINTING OF BALL FIDGET

AIM:
To fabricate a Ball fidget with the give dimensions using uPrint SE Plus 3D printer.

DRAWING:

Fig: Ball Fidget diagram

PREPARING A PART FILE FOR SUBMISSION:

19. Open the Ball fidget part file in Solid Works.
20. Open the “Save As” menu dialog.
xlvi) Set the file as a STL file.
xlvii) Click on “Options...”
xlviii) Set “Deviation” to the lowest value available
xlix) Set “Angle” to 5 degrees (angles less than the value provided will produce larger -
STL files which may or may not be printable)
l) Save the file
DESIGNING COST & TIME EFFICIENT PARTS:
28) Trim unnecessary flanges or wall.
29) Minimize support material used:
a) Rotate the part so it sits as flat as possible on the table
b) Orient parts to eliminate gaps where support material is needed
c) Produce the part as an assembly of smaller parts
30) Specific to Object printers:
a) Select a glossy finish
b) Manually position multiple parts so that they overlap in the Z-axis.
PRECAUTIONS:
28) ABS: Recognized as toxic, based on the micro particles it’s emits during the print process.
29) Never
 Open Guard Doors While Machine is in Running
 Attempt to Bypass Guard Interlock, Safety Devices etc.
 Leave Machine Unattended While in Running
 Remove any Warning or Instruction Tags from Machine
 Operate any Equipment if unusual or Excessive Noise Vibration Occurs
 Remove Chips with the Hands
 Remove or load Work pieces While Machine is in Motion
 Leave Tools or other items on the Machine
 Touch Electrical Equipment When Hands are Wet.
30) Negligence on the above points can cause Personal Injury and Machine Damage.
RESULT:
 Viva Questions

1. Is there adifference between 3d Printing and Rapid prototyping?

2. What is the maximum size of the model that can be built in 3D printer?

3. What is the accuracy of the printing?

4. Which file formats are supported by 3D printer?

5. What is the material used for printing?

6. What is the minimum feature size that it can print properly?

7. What is the approximate printing time?

8. Can the models be joined?

9. What is the approximate cost of the printing a model?

10. Any care must be taken to preserve the 3D printed model?

11. How do we create models that we want to print in 3D?

12. Is there adifference between 3d Printing and Rapid prototyping?

13. Are 3d Printed Goods as Good as Those Manufactured “traditionally”?

14. Who Invented 3d Printing?

15. What types of 3d Printing Filaments are there?

16. How do I find out what Kinds of Filament my 3d Printer Supports?

17. Will Unsupported Filaments Ruin My 3d Printer?

18. What Software Do I Need For 3d Printing?

19. Can I Use A 2d Photo to Get A 3d Printing Model?

20. How Can I Reduce My 3d Printing Costs?

21. Which Materials Can’t Be 3d Printed?

***