In this webinar you will learn specific tips on how to obtain the best accuracy from 3D printing machines for your parts from 3D Systems, Objet, and Stratasys. Each manufacturer will give you 5 tips that will ensure accurate dimensions in your built parts. These tips will cover various design, material, and machine factors that can influence the final outcome of your part. All registrants will also receive free copies of these white papers following the webinar: - Top Five Reasons to Integrate 3D Printing into your Product Development Lifecycle - How 3D Printing works: The Vision, Innovation and Technologies Behind Inkjet 3D Printing

1. Tips for 3D
Printing Accuracy

2. Thank You to our Sponsors

3. Before We Start
This webinar will be available afterwards at
designworldonline.com & email
Q&A at the end of the presentation
Hashtag for this webinar: #DWwebinar

4. Moderator
Presenters
Leslie Langnau
Stacie Hoche
Ben Klein
Bonnie Meyer
Design World
3D Systems
Objet Ltd.
Stratasys

5. ProJet 6000 Accuracy
Stacie Hoche April 2012

6. ProJet™ 6000 Accuracy
Accurate
Precise
High
resolution
• Digital self calibration
• Print accuracy rivaling
CNC
• Digital motion control
• Closed loop monitoring
• <10 m resolution
• Features as small as .3mm

7. ProJet™ 6000 Accuracy
35
30
25
-- 3 x 3 matrix of test parts
-- 12 measurements per part
-- 108 measurements
-- 1mm to 32mm range
-- Standard Deviation of <15
microns
Accuracy is a combination of:
-- System capability
-- Material properties
-- Compared to an absolute
Frequency
20
15
10
5
Difference from nominal in microns
100
90
80
70
60
50
40
30
20
10
0
-10
-20
-30
-40
-50
-60
-70
-80
-90
-100
0

8. ProJet™ 6000 Accuracy
Thin walls that get progressively thicker in 10um increments
10 microns = 0.00039 inches
1010
m
1000
m
How small of a
increment can the
system print?
Result=1450 Dpi; 17.5m

9. ProJet™ 6000 Accuracy
• Machine Build Modes
o HD - Fastest
o UHD – General purpose build mode
o XHD – Fine feature detail

10. ProJet™ 6000 Accuracy
• User adjustment to fine tune
part accuracy
o Shrink Compensation
o Line Width Compensation

11. ProJet™ 6000 Accuracy
• Shrink Compensation
o X, Y and Z adjustments for material
shrinkage due to the material cure
process
o Values specified in the machine
User Interface software

12. ProJet™ 6000 Accuracy

13. ProJet™ 6000 Accuracy
• LineWidth Compensation
o Adjusts for the material cured line width
o Values very due to
• Print Head Characteristics
• Material
• Build Mode
o Values specified in the 3DManage setup
Software

14. ProJet™ 6000 Accuracy
Line-Width Compensation Off
Line-Width Compensation On

15. ProJet™ 6000 Accuracy

16. How to Obtain the Most Out of Your
Objet Printer: Quick Tips

17. CAD to STL - Maintain the Proper Resolution
• When creating an STL file, the goal is to achieve a balance between file
size and a fully-defined model with smooth curved geometries.
• You cannot build the model any better or smoother than the STL. So if
the STL is coarse and faceted, you will see it in the model.
Faceted STL file
translated
with coarse
tolerance
File translated with
fine tolerance

18. “Connexify” a Part
• Divide the CAD files into shells early in the design process
Non-Connex:
Monolithic part, one material
Connex: Assure a distinct separation between the solid bodies:
Create an assembly of one or more parts

19. “Connexify” a Part
Uncheck this to allow separate STL files
(For Connex)

20. Supporting Delicate Parts with Auxiliary Structures
In order to support fine features, an auxiliary part can be
printed and removed later
+
=

21. Matte Vs. Glossy
Matte mode is intended to generate uniform surfaces. Ensure your model is
suitable for this mode.

22. Objet Studio – Other Considerations
The visual differences between Matte and Glossy Parts

23. Accuracy in Appearance
To truly appreciate fine details on the surface, use VeroBlue or VeroGray
materials in the glossy orientation

24. Accuracy in Performance
To imitate final material performance, use Connex for complex applications

25. Fitting Surfaces
Fitting surfaces should be positioned facing up
No support material needs to be removed

26. Print Several Materials on a Single Piece
End part Shore value needs to be determined

27. Print Several Materials on a Single Piece
Connex Technology enables testing of different values on
a single print

28. Print Several Materials on a Single Piece

29. Accurate Parts with
FDM Systems
Bonnie Meyer, Sr. Applications Engineer
Stratasys, Inc.

31. All FDM Systems
 Thermoplastics are stable over days, months or years




ABS
Polycarbonate (PC)
Polyphenylsulfone (PPSF)
ULTEM

32. FDM – thorough analysis
 27 measurements
 12 parts per build
 3 runs per machine
 Repeated on 3 machines
108 sample parts
2916 measurements

33. FDM Repeatability
Results:
 σ: 0.0027 in. (0.07 mm)
 Mean: 0.00034 in. (0.009 mm)

34. Accuracy Over Time
Width
Nominal (3.000”,
Apr-2008
Actual
Aug-2011
Actual
Change over time
Sample 1
2.997”
2.997”
0.000” (0.00 mm)
Sample 2
3.001”
3.000”
-0.001” (0.03 mm)
Sample 3
2.999”
2.998”
-0.001” (0.03 mm)
Average
2.999”
2.998”
-0.001” (0.03 mm)
Length
Nominal (5.000”,
Apr-2008
Actual
Aug-2011
Actual
Change over time
Sample 1
4.999”
4.998”
-0.001” (0.03 mm)
Sample 2
4.998”
4.998”
-0.000” (0.00 mm)
Sample 3
4.998”
4.996”
-0.002” (0.05 mm)
Average
4.998”
4.997”
-0.001” (0.03 mm)
76.2 mm)
127 mm)

35. Maintenance
• Routine User Maintenance
o Keep System Clean
• Purge Area
• Build Envelope
o Replace Worn Components
• Tips – Odometer
• Tip Brush/Flicker
• Preventative Maintenance
o 1-year and 2-year

36. Orientation
• Critical Features
• Rounds

37. Calibration
• Tip Changes
• Periodically

38. Custom Scaling
• Fine Tune in X and Y if Needed
• Quantities of Parts

39. Recap
• All FDM Systems
o Stability and Repeatability
o Routine User and Preventative Maintenance
o Part Orientation
• Fortus 3D Production Systems
o Tip-to-Tip Calibration
o Custom Scaling

40. More Information
• www.stratasys.com/accuracy
o Download “Accuracy Myth” white paper
o Benchmark the process with your part
• Contact Stratasys Application Engineering
• 855-693-0073 (U.S. toll free)
• +1 952-294-3888 (local/international)
• ApplicationSupport@Stratasys.com

41. Questions?
Design World
3D Systems
Objet Ltd.
Stratasys
Leslie Langnau
llangnau@wtwhmedia.com
Phone: 440.234.4531
Twitter: @DW_RapidMFG
Ben Klein
Ben.Klein@objet.com
Phone: +1.972.52.889.2292
Stacie Hoche
Stacie.Hoche@3dsystems.com
Phone: 803.326.4613
Bonnie Meyer
Bonnie.Meyer@stratasys.com
Phone: 952.906.2244

42. Thank You
 This webinar will be available at designworldonline.com & email
 Tweet with hashtag #DWwebinar
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