3D PRINTER

USER GUIDE

A Complete Step By Step User Manual For Understanding The

Fundamentals Of 3D Printing, How To Maintain And Troubleshoot Common
Difficulties

Keith J. Prout
Copyright © 2020 Keith J. Prout
All right reserved
Kindly note that this book cannot be reproduced in any way or by any means
without obtaining written consent from the author or his representative
 Table Of Contents

Introduction
Chapter 1: Basics Of 3D Printing
What Is 3D Printing?
Key History
Chapter 2: 3D Printing Technology And Processes
How it Works
Conversion Of 3D Digital Design To STL File
'Slicing' The STL Format Into G-Code
3D Printing Processes
Material Jetting
Material Jetting schematics
Binder Jetting
Binder Jetting schematics
Material Extrusion
Material Extrusion Schematics
Summary
Chapter 3: Choosing a 3D Printer
Craftcloud
What Printing Process You Should Choose
FDM Printers
Advantages
Disadvantages
Stereolithography Printers
Advantages
 Disadvantages
SLS Printers
Advantages
Disadvantages
What Package Type To Go For
What Is The Need For The Printer?
Things to Look for Before Choosing a 3D Printer
Chapter 4: Tools And Build Materials
How to Store PLA and ABS
Summary
Chapter 5: 3D Slicer Settings
Chapter 6: Benefits and Applications of 3D Printing
Chapter 7: Basic Maintenance of 3D Printer
Conclusion
Glossary
Sales Pitch
About The Author
 Introduction

Although it has not been larger than the internet as it was once projected to
be, 3D printing has slowly and progressively started to change how
manufacturing is done: from the tedious subtractive way of fabrication to a
more easier additive manufacturing.
3D printing involves a host of different technological processes that ensure
the manufacturing of a range of three-dimensional objects by adding layers
upon layers of different build materials. This technology, which has long
been enjoyed by early adopters, has been applied in many industries that
would be discussed extensively later
Other topical issues, talked about in this book, relating to 3D printing you
might want to know are:

What 3D printing truly is

The brief and key history of 3D printing
How 3D printing works and the seven distinctive processes
of 3D printing categorized by the American Society for
Testing and Materials (ASTM)
How to choose a 3D printer
The tools and build materials useful of a good additive
manufacturing

This guide also shed some light on the benefits and applications of 3D
printing which can only be achieved when a quality print is made. The guide
elaborated on how a quality print could be achieved through appropriate
slicer settings and proper machine maintenance.
By the time you are done with this book, you would have been able to fully
understand what 3D printing is, the difference between traditional and
additive manufacturing, what to look out for when buying a 3D printer, what
software, how to slice your 3D digital model, and how to maintain your
personal 3D printer. You would also be vast in the use of some 3D printing
terms.
 Chapter 1: Basics Of 3D Printing

What Is 3D Printing?
3D printing, also known as additive manufacturing, is the process of 'printing'
or manufacturing three-dimensional objects using 3D printers by stacking up
layer-by-layer 3D printing materials.
The manufacturing objects' processes using 3D printers could be more than
one, but the methods are the same. The layer, designed with Computer-
Aided-Design (CAD) software, is printed in a 3D printer.
The term additive manufacturing for 3D printing comes from the method by
which objects are 3D printed. Unlike the traditional subtractive
manufacturing method, 3D printers produce three-dimensional objects by
adding layer upon layer of production materials.
As earlier stated, this is directly opposite to how objects are made
traditionally. The traditional manufacturing process involves subtracting part
of a larger block of material for production. Cutting or carving out objects
from the material they are made of is the hallmark of traditional
manufacturing. For example, woods are cut out of a log of woods to make
wooden shapes
But with 3D printing, complex objects are made only by adding layers of
materials upon layers to meet the objects' 3D digital models. More 3D
beneficial differences to traditional manufacturing would be discussed later.

Key History
Printing in 3D format has been in existence for quite a long time; it all started
in 1981 after Dr. Hideo Kodama of Nagoya Municipal Industrial Research
Institute filed a patent (JP S56-144478) was published. In 1v980, Kodama
invented an additive rapid-prototyping system to produce a model using
photopolymers. They were, at the time, called Rapid Prototyping (RP) plan
because they were thought to be fast and cost-effective.
Before Hideo Kodama's invention, the idea of 3D printing and its additive
manufacturing method was first described by Raymond F. Jones in a 1950
issue of Astounding Science Fiction magazine. He termed the process as
'molecular spray.'
Five years later, in 1986, after Kodama's invention, the first 3D patent was
issued to Charles "Chuck" Hull of the 3D Systems Corporation. His patent
was filed in 1984 for a stereolithography fabrication system, also known as
the stereolithography apparatus (SLA). Hull's stereolithography 3D system
uses digital data of a 3D model to create real three-dimensional objects. His
patent is considered the first because Kodama did not follow through with his
patent request after one year of filing it.
Hull's 3D Systems Corporation went ahead to produce the first commercial
3D printer, the SLA-1, in 1987. The SLA-1 was not sold until 1988, after it
had gone through rigorous testing.
Although SLA could be regarded as the first 3D printing technology
produced in 1987, another technology, known as the Selective Laser
Sintering, was also designed that year. In 1987, Carl Deckard, a student of the
University of Texas and working at the university, filed a patent for the SLS
RP printing process. Hull's 3D Systems Corporation later acquired the 3D
printing process after the SLS patent was issued in 1989.
As research and development continued in the production of RP systems in
finding a more suitable manufacturing process, Scott Crump, who co-founded
Stratasys Inc., developed the technology widely employed by 3D printers
today, the Fusion Deposition Modeling (FDM), in 1988. He filed for a patent
for this process in 1989 and sold the first FDM printer in 1992 through
Stratasys.
With the entrance of different technologies and makers in the years following
the developments of SLA, SLS and FDM printers, the application of 3D
printing grew beyond industrial prototyping. Hence, the materials used also
grew beyond plastic. Metals and human cell materials were successfully
introduced. In 2006, a 3D printer maker, Objet, introduced a 3D printer that
could use different types of raw materials to 3D print any objects.
3D printers became affordable at the entrance of an open-source self-
replicating printer in 2005. Dr. Adrian Bowyer of Bath University started the
RepRap Project to initiate a low-cost 3D printer development. RepRap is an
acronym for Replicating Rapid 'prototype.' This remained until 2008 when
the RepRap makers produced Darwin, the dream of an absolute self-
replicating 3DP (3D Printer) into fruition.
All of the plastic parts for the 3D printer with Vik Olliver on the right were
produced by the machine with Dr. Adrian Bowyer of RepRap on the left.
In 2009, a RepRap open-source investor, MakerBot, started selling 'Do-It-
Yourself' (DIY) kits that would allow buyers to assemble or make their
desktop 3D printers. MakerBot was later, in 2013, acquired by the initiator of
the FDM printing process, Stratasys. The years following this saw a sharp
rise in this tech's adoption, as the world's first 3D printed plane flew the skies
above the University of Southampton.
In 2012, two alternative 3D printing processes were introduced into the RP
market. By June that year, B9Creator introduced its printer using Digital
Light Processing (DLP). The DLP project was funded through the site
Kickstarter.
Although 3D printing has not entirely taken over the world's manufacturing
process, it was initially thought of by some that it has gone beyond the initial
use for rapid prototyping to direct digital manufacturing (DDM) for high-end
industrial manufacturing or desktop manufacturing for low-end
manufacturing for hobbyists.
 Chapter 2: 3D Printing Technology And Processes

Just like many technological products, there is a general principle that

dictates how 3D printing works. There are many processes in printing three-
dimensional objects, but all of these processes follow just one direction:
additive fabrication.

How it Works
The general principle of additive fabrication is to stack up raw materials layer
by layer for an object to be produced. Regardless of the process your machine
takes in processing whatever is made; the production stages are the same.
There are four distinct steps in the operation of any 3D printing machine:

A Digital 3D Model Is Required

This is the starting point for any 3D printing. The 3D digital design can be
made through softwares made for engineering or photo designs. The standard
software programme for 3D digital modelling is CAD. Also, 3D scanners can
be used to scan designs off an already made object.

Conversion Of 3D Digital Design To STL File

The second stage is to export the designed model into a .stl file. The STL
format derives its name from STereoLithography. The printer cannot
understand a 3D model; the model must be saved in a form the machine can
understand.

'Slicing' The STL Format Into G-Code

After the digital model has been Converted into an STL format, the model in
the .stl file is then 'sliced' into layers for the 3D printer to understand how to
go about designing the model. The process of converting the model is Slicing
from STL to G-code. G-code is not peculiar to 3D printers alone. It is a set of
instructions for the machine describing every movement required to produce
an object.
Models are printed according to the G-code: The last step is printing the 3D
model in real-time. The printer's movement during the additive fabrication is
informed by the instructions it receives from the G-code. Layer upon layer, it
prints the designed model.
For any 3D printing to be done, a 3D digital design has to be made first using
a design Software, like CAD or 3D scanner. The designed model must then
be converted into an STL format, which would be 'sliced' into a readable
format (G-code) for the 3D printer to print.
These are the stages involved in the fabrication of three-dimensional and
complex objects by any 3D printer irrespective of what such a printer
employs a technological process in printing objects.

3D Printing Processes
As was mentioned earlier, there are different 3D printing processes employed
by different 3D printers in the business of additive manufacturing.
In the course of defining what 3D printing is and its history, SLA, SLS, and
FDM have been mentioned. All three of these printing processes and more
have diverse technology they utilize in the manufacturing of objects.
The American Society for Testing as well as Materials (ASTM) divides 3D
printing processes into 7 classifications:

Vat Photopolymerisation
Material Jetting
Binder Jetting
Material Extrusion
Powder Bed Fusion
Sheet Lamination
Directed Energy Deposition
Vat Photopolymerisation

There are three different types of 3D printers that function based on the vat
photopolymerisation printing process:

Stereolithography (SLA)
Digital Light Processing (DLP)
Continuous Liquid Interface Production (CLIP)

Of all these three, SLA is the first and the most common. SLA, DLP, and
CLIP are developed to use photopolymer resin as their raw material for
additive fabrication. The printers are built to have a 'vat' to hold the
photopolymer resin. The resin is cured layer by layer on the build platform
when exposed to light from a light source.

SLA schematics. Image source: fabrx.co.uk

While SLA uses UV laser light to cure and solidify the exposed resin, the
DLP utilizes a more conventional light source - more like an arc lamp.

Material Jetting
Material jetting works much like a 2D inkjet paper printer, except it is a 3D
printing process. The production materials are selectively applied through
multiple nozzles to the build platform, cured of ultraviolet light. The build
materials, in this case, are usually liquid photopolymers.
Material Jetting schematics
This process could sometimes be called poly jetting, as it allows for the use
of multiple materials with support materials also simultaneously jetted out
when needed.

Binder Jetting
Binder Jetting schematics
The binder jetting technology was developed and used first at the
Massachusetts Institute of Technology in 1993. This process utilizes two
materials to build a part. One serves as a binder, and the other as the build
material - usually in powdered form.
The binder jets out a glue-like substance which fuses each layer of the part
material (in powdered form) to the next. This method is reiterated until the
part is developed.
As with most processes using powdered materials, binder jetting requires no
support during printing the part. This also allows for the use of different
powdered materials like food flours and ceramics.

Material Extrusion
There are two types of machine using material extrusion process:

Fused Deposition Modeling (FDM)

Fused Filament Fabrication (FFF)
Material Extrusion Schematics
Image Source: Researchgate
Fused Deposition Modeling is the first and most common of these two. It is
the most used of all the printing processes. The FDM process was invented
and patented in the late '80s by Scott Crump of Stratasys Inc. The method
uses plastic filament unwound from a reel into an extruder: it is a chamber
where the plastic filaments are melted. The melted plastic is then extruded
out to the build platform through the small-diameter extrusion nozzle. The
deposited melted filament is stacked up layer by layer as the nozzle moves in
the X-axis and Y-axis, while the build platform moves in the Z-axis.
The FFF works the same way as the FDM, except that this process is
unrestricted to be used by anyone. The acronym FFF could also mean
FreeForm Fabrication. The RepRap movement coined this concept.
Powder Bed Fusion
Just like the name implies, the build material employed in this process is in
powdered form. This powder is fused, melted or sintered together using
different techniques to mold a 3D object.
The various techniques are;

Selective Laser Sintering (SLS)

Direct Metal Laser Sintering (DMLS)
Multi-Jet Fusion (MJF)

SLS is the oldest of them all. This technology developed in the late '80s by
Carl Deckard works by using a high power laser to sinter (mould together)
particles of powder into a solid 3D shaped object. The process is selective, in
that the sintering laser light scans the layers of the 3D digital item on the
powder bed. The powder bed moves a step lower at the size of the thickness
of each layer scanned. This allows the formation of a new scanned layer on
top of the previous layer. These processes are repeated until the 3D object is
wholly made.
SLS schematics. Image source: microworkshops.co.uk
DMLS works in the same vein as the SLS. The only exception to DMLS is
that it uses metal powder only. Just as it is with SLS, DMLS unused power is
packed to be re-use for another additive fabrication.
Instead of sintering using high power laser light, Multi-Jet Fusion (MJF) uses
dozens of glue-like substances to fuse the powder particles. Layer by layer,
an arm of the machine deposits powder particles and the other arm, with a
series of nozzles, injects selective binders (a glue-like substance) to bind each
layer to the next. Because objects built using this technique are not always
rigid, SLS is preferred. Hewlett Packard developed this process.

Sheet Lamination
This is additive manufacturing, whereby sheets in layers are bonded together
to mould a single 3D object. Laminated Object Manufacturing (LOM) and
Ultrasonic Consolidation (UC) are the two 3D fabrication methods that use
the sheet lamination technique.
Sheet Lamination schematics. Image source: 3DPtinting.Lighting
Build sheets used in this process include metal, paper, or polymer. The
bonding method for each of these materials is different. Ultrasonic welding
are used together to weld metal sheet, while paper and polymer sheets are
bound by adhesive glue.

Directed Energy Deposition

DED schematics
DED printers are not the sort of 3D printer found amongst hobbyists. They
are mostly found in large steel milling firms. This process involves the
deposition of layer upon layer of melted build materials - usually metals - by
thermal energy use.

Summary
3D printing technology is additive manufacturing. A 3D model created with a
CAD or scanned is 'sliced' into a readable format for a 3D printer to 'print' 3D
objects by adding a layer to existing layer(s).
This tech comes in different processing styles. Some build three-dimensional
parts from liquid resin, powder, plastic filaments, or sheets. The differences
in the raw materials needed for 3D printing informed the use of different
processes: material deposition (extrusion), material jetting, binder jetting,
powder bed fusion, sheet lamination, directed energy deposition, and more. A
common thing to all is the method of manufacturing. If it is not additive
manufacturing, it is not 3D printing.
 Chapter 3: Choosing a 3D Printer

The previous chapter discussed how 3D printing works and extensively

discussed the different processes involved in 3D print parts. But in this
chapter, the discussion will center on choosing a 3D printer.
The first question you might want to ask yourself is, "Do I need a 3D
printer?" Yes and no, depending on so many factors. You might be running
on a lean budget, and you might not want to add a 3D printer and its expenses
to that. So, if you can't afford one, not to worry; there are many online sites
that provide 3D printing services to the public and deliver your prints.
Below are a few places to get your 3D projects done and delivered to you:

Craftcloud
Craftcloud delivery service is worldwide. This means you can be in Saudi
Arabia; choose and print your 3D object on their site, and get it delivered to
you. The build materials they offer include PLA, ABS, nylon, resin, and
many more. Check online for Craftcloud.

3DExperience Marketplace
Shapeways
Sculpteo
3D Hubs

All of these provide worldwide delivery services. They also offer a wide
range of build materials that you can imagine.
If you decide to get a 3D printer, however, you should know what you are
getting. It would be disastrous if you choose to pick a particular type of 3D
printer without knowing the load of problems that come with it.

What Printing Process You Should Choose

It is essential to know which printing process would be suitable for your
project. Out of all the methods mentioned above, only three 3D printing
processes suit a beginner. This is because these three processes are quite
common: FDM of material extrusion, SLA of vat photopolymerization, and
SLS of powder bed fusion.
All of these processes have been well discussed. But let's take a look at their
strong and weak points so that we can decide on which one to go for.

FDM Printers
This process involves extruding melted filament layer upon layer on a heated
bed to create an object. Much of this has been earlier discussed.

Advantages
3D printers that adopt this manufacturing process are the cheapest because
they are common; they are the most recognizable 3DP process. You can
readily get an FDM desktop printer for as low as $500.

It is also very easy to operate.

Maintenance is the cheapest of all 3D printers using other
processes.
The material (filament) employed by this printer is also very
common.
The online support is great for beginners.
It provides accurate and reliable 3D print of an object.

Disadvantages
Materials are mostly limited to ABS and PLA plastic filaments at the entry-
level. This is changing, however.
The layers of 3D printed objects are usually visible.
The FDM printing process sometimes requires a support structure for
complex designs. This means a second material that could dissolve in water
might be needed.
As fast as the printing of FDM could be, it can be prolonged for some
geometry.
If the right measure of material is not used, the printer could stop working
due to clogging.

Stereolithography Printers
Although SLA printers are not as common as the FDM printers, they are,
however, the oldest 3D printers to be commercialized. SLA printers adopt the
SLA printing process.

Advantages
It is the most accurate of all 3D printers. So anyone needing
great detail in his or her final product should go for SLA.
You can easily get help online.
Final product is smoother than FDM

Disadvantages
Using liquid resin and other limited materials can be quite expensive.
It also requires a support structure for some three-dimensional objects. This
structure needs to be sometimes manually removed.
Sometimes, the final product needs to be subjected to much heating to harden
it.
They are not as common as FDM.

SLS Printers
The SLS printers follow the principle of powder bed fusion in how it
operates. They are likely the third most common printers after FDM and
SLA.

Advantages
Complex shapes that cannot be 'printed' using any other processes or printers
can be done with the SLS printers.
Materials are not as limited as FDM and SLA. SLS printers can process both
metal and plastic materials
No support structure is needed for production.
Objects produced this way are miles stronger than most created using other
3D printers.
They are better in accuracy than the FDM.
Disadvantages
There are no known desktop models for now. So, they are only industrial
models available, which makes them very expensive.
It requires a very high temperature for laser sintering of powder particles.
It takes quite some effort to clean up excess powders around the produced
object.
By understanding the advantages, as well as disadvantages of these three
standard printers, can help you make a healthy choice.
As a beginner, FDM/FFF would be the recommended choice; and this book
would focus on that. Why? FDM/FFF printers are very common and
materials, though limited, are easy to come by. They are also easier to operate
than the rest.
Before opting for any FDM/FFF printers, there are some questions you
should ask yourself: What type of package to go for? And, what is the need
for the printer?

What Package Type To Go For

At the point of buying a 3D printer, you will be faced with the option of
either purchasing a printer kit or a completely assembled printer.
If you love the challenge and are up for it, you can buy a 3D printer kit.
These kits come with guides as to how to assemble your machine. You also
need to have a little bit of some technical abilities. RepRap machines are a
place to start when buying 3D printer kits.
Buying 3D printer kits comes with some of its risks. Don't go for the wrong
kits because they seem cheaper than assembled machines. Poorly constructed
machines by you can lead to fire; this is not very common, though.
Although some benefits are attached to buying kits and assembling your
machine, buying an already completed machine is recommended. If you
would be getting a desktop 3D printer, the chances you will get an already
assembled one by the producer are very high. However, the assembled ones
are a little expensive.

What Is The Need For The Printer?

What do you need this 3D printer for? There are a lot of reasons to buy or
own a 3D printer.
You can decide to hop on the new trend of additive manufacturing as a
hobby. You desire to try the latest tech involved in manufacturing objects.
With this mindset, you can produce anything you think about around your
home or office. You can create toys, vases, a broken dial of a washing
machine, board game pieces, and even models of things or people you love.
The list of what you can create with a 3D printer, as a hobbyist, is vast.
You can also have prototypes of what you want to produce created with your
simple desktop 3D printer; as a business owner into construction, having a
model of what you desire to construct before the actual construction is
helpful. Printing your model with a 3D printer could cut costs and help
convince your clients.

Things to Look for Before Choosing a 3D Printer

When choosing a model or brand of a machine that suits your need, there are
things to consider before you make a purchase:

Price
Reviews
Reliability
Customer support/support community
Material
Price

You have to consider how expensive a 3D printer is before you spend on it.
You have to consider what the 3D printings you will be doing to know the
machine's price range that fits your needs. You have to know what features
you will be getting vis-a-vis the money you will pay for the machine.
As a hobbyist, how much are you willing to part for your hobby?

Reviews
You need to review what people are saying about a brand or model of the
machine you want to get. It is essential to know the strong and weak points of
a machine before you flash the cash. By doing this, you are prepared for
anything that comes your way.
You can ask friends or family members who have experience with the 3D
printer you intend to acquire. There are also online places that provide such
reviews.
Sites like 3dprinterreviewsite.com and toptenreviews.com can pretty much
help you get reviews of any machine you wish to get. There are other online
forums to ask questions about whatever machines before you buy.

Reliability
Reliability might mean different things to different people. To some, it is the
machine's accuracy; to some, it is the quality of a machine's final product.
The speed in completing a task could also mean reliability. Whichever you go
for, both the quality of what is produced and the machine's accuracy to details
are essential.
The quality of what is produced might partly depend on the material used. It
is not always dependent on the machine. It could also depend on your
understanding of how to make necessary adjustments to the printer.
Concerning the speed of operation, some 3D printers complete tasks very fast
at the expense of quality. Some would give you a good quality product longer
than you desire. Not all machines would give you both.

Customer Support/Community
The next thing to take into consideration is the community support for any
model of a 3D printer. There are lots of massive online communities for most
models of 3D printers. There are common problems that you can solve on
your own when you visit these online communities. You meet people who
have had such issues and could put you through on what to do.
Also, there should be customer support from the makers of your machine. If
there are none, buying such a machine is not a good idea.

Materials
Some 3D printer makers design their machines so that the building materials
for production can only be bought from these makers. That wouldn't be a
problem if you get such materials easily and at a low price, but it would be if
that is not feasible. You want a machine that is flexible with available
materials.
There are many other factors to consider when choosing a 3D printer, like the
cost of running it and maintenance cost. But when the factors mentioned
above have been thoroughly considered, be rest assured you will get the best
machine that suits your 'printing' needs.
 Chapter 4: Tools And Build Materials

Our discussions before now have centred on 3D printing, its history, and the
printers and the processes employed in 3D printing. But in this chapter, our
focus would be on the essential software and materials that help make 3D
printing possible.
Essential Steps and Tools Required
In the discussion relating to how 3D printing works, it was mentioned that 3D
printing starts from the data of a 3D digital model. This digital model is then
interpreted to what the machine could understand in the printing of this
model.
By now, you must have got your 3D printer and are feeling so ready to make
your first 3D print, but that is just the beginning. Regardless of how your 3D
printer is set-up, the steps mentioned above to fabrication have to be
followed; and there are tools needed to complete each step in this process.
The first step is designing the model: 3D digital models are mostly designed
using CAD. There are instances where non-CAD applications are used in
designing 3D models. This includes the use of 3D scanners.
If you are bad at creating designs, you can always get an already designed
blueprint of what you intend to create online. Sites like Thingiverse and
Pinshape offer you lots of free 3D printing models that you can use. Their
models are already converted to STL format for your slicer.

The homepage of Thingiverse

But if you are feeling adventurous and very good at designing, then, there are
loads of free CAD software you can use:

TinkerCAD
This is recommended for beginners, as it is browser based software.

SketchUp
This is also browser-based.

FreeCAD
This is really not for beginners but still easy to work on. Available on
Windows, Mac, and Linux.
Fusion360

Google Sketchup
There other advanced and professional CAD software, like AutoDesk
Inventor, you can buy for a full design experience.
Alternatively, you can use 3D scanners. This technology is rare; it also
requires lots of work. So, it is not ideal for a beginner.
The second step is to convert 3D designs into an STL file: for any 3D digital
model that can be sliced, it must be exported into a .stl file. If you use Google
Sketchup, you would have to get Cadspan as a plug-in before converting your
models in STL format.
If you use other non-CAD software like Photoshop, you will need to subject
your designs to a series of processes to convert them into STL.
The third step is slicing the model: Slicing the model involves converting the
saved model in the STL file into an instructional code (G-code) the 3D
printer would understand.
Slicers are computer software, just like CAD software used in the digital
modelling of your design. There are many slicers to choose from. They pretty
much work the same way. However, your machine manufacturer may
recommend one for you. Most modern slicers have inbuilt control software in
them.
Below are five common slicers to choose from:
 Cura
Repetier
Slic3r
KISSlicer
Skeinforge

A Slicer helps control the required temperature, speed, and material flow for
an excellent layer-on-layer fabrication. More on how to set your slicer for
perfect 3D printing would be explained better in the next chapter.
The final step is printing. The G-code from the slicer could be exported to the
machine through a USB cord/drive, SD card, or through the WiFi for
professionals. Once the machine gets the instruction, printing would begin.
Build Materials
Having gone through the diverse processes and technologies involved in the
fabrication of a three-dimensional part, you would have got some ideas of the
materials involved in additive manufacturing. These materials range from
plastic, powder (metals, food, ceramics, and more) resin, to living human
tissue. With the advancement in science and tech, the build materials would
likely be limitless.
Our focus on this subtopic would be on plastic filaments, as the discussion is
centred on FDM/FFF Printers.
There are two plastic filaments common to FDM/FFF printers: ABS and
PLA.
ABS (Acrylonitrile Butadiene Styrene)
ABS is a plastic which is gotten from fossil fuels. It is the plastic used for the
production of Lego blocks because they are reliable. ABS plastics are not
biodegradable, which puts off lots of environmentalists. They smell like
burning plastic when melted in the extruder.
PLA (Polylactic Acid)
This is an environmentally friendly plastic. It is derived from corn, sugar
starch or sugarcane. It is biodegradable and gives off sweet smells when
melted. Although it is very easy to print with, it is prone to clogging. Another
disadvantage it has is that it is brittle. This is why ABS is preferred by
engineers: It is very strong and flexible.
Multiple plastic filament reels

How to Store PLA and ABS

When you buy any PLA or ABS to keep for a while, they must be sealed
against contact with moisture. Contact with water will reduce the quality of
your final product.
If exposed to moisture, both PLA and ABS tend to bubble and gush from the
extruder during the printing process. If any of the plastics was in contact with
moisture before use, you could dry them up using moderate heat from a food
dehydrator.

Before Buying a Filament

Before you buy any of these filaments, it is better you know the design of
your machine. Different machines are designed to specific filament thickness
because both ABS and PLA come in different thicknesses. ABS and PLA
filaments have 1.75mm and 3mm diameters, respectively.

Summary
Printing in 3D format is not just about the printer only; the process involves
using software to develop a 3D model, slicing the model into G-Code
understandable by the machine, and the actual printing. The type of material
used for printing depends on what to be fabricated. Materials include plastic
filaments, living tissue, powders, and woods. The spectrum of build materials
is increasing with the advancement in tech.
 Chapter 5: 3D Slicer Settings

By now, we already have a glimpse of what a slicer can do. But to do one
better, a slicer is not just a type of software converting your models into G-
code; it dishes out printing instructions on how your machine should go about
converting your model into a real object.
The slicer does 'slice' your 3D digital model into horizontal layers and
determines how much time and material would be needed to complete each
layer. After all of this has been done, the information is sent as G-code to the
machine. So, whatever error is made during the slicing process could affect
the final 3D printed object.
The slicer could be the difference between a lousy print and a significant
print. This chapter would focus on helping beginners - or professionals -
make basic slicer settings.
The settings on slicer software
There are nine (9) slicer settings to look at for smooth printing:

Layer Height
Shell Thickness
Retraction
Bottom/Top Thickness
Fill Density
Print Speed
Support Type
Platform Adhesion Type
Nozzle Size
 Layer Height

The layer height shows the toughness of every layer during additive
manufacturing. The thickness chosen here determines the smoothness of your
print. The thicker the layers, the coarser the print would be, and the thinner
the layers are, the smoother the final product's surface.
Imputing a lower number would raise the quality of the printed 3D object, of
course, this at the expense of speed. The printing will take a longer time to
complete if the thickness is set to be thin. This is, however, different with
higher numbers.
An average of 0.15 to 0.2mm would give a fine print and quality. A lower
quality would be achieved at 0.6mm with a much-improved speed than
0.2mm.
Some slicers like Cura recommend 0.1mm for a quality printing that requires
much detail and 0.2mm for prints requiring fewer details.
You can work on this setting to understand how it works on your 3D printed
object.

Shell Thickness
This setting affects the thickness of the outer wall - or sidewalls. This setting
determines the strength of the fabricated object.
3D printers traced the outer walls before getting to the inner hollow part of
the design. The default measurement for almost all 3DP is set at 0.8mm. If,
however, you want a thicker wall, you can raise this number. The lowest we
recommend you go should be 0.4. If you are a little confused about this, stay
at the default number of your slicer.

Retraction
Retraction is mostly enabled on many slicers. This is a good thing because it
occasionally pulls back into the nozzle the melted filament in the extruder to
skip places on your 3D design with gaps.
Although this is good, it can be very messy: The melted filament clogs the
extruder if retraction takes longer than expected. You can always disable this
setting if it does not affect your project.
Bottom/Top Thickness
A 3D object is not always strong on the inside. This setting is directed
towards the thickness of the top and bottom layers of the object. This helps
reduce wastage of build materials. It is recommended that you set it to
between 0.6 and 0.8mm.

Fill Density
This is used to determine the density of the space inside the outer wall of the
3D object. This is measured in percentages (%) as opposed to mm.
A completely solid object has an infill of 100%. This means such an object
would be weighty. The lower the fill density, the less heavy the object would
be.
It will be a waste of material if 3D is always printed with a density of 100%.
The recommended thickness for most objects should be between 15 - 25%.
You can go as high as 45% if you desire a solid object.

Print Speed
This refers to the travelling distance covered by the extruder in laying the
filament per time. The print speed can also affect print quality. The faster the
extruder's print speed, the higher the chance of getting a deficient quality
print. But this shouldn't be an excuse to lower the print speed. It might take
forever to complete a print; yes, the quality is assured.
The advice would be to stick to the recommendation given by the maker of
your slicer. The best speed range should be between 50mm/s to 70mm/s.

Support Type
One of the few disadvantages of FDM printing is the inability to fabricate
complex objects without a support structure. This is because fabrication
always starts from the base.
A dragon is printed on a support structure.
Support in 3D printing is like the scaffolding used in regular construction
sites. Say you intend to fabricate an object with overhangs with angles of 45
degrees; there is always a need for support. To break this down, objects with
"H," "T," and "Y" shapes need support.
In the drop-down menu of the support type, there are two support types to
choose from:

Touching Build Plate

Sometimes, not all the printing parts of a design need support. This is the
type of support to choose where the intended object's section needs support to
build.
Everywhere: Just as its name implies, this is used for part of an intricate
design that needs support all through. When a design has overhangs
everywhere, you choose this.

Platform Adhesion Type

Warping is sometimes common to 3D prints on platforms with either uneven
surfaces or surfaces that wouldn't hold the print nicely. There are two types to
this:
Raft: This is the right choice for an uneven platform. A small horizontal raft
or grid is laid or printed before the actual 3D object is printed when this is
chosen. You can do this for objects with a shallow or thin base.

Brim
This helps reduce warping by printing outer layers around the bottom of the
object, which keep the corners of the object glued to the platform.

Nozzle Size
Nozzle Size could be 0.4mm or 0.3mm; it could be whatever you want. But
know this, the smaller your nozzle's size, the better the quality of your object.
This would also affect your machine's printing speed: The smaller the nozzle,
the slower the 3D printing process and vice versa. If you are unsure, you can
leave this on default on your slicer; google the size right for your machine.
Other settings that you may find on some slicers are;

Printing Temperature
Bed Temperature
Filament Diameter
Flow Percentage

Both printing and bed temperatures can be left to the default settings of the
slicer you are using. Flow percentage can also be set to default, which is
mostly 100%. It is used to adjust the rate of flow of melted filaments from the
extruder. You can either reduce or increase this to suit your needs.
As mentioned earlier, there are only two filament diameters - 1.75mm and
3.0mm - depending on whether you go for ABS or PLA. Set your slice to
meet the filament you use.
When all of these settings have been completed, the slicer converts them to
G-code for the machine. The converted code could be sent to the machine in
three ways:
Through the use of a USB
Through the use of SD Card, or
WiFi
 Chapter 6: Benefits and Applications of 3D Printing

When we began this course, we mentioned that 3D printing technology had

changed three-dimensional objects' fabrication process.
Until the start of the industrial revolution, manufacturing has been
subtractive, but 3D printing tech has introduced a different manufacturing
object, known as additive manufacturing. So, is there any benefit to this?
Yep, there are many! But a few would be discussed.

Speed
Printing in 3D format is often referred to as rapid prototyping because, unlike
subtractive manufacturing, it requires lots of processes before an object is
made; it is fast. Even changes in the design can only take a few minutes to a
few hours for an improved fabricated object. This also helps in complex
structures that could otherwise take months of planning to produce. Within
hours, such complex designs would have been made with 3D printing tech.

Flexibility and Customization

In traditional manufacturing, customization means new casting tools would
be needed for a slight change in the original design. This is different from
3DP tech. Changes in the design can be done with the same machine, in the
same build chamber without additional tools. If a change in the support is
needed, this can be done in the slicer settings. So, with this tech,
customization is possible without additional time or tools.

Cost-Effectiveness
3DP tech eliminates the astronomically high cost involved in the production
of objects. The money expended on labour and machinery for the fabrication
of different objects is immensely cut with 3D printing fabrication. Wastage of
raw or build materials during chiselling and other traditional fabrication
processes are not in 3D printing processes. About 80% of materials used in
traditional manufacturing are waste; such waste is eliminated using 3DP. All
unused materials are reused.
Localizing Production
Goods that may need to be imported into a place where required could be 3D
printed in such a place, cutting the time, cost, and stress involved in
importing such goods. With 3DP, accessibility is a certainty.

Environmentally Friendly
3D printing tech has brought a perfect way to cut the carbon footprints in the
economy's manufacturing sector. Since most of its materials can be recycled
to cut wastage, there wouldn't be many non-biodegradable materials to be
disposed of.

Applications
Based on the massive benefits that come with the use of 3DP in the
manufacturing of products and complex three-dimensional objects, 3DP tech
has been overwhelmingly adopted and used across all industries of the world
economy. From health care to food production, this technology is no less a
force to reckon with.

Health
3D printing tech has been well received in the health care sector. The
technology has been utilized to fabricate some medical items like hip and
knee implants, hearing aids, personalized prosthetics and implants for
patients suffering from diseases such as osteoarthritis, osteoporosis and
cancer.
It has been widely used in the dental industry. Crowns and dentures have
massively been 3D printed. 3D printed surgical guides for dental and other
medical operations have also aided dentists and surgeons in different medical
fields.

Automotive
The automotive industry is one of the early adopters of 3DP tech. Ford, for
example, chunks out about 20,000 3D printed parts yearly. Many other
automotive companies are also looking to produce spare parts using this tech.
Hobbyists, who are eager to show off their 3DP abilities, now try to restore
old cars using 3D printed parts.

Aviation
The aviation industry has keyed in well into the use of this tech. It is on
record that GE Aviation, a subsidiary of General Electric, has used additive
manufacturing to produce more than 30,000 Cobalt-chrome fuel nozzles for
its LEAP aircraft engines. This innovation by GE Aviation has also been used
on Boeing 787 Dreamliner.
Other high-profile users of this tech, besides GE Aviation and Boeing, in the
aviation industry are Rolls-Royce, Airbus, and BAE Systems.

Construction
Hundreds of houses have been 3D printed already. So, there is no question as
to whether this is possible or not. From 3D printed architectural models to
actual home construction, 3DP tech has been relatively active in this industry.
It is estimated that homes additively constructed using this tech can last 50 to
60 years.

Rapid Manufacturing (RM)

This tech has evolved from the rapid prototyping used for rapid
manufacturing by a host of manufacturing industries. Because it provides a
cheap and fast way to the whole production process, 3DP has broadly been
adopted in this industry to produce both prototypes and actual objects.

Food
Although this technology was adopted very late in the food industry, it has
become a very active food processing tool. 3D printing has been used very
actively to process foods with chocolate and sugar as raw materials. Mélisse
in Santa Monica; La Enoteca in Barcelona; La Boscana, also in Spain; and
Food Ink in the UK are all famous restaurants printing food with tech use.
Food Ink serves you 3D printed foods and cutlery while you eat on a 3D
printed table and sit on a 3D printed chair. Almost everything you use in the
restaurant is 3D printed.
Consumer Products
Jewelry, fashion, footwear, eyewear, and many other end-use products have
been produced using additive manufacturing.
Although this has not been fully commercialized, companies into end-user
products have extensively employed this tech in manufacturing. Adidas has
successfully manufactured hundreds of thousands of 4D range midsoles since
2018 using 3D printing.

Education
3D printing is not new to those in the line of education. SLS was first
developed between the four walls of an educational institution. Courses like
architecture, engineering and those relating constructions have been using 3D
CAD applications for a very long time.
There are Universities now offering diploma courses in 3D printing. Besides
that, universities utilize 3DP tech for research purposes. 3D prints help
students with the visualization of complex topics.
Others
3DP tech is applicable in industries like defence, entertainment, art, and many
others not covered in this guide. For example, pieces of board games can and
have been produced using additive manufacturing of 3D printing. In defence,
light-weight surveillance equipment has been manufactured.
 Chapter 7: Basic Maintenance of 3D Printer

To continuously enjoy the many benefits discussed in the last chapter of this
guide, it is essential to care for and maintain your 3D printer.
A machine not cared for would only break down within a short time; if not, it
would not give you quality print or work to its full capacity. You don't want
this for a machine you spend so much to acquire, so below are a few of the
maintenance tips to help keep your machine in shape.
Lubricate the X, Y, and Z rods
As your machine is mostly built of metal, it is vital to lubricate any moving
parts, especially the X, Y, and Z rods. These rods ensure the movement of the
extruder in these axes. If these parts lack lubrication, friction sets in and
movements are restricted. It is vital to lubricate once a month after cleaning.
Also, make sure that the oil applied should not be too much, as it could attract
dust.
When selecting a lubricant, be sure to know the recommendations of the
manufacturer of your 3D printer. If no specific recommendation is given,
there are common lubricants for 3D printers to choose from. This includes
white lithium greases and dry lubricants like silicone and Teflon.

Periodic Inspection and Cleaning

It is vital to inspect your machine once in a while. This can help you assess
minor problems on your machine and detect potential ones. While on this,
you can also clean up your machine. After lubrication, your machine may
have packed some dust. This is why your machine should be cleaned; this
includes the machine's build plate and other components.

Tighten Loosen Screws

The continuous motion of your machine may cause some nuts and bolts to
become less tightened. The pulley screws around the X and Y axes are
mostly affected by these continuous vibrations. Loosened pulley screws will
affect your print quality; therefore, it is recommended that you tighten all the
loosened nuts and bolts on your machine whenever you do your periodical
inspections or when you notice unusual movements or vibration of the
machine.

Adjust Belt Tension

Timing belts are common to most FDM/FFF 3D printers to transfer motion
around the X and Y axes, so they need to have the right tension for quality
printing.
If the belts are too loose, they become slack and respond sluggishly to any
change in command; if too tight, the machine becomes stressed and breaks
down. To prevent this, install a belt-tensioner mechanism that would aid you
in adjusting these belts accurately. You can also consult your printer's guide
book.

Nozzle Cleaning
Use a wire brush to clean the nozzle of your machine. This is important to
avoid clogging of the nozzle due to melted plastics that have accumulated
around the nozzle. You can also use some filaments designed for cleaning.
Besides clogging issues, you can also have extrusion issues if you fail to
clean up your machine's nozzle periodically.

Replace Worn-Out Or Old Parts

After years of using your machine, there would come a time you have to
replace expired parts. These parts may look to still be giving you some
measure of quality work at the moment. But when you notice you are not
getting the level of quality you are used to, then do not hesitate to change
these old parts. This should not be a problem for those using 3D printers like
the RepRap.

Calibration
One good step of maintenance to always consider is calibrating your
machine. It's an excellent way to check the surface quality and bed Adhesion
and solve most of the issues that have been discussed above. Low-quality
prints, under-extrusion, over-extrusion and overheating are other issues
calibration will help eliminate.
Firmware Update
Just as you update your computer's software for optimal functionality, so you
should do with your 3D printer. The manufacturers of 3D printers usually
provide firmware updates. Never hesitate to update your machine's firmware
when available.
 Conclusion

Decades after it was first used, 3D printing has moved from RP to RM. It has
grown beyond the gigantic machine restricted to industrial complexes to a
self-replicating desktop machine that could be found in people's homes. Also,
It has become widely accepted in every industry you could think of. These
might not be unconnected to the rapid advancement in technology and the
different technological processes employed by other 3D printing machines.
3D printers that function based on processes like vat photopolymerization,
material jetting, binder jetting, material extrusion, powder bed fusion, sheet
lamination, and directed energy deposition have made possible the
production of anything across all industries using build materials like plastic,
powders, sheets, ceramics, resins, and human tissues.
As the range of build materials utilized for manufacturing by this technology
grew, industries like healthcare, automotive, aviation, construction, food
processing, and education have thrived using this tech.
Parts of the benefits these industries have derived from adopting 3D additive
manufacturing are the speed of production, the accuracy of producing
complex designs, flexibility, cost-effectiveness, a waste reduction that
characterizes traditional manufacturing, and bringing production close where
it is needed the most.
Nevertheless, all of these benefits would not be accrued to either people
willing to use the 3DP tech in these industries or hobbyists if maintenance is
neglected. It is crucial to make routine checks on a frequently used 3D
printer. A critical step in maintenance is a constant calibration of the machine
for quality object printing.
With most FFF or RepRap 3D desktop printers costing as low as $300, you
can now do some fun manufacturing at home. Boardgame pieces, a broken
machine dial, or damaged car parts can all be manufactured by you. Just
follow the guidelines in this book, become very good at 3D printing your
stuff, and spend nothing on something you can fabricate.

Glossary
3DP: 3D Printing
RP: Rapid Prototyping
CAD: Computer Aided-Design
SLA: Stereolithography Apparatus
FDM: Fusion Deposition Modeling
SLS: Selective Laser Sintering
RepRap: Replicating Rapid Prototyper
DLP: Digital Light Processing
DDM: Direct Digital Manufacturing
STL/.stl: STereoLithography
FFF: Fused Filament Fabrication/FreeForm Fabrication
CLIP: Continuous Liquid Interface Production
DMLS: Direct Metal Laser Sintering
MJF: Multi-Jet Fusion
DED: Direct Energy Deposition
PLA: Polylactic Acid
ABS: Acrylonitrile Butadiene Styrene
RM: Rapid Manufacturing
 Sales Pitch

What if I tell you that it is possible to make your food, in your kitchen,
without paying the chef across the street a dime for it?
Will you believe me?
Oh, the best part, you don't have to know how to cook to make your food!
Will you also believe me if I also tell you that you can produce the broken
piece of your board game and other broken things in your home or office
without paying for them?
Ahhh, who am I that you should believe? You don't have to believe me, but
you can google about these and see how 3D printing is changing the world.
It is estimated that over the last decade, more than 100,000 hip replacements
have been 3D printed by GE Additive.
It is forecasted that by 2029 the total market of 3D printed footwear would
reach $5.9 billion. More of the same is also predicted for 3D printed eyewear.
Even restaurants are not shying away from benefiting from this tech. Mélisse
in Santa Monica; La Enoteca in Barcelona; La Boscana, also in Spain; and
Food Ink in the UK are all famous restaurants using 3D printers to make
foods for their customers.
So why won't you key in as the rest of the world and enjoy the benefits that
come with this tech?
Maybe you think you need about $1000 or need to know about engineering
design to get started. Well, I tell you, you might be wrong.
You don't need to have your 3D printer; neither do you need to have any
engineering design knowledge to enjoy the benefits of 3D printing. All you
need is to buy this book and find out how to go about that.
If, however, you've got yourself an excellent 3D printer or you want to buy a
friendly cheap 3D printer to fully benefit from this trend of additive
manufacturing, this guide is also for you.
This guide is going to teach you about 3D printing:

What it is
The history of 3D printing
How it works
How it is better than traditional manufacturing
The different technological processes of 3D printing
 Why you need a 3D printer
How to choose a machine (If you haven't got one)
3D printing software tools and build materials
Benefits and applications of 3D printing
Slicer settings to ensure smooth printing, and
How to maintain your machine.

You can't get it all in one place like it is done in this book. Order for a copy,
read, practice and don't be left behind by technology.
P.S.: All you have to do to make your own food is a 3D digital design of the
food, a food material - flour maybe - and a good 3D printer. When you buy
this book you get the full gist on how to make that happen.
 About The Author

Keith J. Prout is a professional programmer with over 15 years' experience in

the tech industry.
He has worked for some of the largest tech firms in the United States and has
acquired a deep understanding of software development. Keith and his
partner, Stephanie, founded their own development company in 2009 to be
able to pursue more demanding and innovative projects. They're serving
high-quality customers from all around the world now.
Keith loves spreading his experience through his series of books, creating
revolutionary tech applications for his customers, as well as watching old
science-fiction movies in his spare time.