Printing Lab - VT-DISCO-LAB/Getting-Started-in-the-Discovery-Lab GitHub Wiki
The Printing Lab is outfitted with all the equipment and materials you need for rapid prototyping, manufacturing parts with complex geometries, or fabricating Microfluidic devices. The information below, provides: an overview of the advantages and disadvantages of the Discovery Lab's different 3D printing technologies, how to get submit and process your print, and additional resources.
| Additive Manufacturing Equipment Additive manufacturing, or 3D printing, involves creating an object by adding material layer by layer, following a digital blueprint. This method minimizes waste and allows for complex designs, though material choices can be limited, and print times can be lengthy for certain objects. |  |
| Subtractive Manufacturing Process Subtractive manufacturing starts with a solid block of material, and excess material is removed, or 'subtracted,' using various tools to achieve the desired shape. This process is precise and can use a variety of materials, but material waste and higher costs for low volumes are notable downsides. |  |
Available 3D Printing Technologies
The Discovery Lab provides a variety of 3D printing technologies, each of which presents its own set of advantages and disadvantages.See below for a brief overview of the different 3D printing technologies available for users.
| Type of Technology | Available Printer | Description of Technology | |
|---|---|---|---|
 |
Fused Deposition Printing (FDM) | Bambu Lab P1S | •The most common 3D printing technology and the technology you are probably most familiar with •FDM printing, a project is fabricated through material extrusion - layers of thermoplastic filament are dispensed from a hot-nozzle •FDM printing is able to produce durable and economical parts |
 |
Stereolithography (SLA) | Formlabs Form 4 | •Is a 3D printing technology where an object is produced by using light-activated polymerization to selectively cure liquid photopolymer resin •SLA is an ideal technique when you need strength and accuracy and/or when geometry may be to complex to achieve with FDM printing • Most SLA resins afford high-temperature resistance, sterilizability, and biocompatibility. |
 |
Digital Light Processing (DLP) Printing | CADworks H-Series | •Similar to SLA printing, DLP printing forms an object by selectively curing layers of liquid resin. •Unlike with SLA, DLP uses a digital light source to cure entire layers simultaneously, leading to faster print times. •DLP prints have extremely high resolution. •The Discovery Lab's DLP printer is purpose build for microfluidic applications (more on this later in the module). |
Comparison of Available Printing Equipment
Comparison of Available Printing Equipment
| Printing Technology | Material Strength | Accuracy | Geometric Freedom | Relative Cost | Photo |
|---|---|---|---|---|---|
| FDM Printer | Very Good | Fair to Good | Fair | $ | |
| SLA Printer | Excellent | Very Good | Good | $$ - $$$$$* |  |
| DLP Printer | Good | Excellent | Good | $$$$ |  |
*Cost depends on material (resin) selection
Available Subtractive Manufacturing Equipment
| Type of Technology | Available Equipment | Description of Technology | |
|---|---|---|---|
 |
Benchtop CNC Mill | Nomad 3 Benchtop CNC | •The Discovery Lab's Carbide 3D Nomad 3 is a fully enclosed bench top milling machine. Capable of carving, cutting, and engraving a range of materials, including soft metals (e.g. aluminum & brass) plastics, woods, and machining wax. •You can use the Nomad 3 for printable circuit board (PCB) manufacturing, prototyping mechanical parts, small woodworking projects, or lost-wax casting. |
 |
Automatic Cutting Machine | Cricut Maker 4 | •The Discovery Lab's Cricut Maker 4 is available for users to cut, deboss, and/or engrave a range of flat materials, including paper, cardstock, fabric, vinyl, and leather. •The Cricut Maker 4 is also able to: help you manufacture paper-based microfluidic devices, rapidly prototype custom gaskets and seals for other lab equipment, produce custom filter papers, or producing wearable sensors. |
- Step 1 Find a Model: Create or download a 3D model
- Step 2 Select a Printer: Choose the printer that best fits your needs
- Step 3 Preparing your Model for Printing: Come into the Discovery Lab and we can help you prepare your model
- Step 4 Printing: Print your model
- Step 5 Post Processing: Complete any necessary post-processing steps for your print
Before printing, you need a model to be printed. There are a wide variety of resources available for finding or designing models. If you are new to 3D printing, we recommend starting with a model that is already designed for 3D printing.
Resources for Designing Models
It all starts with CAD - any program you can use to create 3D models.
- TinkerCAD: A free online CAD tool that is ideal for beginners
- Fusion360: A free CAD tool for more advanced users
- Blender: A free and open-source 3D modeling software. Best suited for creating complex models
- SolidWorks: A professional CAD software that is used by industry
- AutoCAD: A professional CAD software that is used by industry
Resources for Finding Models
Don't want to learn CAD? No worries, there are tons of files online.
- Printables: Library of 3D models (hosted by Prusa Research)
- Thingiverse: Popular site for sharing 3D models
- Thangs: A search engine for 3D models (search for models across multiple sites)
[!IMPORTANT] Things to keep in mind when designing or downloading models.
- Format: You will need your model saved as an .stl or .obj file
- Size: Make sure your model fits within your selected printer's build volume
- Tolerance: Consider the tolerances of the model. Some models may require specific tolerances to fit together correctly. Typical printers have a tolerance of 0.2mm.
- Orientation: Consider how the model will be oriented during printing. Some models may require supports or may not print well in certain orientations.
- Minimal Wall Thickness: Ensure the model has a minimum wall thickness of 1.2mm to ensure structural integrity.
After you have finalized your model. You will need to select the printer that best fits your purpose. See above for a detailed description of the different strengths and weaknesses of our available 3D printers. If you are unsure of which printer to use, reach out to a Peer Leader.
Once you have prepared your model and selected your printer. You will need to use a slicing software to slice your model. A Peer Leader or member of the Discovery Lab's Leadership team is happy to assist you with the slicing process - If requested.
Printing Material
Currently, we stock the following resins and filaments. These are available to Discovery Lab users. Printing in the lab is completely free for all student users.
- For the SLA printer we can work with users to order specific Formlabs Resin.
- For our SLA printers, we are able to print with any 405 nm photopolymer resin. Reach out to the Discovery Lab team if you have questions about which material is best suited for your project.
| SLA Printer Resins | DLP Printer Resins | Thermoplastic - FDM |
|---|---|---|
| White Resin V5 | Clear Photopolymer Resin | PETG-HF |
| Black Resin V5 | Master Mold for PDMS | ABS-GF |
| Clear Resin V5 | --- | PETG |
| Fast Model Resin | --- | PLA Basic |
| Flexible 80A Resin | --- | --- |
Slicing Process
After you slice your model, you will get a preview of your print. This will include the estimated print time, material usage, and any supports that will be needed.
Use this information to Submit a Request to Use the Discovery Lab's 3-D Printing Technologies - In order to use the Discovery Lab's 3-D printers you first need to complete our required training and submit a request to use one of our 3-D printers
Once your form has been submitted, a member of the Discovery Lab Team will review your request and follow up with any additional questions (if needed) and final approval for your print. You will receive an email or teams message once your print is complete.
[!IMPORTANT] Remember to keep the following guidelines in mind before submitting your request.
- Time: Your print must have an estimated print time less than 8 hours.
- Volume (SLA Printing Only): Your print must use less than 100ml of resin.
- Concurrent Prints: You must not have any prints currently in the printing queu or actively printing.
- Print Management: The Discovery Lab Leadership Team and Peer Leaders reserve the right to deny any model from being printed. Discovery Lab Leadership Team members and Peer Leaders reserve the right to cancel any print at any time. The completion of a print in the space is not guaranteed.
Once your model is prepared, a Discovery Lab Peer Leader will help start your print. We will monitor the print to make sure it is printing correctly. You can also monitor your print remotely using formlabs' Preform program or Bambu Lab's Bambu Studio. If there are any issues we will email you a notification and work with you to troubleshoot issues.
Important
For users that have completed the Printing Lab Training module and been signed off to operate the SLA printer or FDM Printer, you are able to process and initiate your print without a Discovery Lab Peer Leader.
Post processing is required for prints using the Discovery Lab's Printers. Prost-processing may include washing, removing supports, curing, etc. A Discover Lab Peer Leader will assist you with post-processing (if requested).