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= Objective =
= Objective =
In this exercise, drafting software used by technical professionals will be introduced. Basic technical design methods will be shown using Computer-Aided Design (CAD) software, specifically AutoCAD. Later on, this knowledge can be incorporated in the semester-long design project by constructing physical prototypes with 3D printing.
This exercise will introduce Autodesk Fusion 360, which is drafting software that is used by technical professionals,  and basic technical design methods will be shown using this computer-aided design (CAD) software. This software  will be used in your semester-long design project by constructing physical prototypes with 3D printing.


To practice this prototyping procedure, a EG Logo keychain will be created in AutoCAD to export for a 3D print. The members of the winning team of [[Mousetrap Vehicle Competition|Lab 1C: Mousetrap Vehicle Competition]] will each receive a 3D-printed keychain.
To practice this prototyping procedure, an NYU logo keychain will be created in Autodesk Fusion 360 and exported to be 3D printed. The members of the winning team of “Lab 1C: Mousetrap Vehicle Competition” will each receive a 3D-printed keychain.


= Overview =
= Overview =
== Computer-Aided Design ==
== Computer-Aided Design ==
CAD programs (AutoCAD, Inventor, Revit, SolidWorks, SketchUp) allow engineers to make precisely scaled drawings. These drawings can be used to manufacture equipment and construct infrastructure. CAD drawing allows designers to display designs with complete specifications and detail. Orthographic views (top, bottom, side, front, back, etc.) can be used to document every aspect of the technical drawing needed for production. Isometric views can be used to interpret the final 3D representation of the product.  
CAD programs, which include Fusion 360, AutoCAD, Revit, SolidWorks, and SketchUp, allow engineers to make precisely scaled drawings. These drawings are used to manufacture equipment,  build infrastructure, and allow designers to display their designs with complete specifications and detail. Orthographic views (top, bottom, side, front, back, etc.) can be used to document every aspect of the technical drawing needed for production while isometric views can be used to view the final 3D representation of a product.


This exercise will teach the components of CAD software, file formats, and the basics of 3D drafting. It will provide enough information to learn how to create drawings, as well as explore the other tools and functions.
This exercise will teach the basics of Autodesk Fusion 360, 3D file formats, and the basics of 3D printing. After this lab, you will be able to create simple 3D files and set them up to be 3D printed.
 
Additional AutoCAD instruction can be found in the [[AutoCAD Skill Builder]]


== 3D Printing ==
== 3D Printing ==
3D printing allows for rapid prototyping and onsite manufacturing of products. Plastic 3D printing has led the way for new techniques using metals and biomaterials. As materials science engineering develops, more materials will be incorporated into 3D printing techniques.
3D printing allows for rapid prototyping and onsite manufacturing of products. Initially done with plastic, 3D printing now uses new techniques with new materials, such as aluminum, bronze, and  glass. Biomaterials are also being incorporated, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D printing will become a big part of many engineering fields.


In this class, 3D printing can be used to produce a team logo for the semester-long design project.
In this course, 3D printing can be used to produce SLDP course modifications, robot parts, and a team logo for extra credit.


= Procedure =
= Procedure =
:: <h2 style="margin-left: -4.1em;"> Setting up the file </h2>
== Setting up the file ==
# Start AutoCAD and open a new file.
# Start AutoDesk Fusion and create an account IMPORTANT: Make sure to use your NYU email.(Figure 1)
#: [[Image:lab_3dprint_1.png|frame|center|Figure 1: AutoCAD Quick Access Toolbar.]]
#: [[Image:Lab 1B.jpg|thumb|center|600px|Figure 1: Fusion 360 new file options]]
# Select the AutoCAD 3D template.
 
#: [[Image:lab_3dprint_2.png|frame|center|Figure 2: List of available AutoCAD templates.]]
 
# Modify the units for the drawing.
== Designing the NYU Keychain ==
#: [[Image:lab_3dprint_3.png|frame|center|Figure 3: AutoCAD Application Button menu.]]
# The first step to designing the keychain is to draw the base shape:
# Change the length unit type to Engineering.
#:# Start 2D Sketch. (Figure 2)[[Image:Lab 1B2.jpg|thumb|center|400px|Figure 2: Sketch Mode]]
#: [[Image:lab_3dprint_4.png|frame|center|Figure 4: Drawing Units dialog.]]
#:# Select the XZ plane. (Figure 3)[[Image:Lab 1B3.jpg|thumb|center|400px|Figure 3: XZ Plane]]
#: <h2 style="margin-left: -4.1em;"> File formats and viewing mode </h2>
#:# Rotate the camera to orient the top correctly using the arrows in the top right of the screen.
#: AutoCAD drawing files formats:
#:# Select the rectangle tool from the "Sketch" section of the toolbar. (Figure 4) [[Image:Lab 1B4.jpg|thumb|center|400px|Figure 4: Rocking Rectangle]]
#:# DWG – the primary drawing file for the 3D model view
#:#:# Draw a 2.6” x 0.7” rectangle starting at the origin.
#:# STL – the file exported from AutoCAD for input into 3D printing software
#:#:# These values can be typed in (switching which value is changed is done using the tab key)
#:# DWT – the file of the sheet set seen in the layout view
#:# Select the circle tool.
#:# DXF – a drawing format for compatibility with other software
#:#:# Draw a 0.7” diameter circle centered in the middle of one of the short sides of the rectangle (the cursor should snap to the center position and becomes blue X with a triangle when you get close.) (Figure 5) [[Image:Lab 1B5.jpg|thumb|center|400px|Figure 5: Cool Circle]]
#:# PLT – the file sent to the printer of the layout view
#:#:# Draw another circle 0.45” in diameter in the same position, the sketch should look like Figure 6.[[Image:Lab 1B6.jpg|thumb|center|400px|Figure 6: Smaller Circle]]
# Click on the layout view as the default AutoCAD view is model view.
#:# Fillet (round) sharp edges.
#: [[Image:lab_3dprint_5.png|frame|center|Figure 5: View tabs.]]
#:#:# Select the fillet tool from the “Sketch” section of the toolbar (do not use the one under "Modify"). (Figure 7)[[Image:Lab 1B7.jpg|thumb|center|400px|Figure 7: THE Fillet Tool]]
# Change to model space in the layout view to change the viewport.
#:#:# Select one of the two intersecting lines that form the right angles on the base.
#: [[Image:lab_3dprint_6.png|frame|center|Figure 6: Application status bar.]]
#:#:# Use the default fillet size of 0.125” and repeat on the other corner.
#: <h2 style="margin-left: -4.1em;"> Designing the EG Keychain </h2>
#:#:# The sketch should look like Figure 8.[[Image:Lab 1B8.jpg|thumb|center|400px|Figure 8: Fillet Everything]]
# Download and open the [[Media:EG Logo Template.dwg|EG Logo Template]].
#:# Remove the extra lines using the trim tool
# Open the layer properties and click the lightbulb next to the EG Logo layer.
#:#:# Select the trim tool from the “Sketch” section of the toolbar (It is under the fillet tool).
#* Layers are a useful way to separate different components of a drawing file.
#:#:# Select all interior lines that divide the keychain.
#* In this DWG, the EG Logo layer is the image file used to create the text outline.
#:#:# If error messages are indicated, remove the dimensions on the rest of the keychain.
#* Separating model features (e.g. plumbing and electrical) allows separate viewing.
#:#:# The sketch should look like Figure 9.[[Image:Lab 1B9.jpg|thumb|center|400px|Figure 9: Keychain base]]
#: [[Image:lab_3dprint_8.png|frame|center|Figure 7: Layer properties manager.]]
#:# Exit the sketch using the "Stop Sketch" button.
# Turn the EG Logo layer back off by clicking the lightbulb.
#After creating a 2D sketch, the next step is to use that to create a 3D object. In this lab the extrude tool will be used to create a 3D block. In the future,  the revolve or other tools can be used to create more advanced geometry.
# Fill the EG Logo text outline by typing the command REGION. Use Figure 8 to help determine the selection area.
#:# Select the “Extrude” tool from the “Create” section of the toolbar (Figure 10).[[Image:Lab 1B10.jpg|thumb|center|400px|Figure 10: Extrude Tool]]
#: [[Image:lab_3dprint_9.png|frame|center|Figure 8: Filling with REGION command.]]
#:#:# Select the profile of the object  to be extruded, which is the object that was just created.
#: In general AutoCAD commands operate with the same basic steps.
#:#:# Change the extrusion thickness to 0.15” and press Enter.
#:# Type the command.
#:#:# The model will look like Figure 11.[[Image:Lab 1B11.jpg|thumb|center|400px|Figure 11: #Deep]]
#:# Choose command parameters and objects.
# The next step is to add the design to the key chain. For this lab, a vector graphics file will be used in the dxf format provided by NYU. In the future,  a logo can be designed using the sketch tool.
#:## Select object (hit enter after).
#:# Download the NYU Tandon Vector Logo (This logo was converted from the file provided on NYU's identity page).
#:## Enter quantity (type and hit enter).
#:#:# * [[Media:Tandon_long_white.zip|Tandon logo ACAD format]]
#:## Specify position (click on screen).
#:# Select “Insert DXF" under the "Insert" section of the toolbar. (Figure 12)[[Image:Lab 1B12.jpg|thumb|center|400px|Figure 12: Insert DXF]]
#:# Hit the enter key to execute command.
#:# Select the top surface of the key chain (Figure 13).[[Image:Lab 1B13.jpg|thumb|center|400px|Figure 13: Top Surface Select]]
# Remove the inner holes (the counter-space) of the letters A and R in the EG logo.
#:# Rotate the camera again to orient the top correctly.
## Move the letters to the back by using DRAWORDER, select the Rs and As, hit enter, and select ''back'' in the command line. This will move the outlines of the letters back and allows you to select the inner parts of each letter.
#:# Click on the file folder on the window that pops up and select .dxf file you downloaded.
## Input SUBTRACT into the command line and hit enter. SUBTRACT is composed of two parts. Selecting the region to remove from and what needs to be removed.
#:# The logo should appear. (Figure 14)[[Image:Lab 1B14.jpg|thumb|center|400px|Figure 14: Beautiful Logo]]
### Select all of the As and Rs and hit enter. (Note: these will still have the insides filled)
#:#:# Make sure you change the units to inches.
### Select the inside regions you want removed and hit enter.
#:# For this side of the key chain the "Tandon School of Engineering" portion of the logo is not needed.
#: [[Image:lab_3dprint_10.png|frame|center|Figure 9: Create holes with command SUBTRACT.]]
#:#:# Select the bar and everything to the right using click and drag (Figure 15).[[Image:Lab 1B15.jpg|thumb|center|400px|Figure 15: RIP Tandon]]
# Use the EXTRUDE command to add 3/8” height to the text.
#:#:# Delete this portion with the “Delete” key on the keyboard (Not Backspace).
#: [[Image:lab_3dprint_11.png|frame|center|Figure 10: Add height with command EXTRUDE.]]
#:# The logo needs to be scaled to fit the key chain. To keep the spacing of the design,  select an appropriate base point. Use the midpoint of the line on the right side of the box.
# Use the REGION command on the box outline and EXTRUDE to 1/4”.
#:#:# Select the point tool under the "Sketch" section of the toolbar.
# Create a keychain hole.
#:#:# Place a point at the center point of the right side of the box.
## Draw a CIRCLE with radius 1/8”.
#:#:# Delete the bottom and the left side of the box. (Figure 16)[[Image:Lab 1B16.jpg|thumb|center|400px|Figure 16: Partly Delete Box]]
## Change the DRAWORDER of the box to the back.
#:#:# Select the "Scale tool from the "Modify" section of the toolbar.
## EXTRUDE the circle -1/4”.
#:#:# Select the box and torch of the logo by clicking and dragging.
## Change the DRAWORDER of the box to the back.
#:#:# Select the midpoint that was just placed as the base point for scaling
## SUBTRACT the cylinder from the box.
#:#:# Enter a scaling factor of 0.75. (Figure 17)[[Image:Lab 1B17.jpg|thumb|center|400px|Figure 17: Scale the Box]]
#: [[Image:lab_3dprint_12.png|frame|center|Figure 11: Create holes with command SUBTRACT.]]
#:#:# Redraw the 2 sides of the box we deleted using the line tool in the “Sketch” section of the toolbar. (Figure 18)[[Image:Lab 1B18.jpg|thumb|center|400px|Figure 18: Redraw Box]]
# Select all features and publish or export as an STL file.
#:# The logo will be positioned on the keychain.
#: [[Image:lab_3dprint_13.png|frame|center|Figure 12: Export to 3D Print Service.]]
#:#:# Select the entire logo and use the “Move” tool from the Modify section of the toolbar to move it off the base so there is space to draw the alignment line. [[Image:Lab 1B19.jpg|thumb|center|400px|Figure 19: Adjust the Logo]]
# Open the STL file in MakerBot Desktop, click rescale object to convert from inches to millimeters.
#:#:# Select the line tool and draw a 0.925” line from the center of the circle towards the center of the keychain.
#: [[Image:lab_3dprint_14.png|frame|center|Figure 13: Scaling from inches to millimeters.]]
#:#:# Select the logo using the move tool again.
# Explore the features of 3D printing software (scaling, position, rotation).
#:#:# Select “Point to Point” as the move type in the window that appears. (Figure 20)[[Image:Lab 1B20.jpg|thumb|center|400px|Figure 20: Move the Logo]]
#: [[Image:lab_3dprint_15.png|frame|center|Figure 14: Makerbot software.]]
#:#:# Select the midpoint from the side of the box and the end of the line you just created.
#:#:#:# The logo should snap to it. (Figure 21)[[Image:Lab 1B21.jpg|thumb|center|400px|Figure 21: Snap the Logo]]
#:#:# Delete the guideline you created.
#:#:# Exit the sketch.
#:#:# The final sketch is shown in Figure 22.[[Image:Lab 1B22.jpg|thumb|center|400px|Figure 22: Finally Final Sketch]]
#To finish this side of the keychain, the design must be cut into the base. To do this, the extrude tool will be used.
#:#:# To cut the design, select “Extrude" from the "Create" section of the toolbar.
#:#:# Select the profile of the design to cut, in this case, the area around the torch and each of the letters. (Figure 23)[[Image:Lab 1B23.jpg|thumb|center|400px|Figure 23: Select the Outline]]
#:#:# Select "Cut" from the drop down menu next to "Operation" in the window that appeared on the right. (Figure 24)[[Image:Lab 1B24.jpg|thumb|center|400px|Figure 24: Cut the Outline]]
#:#:# Select a distance of -0.06".
#:#:# The final model is shown in Figure 25.[[Image:Lab 1B25.jpg|thumb|center|400px|Figure 25: Depth to the Outline]]
# To 3D print the design, export the file as an STL. This is the only format that can be opened by the 3d printing software.
#:# Click on triangle to the left "Document Settings" to expand the menu, and hover over "Units" to click on the "Change Active Units" button on the right to change to millimeters, but DO NOT set millimeters as the default (default units should be inches). This will convert the model into millimeters. Even though the models are built in inches, millimeters is the only unit that 3D printing software will recognize.
#:# Right click on the box above “Document Settings” and select “Save as STL”. (Figure 26)[[Image:Lab 1B26.jpg|thumb|center|400px|Figure 26: Save Your Work]]
#:# Click "OK" no need to change any of the setting.
#:# Make sure you save it to a location you'll remember like the desktop.
# The last step of the keychain is to make the white insert that will fit in the center to make it two colors.
#:# Click “File" in the toolbar at the top of the screen.
#:# Start a "New Design". (Figure 27)[[Image:Lab 1B27.jpg|thumb|center|400px|Figure 27: New Design]]
#:# Create a rectangle with dimensions 2.2”x0.65”.
#:# Extrude the rectangle 0.12”.
#:#:# This model is shown in Figure 28.[[Image:Lab 1B28.jpg|thumb|center|400px|Figure 28: Inside Box]]
#:# Save this the same way as before.
 
== Preparing to print ==
# Now that the logo design is complete, the next step is to put it together in the 3D printing slicer software. We will be using Cura as the software for orienting parts on the printer and selecting the color of each object. It also generates toolpaths that the printer will follow to print the objects.  
#:# Open Cura. If a menu pops up prompting for the printer, select the “Ultimaker 3”
#:#:# If a menu does not pop up, make sure the printer currently selected is “Ultimaker 3” on the top right corner
#:#:# Otherwise, click the arrow, select the “Add Printer” option, and add “Ultimaker 3.”
#:# To load your two files from above, select “Open File” on the top left corner and open the STL file containing the base of the keychain
#:# Using the “Rotate” tool on among the options to the left, rotate the part so the torch is facing up
#:#:# Uncheck the “Snap Scaling” option to allow for a more precise rotation
#:# Select “Open File” again and load the filler rectangle
#:# Again, orient the part correctly using the “Rotate” tool
#:# Cura, by default, drops the objects on to the build-plate and keeps objects apart. The following steps are needed to combine the filler rectangle within the keychain:
#:#:# Under “Preferences”, select “Configure Cura”
#:#:# Under “Viewport behavior,” make sure to deselect both “Ensure models are kept apart” and “Automatically drop models to the build plate” if they are not already deselected
#:#:# Save your preferences
#:#:# Return to the buildplate and make sure both objects are lying flat on the build-plate by using “Rotate” => “Lay Flat”
#:#:#:# If the “Lay Flat” tool does not lay the object flat, manually type in 0 mm in the “Move” tool for the Z axis
#:# Select the filler rectangle, and using the “Move” tool on the left, enter 0.15mm as the Z value to raise it vertically
#:# Select one object and choose a different extruder on the left. That piece will appear as a different color
#:# Drag the filler piece and place it in the keychain base part
#:# Save the file as a .gcode and upload it to the website
[[Image:Cura_1.png|thumb|center|220px|Figure 29: Cura with both parts loaded]]
[[Image:Cura_2.png|thumb|center|220px|Figure 30: Cura with the base and the infill of the logo]]
 
= Assignment =
 
A *.'''gcode''' file must be [https://eg.poly.edu/submit.php submitted to eg.poly.edu]. It is required for a lab report grade.


{{Laboratory Experiments}}
{{Laboratory Experiments}}

Revision as of 22:17, 29 January 2019

Objective

This exercise will introduce Autodesk Fusion 360, which is drafting software that is used by technical professionals, and basic technical design methods will be shown using this computer-aided design (CAD) software. This software will be used in your semester-long design project by constructing physical prototypes with 3D printing.

To practice this prototyping procedure, an NYU logo keychain will be created in Autodesk Fusion 360 and exported to be 3D printed. The members of the winning team of “Lab 1C: Mousetrap Vehicle Competition” will each receive a 3D-printed keychain.

Overview

Computer-Aided Design

CAD programs, which include Fusion 360, AutoCAD, Revit, SolidWorks, and SketchUp, allow engineers to make precisely scaled drawings. These drawings are used to manufacture equipment, build infrastructure, and allow designers to display their designs with complete specifications and detail. Orthographic views (top, bottom, side, front, back, etc.) can be used to document every aspect of the technical drawing needed for production while isometric views can be used to view the final 3D representation of a product.

This exercise will teach the basics of Autodesk Fusion 360, 3D file formats, and the basics of 3D printing. After this lab, you will be able to create simple 3D files and set them up to be 3D printed.

3D Printing

3D printing allows for rapid prototyping and onsite manufacturing of products. Initially done with plastic, 3D printing now uses new techniques with new materials, such as aluminum, bronze, and glass. Biomaterials are also being incorporated, such as 3D printing ear cartilage and liver tissue. As the 3D printing industry grows, 3D printing will become a big part of many engineering fields.

In this course, 3D printing can be used to produce SLDP course modifications, robot parts, and a team logo for extra credit.

Procedure

Setting up the file

  1. Start AutoDesk Fusion and create an account IMPORTANT: Make sure to use your NYU email.(Figure 1)
    Figure 1: Fusion 360 new file options


Designing the NYU Keychain

  1. The first step to designing the keychain is to draw the base shape:
    1. Start 2D Sketch. (Figure 2)
      Figure 2: Sketch Mode
    2. Select the XZ plane. (Figure 3)
      Figure 3: XZ Plane
    3. Rotate the camera to orient the top correctly using the arrows in the top right of the screen.
    4. Select the rectangle tool from the "Sketch" section of the toolbar. (Figure 4)
      Figure 4: Rocking Rectangle
      1. Draw a 2.6” x 0.7” rectangle starting at the origin.
      2. These values can be typed in (switching which value is changed is done using the tab key)
    5. Select the circle tool.
      1. Draw a 0.7” diameter circle centered in the middle of one of the short sides of the rectangle (the cursor should snap to the center position and becomes blue X with a triangle when you get close.) (Figure 5)
        Figure 5: Cool Circle
      2. Draw another circle 0.45” in diameter in the same position, the sketch should look like Figure 6.
        Figure 6: Smaller Circle
    6. Fillet (round) sharp edges.
      1. Select the fillet tool from the “Sketch” section of the toolbar (do not use the one under "Modify"). (Figure 7)
        Figure 7: THE Fillet Tool
      2. Select one of the two intersecting lines that form the right angles on the base.
      3. Use the default fillet size of 0.125” and repeat on the other corner.
      4. The sketch should look like Figure 8.
        Figure 8: Fillet Everything
    7. Remove the extra lines using the trim tool
      1. Select the trim tool from the “Sketch” section of the toolbar (It is under the fillet tool).
      2. Select all interior lines that divide the keychain.
      3. If error messages are indicated, remove the dimensions on the rest of the keychain.
      4. The sketch should look like Figure 9.
        Figure 9: Keychain base
    8. Exit the sketch using the "Stop Sketch" button.
  2. After creating a 2D sketch, the next step is to use that to create a 3D object. In this lab the extrude tool will be used to create a 3D block. In the future, the revolve or other tools can be used to create more advanced geometry.
    1. Select the “Extrude” tool from the “Create” section of the toolbar (Figure 10).
      Figure 10: Extrude Tool
      1. Select the profile of the object to be extruded, which is the object that was just created.
      2. Change the extrusion thickness to 0.15” and press Enter.
      3. The model will look like Figure 11.
        Figure 11: #Deep
  3. The next step is to add the design to the key chain. For this lab, a vector graphics file will be used in the dxf format provided by NYU. In the future, a logo can be designed using the sketch tool.
    1. Download the NYU Tandon Vector Logo (This logo was converted from the file provided on NYU's identity page).
      1. * Tandon logo ACAD format
    2. Select “Insert DXF" under the "Insert" section of the toolbar. (Figure 12)
      Figure 12: Insert DXF
    3. Select the top surface of the key chain (Figure 13).
      Figure 13: Top Surface Select
    4. Rotate the camera again to orient the top correctly.
    5. Click on the file folder on the window that pops up and select .dxf file you downloaded.
    6. The logo should appear. (Figure 14)
      Figure 14: Beautiful Logo
      1. Make sure you change the units to inches.
    7. For this side of the key chain the "Tandon School of Engineering" portion of the logo is not needed.
      1. Select the bar and everything to the right using click and drag (Figure 15).
        Figure 15: RIP Tandon
      2. Delete this portion with the “Delete” key on the keyboard (Not Backspace).
    8. The logo needs to be scaled to fit the key chain. To keep the spacing of the design, select an appropriate base point. Use the midpoint of the line on the right side of the box.
      1. Select the point tool under the "Sketch" section of the toolbar.
      2. Place a point at the center point of the right side of the box.
      3. Delete the bottom and the left side of the box. (Figure 16)
        Figure 16: Partly Delete Box
      4. Select the "Scale tool from the "Modify" section of the toolbar.
      5. Select the box and torch of the logo by clicking and dragging.
      6. Select the midpoint that was just placed as the base point for scaling
      7. Enter a scaling factor of 0.75. (Figure 17)
        Figure 17: Scale the Box
      8. Redraw the 2 sides of the box we deleted using the line tool in the “Sketch” section of the toolbar. (Figure 18)
        Figure 18: Redraw Box
    9. The logo will be positioned on the keychain.
      1. Select the entire logo and use the “Move” tool from the Modify section of the toolbar to move it off the base so there is space to draw the alignment line.
        Figure 19: Adjust the Logo
      2. Select the line tool and draw a 0.925” line from the center of the circle towards the center of the keychain.
      3. Select the logo using the move tool again.
      4. Select “Point to Point” as the move type in the window that appears. (Figure 20)
        Figure 20: Move the Logo
      5. Select the midpoint from the side of the box and the end of the line you just created.
        1. The logo should snap to it. (Figure 21)
          Figure 21: Snap the Logo
      6. Delete the guideline you created.
      7. Exit the sketch.
      8. The final sketch is shown in Figure 22.
        Figure 22: Finally Final Sketch
  4. To finish this side of the keychain, the design must be cut into the base. To do this, the extrude tool will be used.
      1. To cut the design, select “Extrude" from the "Create" section of the toolbar.
      2. Select the profile of the design to cut, in this case, the area around the torch and each of the letters. (Figure 23)
        Figure 23: Select the Outline
      3. Select "Cut" from the drop down menu next to "Operation" in the window that appeared on the right. (Figure 24)
        Figure 24: Cut the Outline
      4. Select a distance of -0.06".
      5. The final model is shown in Figure 25.
        Figure 25: Depth to the Outline
  5. To 3D print the design, export the file as an STL. This is the only format that can be opened by the 3d printing software.
    1. Click on triangle to the left "Document Settings" to expand the menu, and hover over "Units" to click on the "Change Active Units" button on the right to change to millimeters, but DO NOT set millimeters as the default (default units should be inches). This will convert the model into millimeters. Even though the models are built in inches, millimeters is the only unit that 3D printing software will recognize.
    2. Right click on the box above “Document Settings” and select “Save as STL”. (Figure 26)
      Figure 26: Save Your Work
    3. Click "OK" no need to change any of the setting.
    4. Make sure you save it to a location you'll remember like the desktop.
  6. The last step of the keychain is to make the white insert that will fit in the center to make it two colors.
    1. Click “File" in the toolbar at the top of the screen.
    2. Start a "New Design". (Figure 27)
      Figure 27: New Design
    3. Create a rectangle with dimensions 2.2”x0.65”.
    4. Extrude the rectangle 0.12”.
      1. This model is shown in Figure 28.
        Figure 28: Inside Box
    5. Save this the same way as before.

Preparing to print

  1. Now that the logo design is complete, the next step is to put it together in the 3D printing slicer software. We will be using Cura as the software for orienting parts on the printer and selecting the color of each object. It also generates toolpaths that the printer will follow to print the objects.
    1. Open Cura. If a menu pops up prompting for the printer, select the “Ultimaker 3”
      1. If a menu does not pop up, make sure the printer currently selected is “Ultimaker 3” on the top right corner
      2. Otherwise, click the arrow, select the “Add Printer” option, and add “Ultimaker 3.”
    2. To load your two files from above, select “Open File” on the top left corner and open the STL file containing the base of the keychain
    3. Using the “Rotate” tool on among the options to the left, rotate the part so the torch is facing up
      1. Uncheck the “Snap Scaling” option to allow for a more precise rotation
    4. Select “Open File” again and load the filler rectangle
    5. Again, orient the part correctly using the “Rotate” tool
    6. Cura, by default, drops the objects on to the build-plate and keeps objects apart. The following steps are needed to combine the filler rectangle within the keychain:
      1. Under “Preferences”, select “Configure Cura”
      2. Under “Viewport behavior,” make sure to deselect both “Ensure models are kept apart” and “Automatically drop models to the build plate” if they are not already deselected
      3. Save your preferences
      4. Return to the buildplate and make sure both objects are lying flat on the build-plate by using “Rotate” => “Lay Flat”
        1. If the “Lay Flat” tool does not lay the object flat, manually type in 0 mm in the “Move” tool for the Z axis
    7. Select the filler rectangle, and using the “Move” tool on the left, enter 0.15mm as the Z value to raise it vertically
    8. Select one object and choose a different extruder on the left. That piece will appear as a different color
    9. Drag the filler piece and place it in the keychain base part
    10. Save the file as a .gcode and upload it to the website
Figure 29: Cura with both parts loaded
Figure 30: Cura with the base and the infill of the logo

Assignment

A *.gcode file must be submitted to eg.poly.edu. It is required for a lab report grade.