3D Printed Bird Automata

This document outlines the design and CAD process for creating a Bird Automata, a mechanical bird model designed for 3D printing.

Materials Needed

1. PLA filament
2. 3D printer
3. Patience

CAD Download

Pre Sliced:

MakerWorld - https://makerworld.com/en/models/789180#profileId-727357

STEP:

printables - https://www.printables.com/model/1073775-bird-automata/collections

Thangs - https://thangs.com/designer/Pixel%20Shark/3d-model/Bird%20Automata-1181373

When designing a product, several factors should be considered:

1. Functionality: Ensuring the design fulfils its intended purpose.
2. Assembly: Simplifying how parts are put together.
3. Manufacturing Process: Optimizing the tools and materials available.
4. Cost: Balancing affordability and quality.
5. Complexity: Keeping the design user-friendly.
6. Waste: Minimizing material waste during production.
7. Uniqueness: Adding innovative or distinctive features.

For this project, the primary focus was to simplify assembly, particularly since the target audience includes children and the general public. The design allows users to infer and complete the assembly process intuitively by minimising the need for detailed instructions.

To achieve this:

1. Print-in-place methods were used for components like the body, shaft, and cam. Although this approach compromises some strength, it greatly simplifies assembly.
2. Connections were optimized for 3D printing for parts like the body and wings. For instance, printing parts along the X-Y axis improves strength and reduces reprints, especially in cases where excessive force might be applied.

A CAD model is essential for 3D printing. Before starting with CAD software, spend time brainstorming and sketching rough ideas to clarify your design.

Choosing CAD Software

Here are some commonly used CAD programs:

1. Beginner-Friendly:
2. Tinkercad
3. Intermediate to Advanced:
4. Fusion 360
5. Onshape
6. Shapr3D
7. Autodesk Inventor
8. SolidWorks
9. FreeCAD

For beginners, Tinkercad is a great entry point. However, advanced software like Fusion 360 provides more flexibility and functionality for complex designs.

Designing the Bird Automata

When creating the CAD model, plan the design process carefully. You can:

1. Use multiple sketches or a few "parent" sketches, depending on your workflow preference.
2. Create a parametric model, which updates dynamically when variables change.

For this project, most sketches were made on the top and front planes for simplicity. Using fewer sketches helps identify constraints easily, as fully constrained sketches are visually distinct in CAD software.

Animation and Testing

Animating the model is especially useful for designs with mechanisms. By using tools like sectional analysis, you can simulate motion to identify collisions or tolerance issues before printing. This step reduces material waste during prototyping.

Before 3D printing, optimize your design in the slicer software to minimize waste and improve functionality.

Key Considerations

1. Purpose: What is the print’s intended use?
2. Forces: Will the print bear weight or stress?
3. Environment: Will it face extreme temperatures or humidity?
4. Durability: Will it experience wear and tear?
5. Weight: Should the model be lightweight?
6. Cost: How much material and time are you willing to invest?

Slicer Settings to Adjust

1. Infill Density: Adjust for strength or material savings.
2. Infill Pattern: Choose patterns based on stress distribution.
3. Top/Bottom Wall Thickness: Optimize for durability.
4. Wall Loops: Increase for additional strength.
5. Layer Height: Smaller layers improve detail but increase print time.
6. Nozzle Diameter: A larger nozzle speeds up printing but reduces precision.
7. Acceleration Settings: Adjust for speed and stability.
8. Temperature: Fine-tune for material consistency and print quality.

By optimizing these settings, you can enhance the quality and performance of your Bird Automata while minimizing material usage and print failures.