Keychain by 3D Printer

Introduction to 3D Printers

A 3D printer is a device that creates three-dimensional objects by depositing material layer by layer based on a digital design. 3D printing is an additive manufacturing process, meaning it builds objects from the ground up using precise layering techniques. It can be done in a variety of processes in which material is deposited, joined or solidified under 3D Designing software.

In the 1980s, 3D printing techniques were considered suitable only for the production of functional or aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping. As of 2019, the precision, repeatability, and material range of 3D printing have increased to the point that some 3D printing processes are considered viable as an industrial-production technology; in this context, the term additive manufacturing can be used synonymously with 3D printing. One of the key advantages of 3D printing is the ability to produce very complex shapes or geometries that would be otherwise infeasible to construct by hand, including hollow parts or parts with internal truss structures to reduce weight while creating less material waste. Fused deposition modelling (FDM), which uses a continuous filament of a thermoplastic material, is the most common 3D printing process in use as of 2020.

Types of 3D Printers:

1. Stereolithography (SLA): Stereolithography (SLA) is an additive manufacturing (3D printing) technology that uses a laser to cure liquid photopolymer resin layer by layer, creating highly detailed and precise 3D objects.
2. Selective Laser Sintering (SLS): SLS is a 3D printing technology that uses a high-powered laser to sinter (fuse) powdered material layer by layer, creating solid objects without needing support structures.
3. Fused Deposition Modelling (FDM): FDM is the most common and affordable 3D printing technology, where a thermoplastic filament is melted and extruded layer by layer to create objects.
4. Digital Light Process (DLP): DLP is a resin-based 3D printing technology similar to Stereolithography (SLA) but uses a digital light projector to cure an entire layer of liquid resin at once, making it faster than SLA.
5. Multi Jet Fusion (MJF): MJF is an industrial 3D printing technology developed by HP, which uses a fine powder (usually nylon) and a combination of fusing and detailing agents to create high-quality, durable parts.
6. Poly Jet: Poly Jet is a high-resolution resin-based 3D printing technology that jets liquid photopolymer onto a build platform and cures it with UV light, creating extremely detailed, smooth, and multi-material prints.
7. Direct Metal Laser Sintering (DMLS): DMLS is an industrial metal 3D printing technology that uses a high-powered laser to selectively fuse metal powder layer by layer, creating strong and complex metal parts.
8. Electron Bean Melting (EBM): Electron Beam Melting (EBM) is an industrial metal 3D printing technology that uses a high-energy electron beam to fully melt metal powder in a vacuum, creating dense, high-strength metal parts.

Types of Filaments:

1. Polylactic Acid (PLA): PLA is one of the most popular and used in Fused Deposition Modeling (FDM) 3D printing. It is a biodegradable thermoplastic made from renewable resources like corn starch or sugarcane.
2. Acrylonitrile Butadiene Styrene (ABS): ABS is a widely used thermoplastic in Fused Deposition Modeling (FDM) 3D printing. Known for its strength, impact resistance, and heat resistance, ABS is a great material for making durable and functional parts.
3. Polycarbonate (PC): PC is a strong, durable, and heat-resistant thermoplastic used in Fused Deposition Modeling (FDM) 3D printing. Known for its high mechanical properties, impact resistance, and thermal stability
4. Polyethylene Terephthalate (PET): PET is a widely used thermoplastic in Fused Deposition Modeling (FDM) 3D printing, known for its durability, chemical resistance, and flexibility. PET is also recyclable, making it an environmentally friendly filament choice for many applications.

FUSION 360 - The Software

Autodesk Fusion 360 is the most used designing software for 3D designing.

I used Fusion 360 for the designing of the 3D design. Approximately, I spend one week for understanding the software, for the better and quick learning I watched Youtube videos. I faced too much problems while understanding the setting and features of the software.

About FUSION 360 - Fusion 360 is a CAD/CAM/CAE cloud-based software developed by the software design campany autodesk. This software combines simple and dynamic modeling option with high versatility to create manufacturable designs, prototypes, and solids. Fusion 360 offers a wide range of powerful tools and features to support the design for flow of work. From sketching and parametric modeling to simulation and rendering. It take some time to explore the different Fusion 360 library features, tools tabs, menus, and commands to familiarize ourself with the capabilities of Fusion 360. Fusion 360 includes parametric modeling, timeline-based design history, integrated simulation, generative design, CAM capabilities, and cloud collaboration.

Understanding the different types of Fusion 360 -

1. Welcome to Autodesk Fusion 360: Guide to Getting Started
2. Autodesk Fusion 360 Basics: Getting Started with Sketching
3. Autodesk Fusion 360 Basics: 3D Modeling Made Easy
4. Autodesk Fusion 360 Basics: The Fundamentals of Assemblies
5. Autodesk Fusion 360 Basics: Manufacturing Fundamentals
6. Autodesk Fusion 360 Basics: Simulation Tools for Everyone
7. Autodesk Fusion 360 Basics: Collaboration and Data Management
8. Autodesk Fusion 360: It’s More Than Just a Great CAD Tool

(Each plan has a different price point depending on the features and services included.)

Ctrl+Shift + F - Full-screen

Delete - delete selected object

Shift + Middle Mouse Button - orbit

Crtl + Z - undo

Crtl + C - Copy

Crtl + V - Paste

Crtl + X - Cut

S - Sketch Toolbox

R - 2-point rectangle

C - center diameter circle

E - Extrude

F - Fillet

H - Hole

J - Join

L - Line

I - Measure

M - Move

O - Offset

P - Project

D - Sketch dimension

T - trim

Crtl + A - All CAM tools

Crtl + I - Import Tool Library

Crtl + E - Export Tool Library

Crtl + G - Generate Toolpath

How to male Keychain:

I used Fusion 360 for the designing of the keychain. Approximately, I spend one week for understanding the software settings and features, for the better and quick learning I watched youtube videos. I used Creality Ender V3 se 3D printer.

Step-by-step:

1. Create a sketch and select a "Plane".
2. specify the size of rectangle (select 2 point rectangle).
3. Draw a rectangle (ex: 65mm * 25mm).
4. Use "Sketch dimension" for accurate measurement.
5. Select the "Offset option" and click on the "Rectangle".
6. Offset the sketch by 2mm.
7. Select "Fillet" and click on the 4 outer corners.
8. Type 5mm for the radius.
9. click the "Line".
10. Right click on the "line" and select "Normal/construction".
11. Select line to define a 7mm distance between them.
12. Create a "Point" in the middle of the line.
13. Draw a 5mm circle from the point that was created in line.
14. Select the "Create text".
15. Type your name, select impact as the font type and adjust the heights to fit the rectangle.
16. Create the Name accordingly.
17. Finish sketch.
18. Now Extrude the sketch by 3mm. (Do not select the hole)
19. Hide all bodies from the browser and show the sketch.
20. Now select the Border and Name.
21. Select extrude and type 1.5mm.
22. From the extrude menu select offset plane and enter 3mm.
23. Click the "eye" icon to show all bodies.
24. hide the sketch.
25. Complete 3D Design of keychain

IMPORTANT: In fusion 360 STL file is very important. For the next step of 3D printing the file must be imported in STL file. The full form of STL is Standard Tessellation Language. By using STL files in Fusion 360, you ensure that your designs are ready for the next steps, whether it's prototyping, printing, or sharing with colleagues.

In Fusion 360 we have to import STL file for 3D Printing and DXF file for Laser Cutting.

STL= File -> Import -> STL -> Select file -> Open

I post some picture that may help you for the doubt while making the keychain. I took help from some videos that help me lot while learning and once I completed the all over design of keychain my interest for 3D designing had increased. Now I can design whatever I want.

**Here I uploaded the design I made and the problem I face while making the keychain and also shared where I made mistakes.

The Software- CREALITY SLICER

Creality Slicer is a slicing software developed by Shenzhen Creality 3D Technology Co.Ltd. Based on Cura, an open source slicing application for 3D printers, Creality Slicer is featured with 3D model editing and importing, supports for slicing and parameter profile editing, previewing and saving.

Creality Slicer is a free slicing software developed by Creality, primarily designed for their FDM 3D printers. It is based on Ultimaker Cura but modified to work seamlessly with Creality printers like Ender, CR, and Sermoon series.

Popular Free Slicers:

1. Creality Slicer
2. Ultimaker Cura
3. PrusaSlicer
4. OrcaSlicer
5. MatterControl

How to work with Creality Slicer:

Step-by-step:

1. Download and install the Creality Slicer 6.0
2. Setup the Printer. (Settings > Printer > Add Printer.)
3. Select the Creality printer model (e.g. Ender 3, etc.)
4. Click "Add" to save the settings
5. Import Your 3D Model. (Click "Open File" or drag & drop your STL file into slicer).
6. The model will appear on the plate.
7. Use the Move, Scale, Rotate tools to adjust the position of the model if needed.
8. Adjust Print Settings. (Layer height, Infill density, Support, Adhesion).
9. Choose Print Quality. (Fast print, Standard, High quality).
10. Slice the Model.
11. Click "Slice" to process.
12. The slicer will generate the G-code file and show estimated print time.
13. Click "Preview" to check the print layers.
14. Save & Transfer G-code.
15. Click "Save to File" and save the G-code onto a SD card/USB drive.
16. Insert the storage device into your 3D printer.

The 3D Printer:

I used "FDM Printer" for 3D printing and used ABS type of filament. FDM known as "Fused Deposition Modelling". FDM is one of the most common and affordable 3D printing model. It works by melting a "thermoplastic filament" and depositing it layer by layer to build a 3D object.

Main Components:

1. Control Box
2. Control Knob
3. Surface Printer
4. Display Screen
5. Nozzle Assembly
6. Spool Handle
7. Extruder and Hotend
8. Power
9. Y Limit Switch
10. Z Limit Switch
11. X Limit Switch
12. Y Stepper
13. Z stepper
14. X Stepper
15. Coupling
16. Cooling fan

Important: In display information we will see

1. Model Name
2. Set Temp. of Nozzle
3. Current Nozzle Temperature
4. Set Temp. of Hotbed
5. Current Temp. of Hotbed
6. Part Cooling Fan speed
7. Current location of the nozzle
8. Print time
9. Print progress
10. Prompt massage
11. Print Speed

Filaments in FDM:

1. PLA (Polylactic Acid)
2. ABS (Acrylonitrile Butadiene Styrene)
3. PETG (Polyethylene Terephthalate Glycol)
4. TPU (Thermoplastic Polyurethane)
5. Nylon
6. Carbon Fiber Filaments
7. Wood, Metal, & Glow-in-the-Dark Filaments.

Applications of FDM:

1. Prototyping & product design
2. Functional parts & mechanical component
3. Hobbyist & DIY projects
4. Educational models & learning tools
5. Customized tools, brackets, and casings.

How it works:

1. I used Creality Ender V3 se 3D printer.

1) Printer Preparation:

1. Turn on the power button.
2. Load Filament
3. Insert a filament (PLA, ABS, etc.) into the extruder.
4. Heat the nozzle to the required temperature.
5. Level the Print Bed
6. A properly leveled bed ensures a smooth first layer.
7. Use paper test. (Slide a paper between the nozzle and bed—it should have slight resistance).

2) Printing Process:

1. Start the Print
2. Select the G-code file from the printer’s screen.
3. The printer will heat the nozzle and bed to the required temperature
4. Extrusion & Layer-by-Layer Printing
5. The hotend melts the filament and deposits it layer by layer.
6. The cooling fan helps solidify the layers quickly.
7. The print bed moves down (Z-axis) as each layer is completed
8. Monitor the Print.

3) Print Completion:

1. Print Finishes & Cool Down
2. Once printing is done, the nozzle and bed start cooling down
3. Remove the print.(Use a spatula).
4. Complete the print.

4) Key notes:

i) Bed Levelling:

1. Prepare >auto home (wait for nozzle move).
2. Prepare >disabled steppers (close steppers drives).
3. Move the nozzle front/left leveling screw.
4. Adjust platform heights by turning knob underneath.
5. Screw on all 4 corners for adjustment.

ii) Diameter of Filament:

1. The ABS filament has 1.75mm diameter.
2. The PLA filament has 1.75mm diameter.

iii) Note:

1. If our Heat Bed is not calibrated then our 1st layer will not print properly.
2. Every printer have 3 end stops, which shows the starting point of Axis.

For Keychain making:-

1. https://www.youtube.com/watch?v=y2yezZKNiOo

For Fusion 360:-

1. https://www.youtube.com/watch?v=9Jgty4QDtss&list=PPSV
2. https://www.youtube.com/watch?v=0ByAnvgcRV8&list=PPSV
3. https://www.youtube.com/watch?v=d3qGQ2utl2A&list=PPSV

For Creality Slicer:-

1. https://www.youtube.com/watch?v=c1-gOxbuoZ8&list=PPSV&t=62s
2. https://www.youtube.com/watch?v=6Ws6_ApBQLI&list=PPSV

For 3D Printer:-

1. https://www.youtube.com/watch?v=c1-gOxbuoZ8&list=PPSV
2. https://www.youtube.com/watch?v=btZ3uUviR_8&list=PPSV

Conclusion:

I personally enjoy the work. I learnt so many new things in Fusion 360,Creality Slicer, Creality Ender V3 SE. Fusion 360 is a powerful and versatile CAD software that makes my keychain easy and efficient. With its parametric modeling, sketching, and extrusion tools, I can create personalized keychain designs with precise dimensions and unique styles.

Creality Slicer is a user-friendly and efficient slicing software designed specifically for Creality 3D printers. It simplifies the process of converting 3D models. Making it easier for beginners and experienced users to prepare prints in 3D printers. I took 2-3 days for learning the settings and features and tools of Creality Slicer. I use Creality Print 6.0 which is the latest version in creality and it could be very easy for me to learn from some youtube videos. That I mentioned in my blog.

For the very first time when I was the beginner for the Fusion 360. I started learning Fusion 360 from the keychain making that was very interesting aspect for me. It has some advantages and disadvantages also that we know while learning the 3D designing software.

Thank You.