#SortIT, Problem Solving and Usage Guide (SortIT.co.za)

3D printing has revolutionised the way we approach design and manufacturing, offering unparalleled flexibility and precision. Today, we're diving into a real-world application to not only learn the basics of 3D printing but also to solve a practical problem for a customer. Our primary focus will be on dual-colour 3D letter channel printing, but we'll start by tackling a challenge involving concrete containers.

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Understanding the Challenge

A customer who makes concrete containers approached us with a problem. Their containers, which are poured into silicone moulds, often warp into an oval shape rather than maintaining a perfect circle. To address this, we've designed a prototype insert to help the mould retain its shape during the curing process. This insert will be printed using our new 3D letter channel printer from AM.CO.ZA

Designing the Insert

To design the insert, we'll use TinkerCAD, a free and user-friendly program ideal for beginners. TinkerCAD allows us to create and modify 3D models easily.

Creating the Cylinder:

We begin by measuring the internal and external diameters of the mould. For this example, our internal diameter is 106 mm.

In TinkerCAD, we select a cylinder and set its outer diameter to 106 mm. We then adjust the edges to create a perfect circle.

Adjusting the Height:

The next step is to set the height of the cylinder. We use the ruler tool to set the height to 25 mm.

Creating the Ring:

To create a ring, we need to punch a hole in the middle of the cylinder. We duplicate the cylinder, resize it to an internal diameter of 91 mm, and set it as a hole. Aligning both cylinders perfectly, we then group them to form a ring.

Designing the Handle:

For easy removal from the mould, we add a handle to the insert. Using a rectangle, we adjust its dimensions to 10 mm thick and position it across the ring, ensuring it's centred and aligned. This handle will be our grip point.

Preparing the Model for Printing

Once the design is complete, we export the model as an STL file, the standard format for 3D printing. The next step involves preparing the file for our 3D printer using Cura, a popular slicing software.

Loading the File:

We open the STL file in Cura, where we can adjust settings such as layer height and infill percentage. For our project, we select a 0.25 mm layer height and a 5% infill, balancing strength and material usage.

Material Settings:

Using PETG filament from AM, we set the nozzle temperature to 240°C and the bed temperature to 70°C. These settings ensure proper adhesion and print quality.

Speed and Cooling Adjustments:

We configure the printer to an initial layer speed of 10 mm/s, increasing to 150 mm/s for subsequent layers. Cooling fans are set to 100% to ensure each layer solidifies correctly.

Printing the Insert

With the model sliced and settings configured, we save the file to an SD card and load it into the printer. After preheating the bed and nozzle, the printer begins the job, starting with a skirt to check layer height and adhesion.

Post-Processing

After printing, the insert might have rough edges, especially if printed at higher speeds. Using sandpaper or clippers, we clean up any excess material or stringing to ensure a smooth finish.

Final Steps

Once the insert is cleaned, it's ready to be used. We slide it into the silicone mould to prevent warping during the concrete curing process.

Conclusion

This exercise not only teaches us the basics of 3D printing but also demonstrates how to solve real-world problems with custom-designed solutions. As we continue to explore the capabilities of our 3D printer, stay tuned for more projects and tutorials that will help you master this incredible technology.

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