ROUND TWO! - Here are some notes on my attempt (!) to print out the individual parts from this mechanism. I learned a few ‘what not to do’ things here, with some successes, and more tests coming. Read on if you are interested…
For this test, I took the original CAD parts and brought them in to a single Preform 1.6 session. It took me a minute to realize I could multi-select them all - that was a huge help
Once I brought them in, I manually spaced them out and decided (for this round) to manually set up supports. (not entirely successful… more on that below).
I also decided to attempt to print some flat-based objects directly on the build platform with NO supports. (also not entirely successful, but educational - and somethings did work).
I should also point out that I used the native scale of these parts (where in the assembled print run I did first, I had to scale things down to 75% of native to get it to fit the build volume. It was interesting to see that the assembled part did better in some ways - though smaller - than the un-assembled parts printed individually at a larger size. I think this was because the assembled part fused super small parts together and they maintained some integrity. Where printing those small parts separately resulted in failures… more on that below
In all, set up time was 45-60 minutes. NOTE: as indicated by Preform support folks, this is NOT strictly necessary to do - I’m on a quest though to understand how/what/why and so I’m going this route for a bit longer).
I printed still at 0.05 with Grey Resin. VERY tempted to try .025, but not ready for that yet.
Here’s the Preform 1.6 layout:
Print Time was just over 7 hours.
As you can see - it is perhaps a crazy layout. Pretty tight. I had no clue if I would have ‘resin flow’ issues or what. Also as this was my third or fourth print, I was hoping I would not start to see any issues with peel as the tray is starting to get some built up use and I can SEE where things have been printed on the tray floor when scraping the resin tank…
Furthermore, in one case (below), I kept getting RED in the support editing mode. And though you can see I did not add a lot of supports, even when I added more, it stayed red. I was unsure where the magic missing support was, so I just went with less. Which you will see below may have been the source of the failure.
Flirting with Disaster - manual edits and too much red.
So here’s how it turned out on the build platform:
Definitely some failures here… but some successes too (some better than in the assembled part).
Here are the cleaned parts… some good. many bad:
and some close-ups of failures (note - these are probably bad because they were simply too small, on the build platform directly, or not angled in their supports… again, I was testing the bottom here and not suggesting this is the right way to go… )
These two were manually mounted the same way. Still, one printed fine and the other failed. Not sure why. Will try again in a future print.
Not enough supports? Likely.
This simple post or pin was directly on the build platform. Seemed pretty straight forward (a simple cylinder), but the sides came out quite badly. Odd contrast to the screw (configured the same on the platform, no supports) not far away that printed perfectly - threads too. So maybe this failure had more to do with proximity to other parts? Not sure.
This one was nearly flawless except where this base touched the build platform. I am just curious how/why the auto-support bases come out so clean, but this one failed. Alas it will need a reprint.
And lastly this barrel, which printed very well - the grooves are geometry. wow. And yet the super thin transition this next region cracked. The mounting for this piece was manual, but off the build platform (it had supports) and its was oriented so that those grooves were vertical and needed no supports. I thought that worked well, but the flat neck area failed. Maybe just too thin. But from inspecting the thickness in Grabcad (they have a nice measuring tool btw), this failed wall was .5 mm thick. Is that too thin for this printer? Seems it should be able to do that. Note also that this part is NOT closed. So this failure would not seem like a blow out. I will probably reprint this either at an angle, or at a finer resolution (0.025) to see if I can get it to work.
In the end, I’m not convinced I can get all these parts to print successfully at this scale - even though the thinnest walls appear to be about 1/2 mm thick. That may be the practical limit at 0.05 with grey resin, or my crazy approach to mounting may be to blame.
Next up: auto-generated supports for failed parts. I will go the auto-route on a few of the key parts next and see how they turn out. Still at 0.05 resolution setting with grey.