Structure Design

  1. Design the 3D structure via the software Solidworks (not free) or Onshape (free, online)
  2. Design the mold within the part skeleton, then set the output file format as ‘stl’, the size of stl mold is in mm size.

Mold printing

Equipments

  1. Hardware: Wanhao Duplicator 4S, with the filament material of ABS or PLA
  2. Software: 1) Java; 2) Python; 3) ReplicatorG/ SIMPLIFY 3D(Optional);
  3. Environment setting and software installation

Operations

  1. connect the computer with the printer via USB connector, then configure the port and driver for the 3D printer, then click “Connect” –> successful connection;
  2. slice the file (‘stl’ model) for gcode file (Parameter adjustment: fill with 100%; layer thickness: 0.2mm; speed: 35mm/s; temperature: 230 degrees or 220 degrees); then generate the gcode file for the current model (equal to the slice function), and generate .x3g file into the SD card –> file generation for printing;
    Alternatively, we can also print the mold directly from the PC control.
  3. printer operations
    level the building plate:
    1) select the option for leveling;
    2) change the position of the nozzle by moving the nozzle base;
    3) change the height of the nozzle in the four corners (where the 3d tape is covered.) with adjustment of the four knobs under the plate; ensure the distance between the nozzle and plate is around the height of A4 paper;
    load the filament:
    1) wait until the nozzle has reached the temperature about 220 degrees for printing;
    2) gradually fill the filament into the nozzle through the top hole of the nozzle base.
    3) stop filling until the filament has come out from the nozzle. Select the file for printing:
    1) preheat and wait;

Tips or notices

  1. After the first layer is printed, screw down the nut a little bit to bring it closer together; –(aim for the better printing mold);
  2. In order to print better mold, PLA is better than ABS material during experiments.

Common problems:

  1. Solution for Edge warping?
    • PLA can have better performance than ABS, although the quantity printed is lower.
    • Exterior support is necessary
    • Large base can help prevent the edge warping. In order to take it off easily, the base should not be very thick, 1mm is enough.
  2. Solution for Printing discontinuity?
    • Unload the filament and reload it, in order to make sure the wire is good for printing.
    • Set the printing width suitable.