Friday, May 12, 2017

3D Printed Gift Box lid redesign

The first lid (left) and the refined improved version (right)
Challenge: Following on from the previous sequential print the student was unhappy with the quality of the lid.  He was insistent on redesigning the lid to improve the finish of the print.
Background: As noted in the previous details two aspects of the lid of the Mothers Day Gift Box had not proved successful.   The rose had been printed as part of the lid and then manually removed - which left residual filament on the lid.   The handle for the box detatched when the print was lifted, the lid was increased in size and sunk deeper into the lid to provide more strength and stability.
Level of difficulty: Low the student had got significantly close with the first print, and was given the option of using this lid in the final version.  He wanted to improve its design and was
therefore making adjustments to the print instead of designing a new lid.
Size: 10cm by 10cm to a depth of 5mm.
Timeframe: Seven hours.
Issues: Non - the two probelm areas were successfully addressed.
Process: Tinkercad/Cura, refining of already created work.'
What we would do differently: The student (Y5/9 YO) was driving the design and the process.  He was the one who wanted to reprint and we were happy to allow him to do so, on the basis that he had created an original idea - this should allow a student to move onto greater things in the future and should also be put in the context of the student creating his first challenging print and doing so in his own time to completed the project.

Thursday, May 11, 2017

3D Printed Gift Box

Above: Completed in two stages - gift box with lid
Challenge: Student given free range to create an original design piece from scratch.
Background: This student had produced a name plate, was then looking for an additional challenge to really stretch himself.  He came upon the idea of producing a gift box for either Mothers Day (which is this weekend) or for his mothers birthday (if the timeframe would prevent it from being ready).  The student is a nine year old student who was experiencing an opportunity to use the 3D Printer for the first time.
Level of Difficulty: High - this was a challenging print in multiple stages involving significant planning.
Size: The print was constructed in two significant pieces.  The box itself had a 10cm base and width and depth of 10cm.  The lid was 9.5cm by 9.5cm with a depth of 5mm.  This allowed it to fit into the box itself.
Above: Box with interior visible
Timeframe: Box - ten hours.   The lid was initially eight hours and then seven hours with the reprint.
Issues: The lid initially had two aspects to it, the handle pictured above and a rose next to it.  The rose did not print successfully and was removed (as seen by the filament on the lid above).  The handle was removed as a result of printing and detatched the first time it was picked up.  The box itself held a number of objects that were built into the sides of it 'Mum' and a heart on the other three sides.  The box contained considerable rafting to allow it to be layered which had to be removed.  The finish was not perfect on the base when the rafting was removed, but this required some basic sanding and the use of a craft knife.  As a result a repeat print was made of the lid, with the second version having a removal of the rose.
Above: Lid seperate with handle visible
Process: Initial design was created in Tinkercad.  The design was then passed between three students, the one with the original design and then two who contributed tweaks and details to the completed project.
What we would do differently: Not a lot this is an example of a student really pushing himself with his 3D design in creating an intricate project that had parts that related to each other.  The student refined his idea repeatedly to include significant detail and produce an outstanding 3D Print.

Tuesday, May 9, 2017

3D Printed iPad Stand - Delux

Above: iPad stand Mark Two
Challenge: To improve the design of the student created iPad stand.
Background: This was a follow up print to one previously designed by the student.  The student had created it independently but as a result of feedback was asked to personalise the stand and also this about providing extra support for the stand by the addition of a bracket at the back.
Above: Brace at back clearly visible
Level of Difficulty: Medium - the original print was a success but the challenge was to add value or additional features to a print that had already been successful.
Size: As previously stated, 80mmx 70mmx 60mm.
Timeframe: Eight hours with the addition of the brace and personalisation of the name, a two hour increase on the original.
Issues: the rafting provided by Cura 2 software was difficult to remove perfectly from the base.
Process: All additional changes to design were carried out by using Tinkercad and then imported again into Cura 2.
What we would do differently: Nothing.  This is a considerable improvement on the original design (which also worked fine) as a display piece and a conversation piece about 3D Printing this is an excellent example of something positive and there is clear progression for the student from his first original design (name plate) to create something with an expressed purpose.

Sunday, May 7, 2017

Beginners Guide to 3D Printing

Above: Students 'heart' design
Challenge: Starter for the students to use the 3D Printer in a creative way.  Students were shown Tinkercad and encouraged to come up with a design of thier own choosing independently.
Background: It was the first time the student had used the 3D Printer as the New Zealand school year runs February to December, by this stage (May) some students had not taken an opportunity to use the 3D Printers so they were encouraged to do so. (the machines had been serviced and were previously not available).
Level of Difficulty: Low - student had not previously had any experience with Tinkercad or 3D Printing and this was produced by the student in under five minutes.
Issues: None - student was extremely pleased with the process and the opportunity to produce a novelty item in a short time.
Size: As shown in the photograph - three cm in length.
Timeframe: Thirty minutes.
Process: Tinkercad default used, with the new interface there are a number of objects that are able to be produced instantly, the heart being one of them.  With this produced the only other detail was the hole that was put into the centre (so it could be used as a necklace).  
What would be done differently: This was a positive experience an a relatively straightforward print with an extremely short print time.  Using this format as an introductory lesson or creation process it would be possible to produce an entire classroom worth of design in a short period of time and be able to print on a single printer during a short two or three day period.  The other consideration is due to the print time the students saw the machine operating from start to finish in the classroom.  

Saturday, May 6, 2017

3D Printed iPad Stand

Challenge: Once the name plates were completed the students were encouraged to come up with an original design that served a practical purpose, something that they could use.  They were give
As shown from above the completed print
n free reign to come up with any design however the printing of designs was dependant on a filtering process.  Students worked on design in thier own time.
Background: This was a progression from the 'name plate' as mentioned above.  The student wanted to create a stand to hold his iPad in the classroom so it would stand up.
Level of Difficulty: Low-Medium - this task was dependant on the student creating a stand that would would and needed preparation and measurement to ensure that it worked successfully.
Issues: None - this print worked perfectly, however on discussions there were ideas to personalise it (including the students name as a plate on the front) and strengthen the back of it.   It is robust but including a back rod or brace built into the design would allow pressure to be applied to it.  Student was thrilled with result and the project created a buzz with the creator and the other students in the classroom.
Above: The completed print in use
Size: As shown in the photographs a width of 80mm a height of 70mm and 60mm across.  These would probably be the minimum print sizes for the iPad holder to serve its purpose.
Timeframe: Six hours with an Ultimaker 2+ on regular print setting.
Process: The student has shown a desire and creativity to come up with ideas independently of teacher input.  By allowing a print run of an independent project the idea is to encourage the student (who is nine years old) to continue to think of practical applications and uses for the 3D Printer.  Tinkercad was used for the students design, and then the file was converted into Cura.   The print was then completed on an Ultimaker 2+.   (All prints on this site from this point forward unless otherwise mentioned will now follow this process as all machines at our school are now upgraded to Ultimaker 2+ with the newer version of the (free) Cura Software.  We are also using standard print settings and regular filament unless otherwise specified.  The student is already re-designing this print based on feedback given to include his name to personalise it and a brace that will sit at the back of the stand.

Friday, April 14, 2017

First 3D Prints of 2017: Name Plates #2

Design Two - shown to scale.
Challenge: For students to create an original 3D Print design (the students first 3D Print).
Background: This has been detailed in a previous post but with the New Zealand School year running from February to December this is the first project of new school year for a new group of students, their first 3D printing projects in the classroom.  One student designed the name plate featured on the 29th March print.   These two students were inspired by that to produce their own versions for thier first 3D Print.  
Task: Produce an original 3D print, with design from scratch having some purpose/use.
Above: Design One: - name plate.
Level of Difficulty: Low - this was the students first project and print and as a result the print was created using some of the default/basic settings on Tinkercad.   The students were able to produce something like this within a ten minute time frame.
Issues: None - both prints worked from the plan without any issues.
Size: Both prints were similar with their dimensions - 'Mum and Dad' was 80mm by 50mm with a depth of 20mm.   'Connor' had a length of 100mm by 50mm with a depth of 20mm.  On reflection both prints could have been a depth of 10mm and this would have had a considerable impact on the print time (see below). Timeframe: Design one 'Connor' eight hours and design two 'Mum and Dad' was a six hour print.
Process: The students first original designs, with the idea that this will act as a springboard to more detailed projects.   It was an introduction to show the student what would be possible.

Monday, April 3, 2017

3D Printing - 'join' challenge 2017

Above: the laser cut wood with holes
Challenge: Set by our school Principal the students were asked to create a 3D printed join to link together two pieces of wood manufactured by the schools laser cutter.  The task was relatively small in design and size however the design had to be specific to link the two pieces of laser cut wood at a right angle, and had to fit the specific hole detailed right.  This was also the second outright task this group of students had completed having the previous name plate.
Above: Original design on the right 
Background: For the school year (2017) the school has purchased a new laser cutter.  The idea is to integrate this machine with the schools 3D Printers to produce material and projects that use both.   Having just started the school year the tasks are relatively basic but reflect first use of the printer.   As a reminder the Ultimaker 2 printers at our school have been upgraded to Ultimaker2+ which is reflected in a faster than expected print time.
Task: Students were supplied with the wood, with the inserted holes cut into the wood.  This allowed students to determine the shape and design of the 'join'.  The first print on the right was created without an attempt to measure the join, therefore the students were estimating without measuring.  The second version was designed with measuring as part of the process, the students grasping the concept of measuring and then transferring the measurements to the Tinkercad program.
Above: joint featured in the 
Level of Difficulty: Low - it appeared straight forward, however this task was slighly more complex than it seemed as the 'join' did not fit and required additional work.  As well as this the base of the 3D print left some residual PLA while this was normally not an issue in this case it prevented the join from being able to fit into the hole for it.
Issues: As noted as the fit was extremely tight anything that would create additional material would hinder the fit.  The extra PLA at the base of the join caused it to require sandpaper to remove it.
Size: This varied depending on the print run.  The first was 2cm by 2cm (as shown).  The reprint was 1.5cm by 1.5cm and this completed the task as expected.
Timeframe: There were eight protoypes that were printed in one go - a combined time of 90 minutes.
Process: This was a challenge that was set by the Principal of our school as a follow up to the name plate challenge.  Students were supplied with the wood for the join which they would eventually use to measure an exact size.
What we would do differently: This was again a simple introductry task that relied on the students ability to create and problem solve a practical task, it reinforced the students to measure accurately and then translate this measuring to 3D Printing.

Wednesday, March 29, 2017

3D Printing: Name plates for 2017

Above: Completed name badge/sign
Challenge: A new school year has a new group of students who have not had previous had experience with the 3D printers.   The challenge is to get a new group of students excited and producing original material with unique designs and problem solving ideas.
Background: The school year in New Zealand runs from February to December, so the new class were wanting an opportunity to use the 3D printers.  Our school had made the decision to upgrade our printers to Ultimaker 2+.   Classroom time at this point was not allocated to 3D printing so we were looking for the students to be proactive in their own time.  Tinkercad accounts were outlined and the students were encouraged to create their own account and designs in their own time, with the intention being if the students created the work we would take the time to print the designs.
Above: 12cm long name plate
Task: Students in a Y5/6 class (nine and ten year olds) were explained the design process and shown how to create an account.  They were then tasked with creating an original design with purpose for printing.
Level of Difficulty: Low.  The first students were able to use Tinkercad to create a design of their choice with a purpose.
Issues: None - the design was the students first, designed overnight and worked perfectly the only minor issue was the hole designed for looping of cord etc.  This had to be fully worked with a screwdriver, which was a minor issue.
Size: 12cm long, 4.5cm high and a depth of 1cm.   Black filament was the default.  Conceivably the depth could have been halved as 5mm has been fine for similar projects in the past.
Timeframe: Three hours - this is reflective of a 'fast' print but our printers have been recently upgraded, as a result we are anticipating an improved time in the projects from this point forward.
Process: This was genuinely created by the students, with their first attempts at Tinkercad completed without any input from the teacher.  The student independently created the entire project and was able to bring a completed project to the classroom - and explain the justification behind the process and what he wanted to achieve as a result of the print.  This was intended to inspire the student and others in the classroom as what might be possible and would hopefully lead to more complex and detailed designs and creations.

Friday, January 6, 2017

3D Printing: Sky Tower Model

Model of Auckland Sky Tower
Challenge/Background: Our School was contacted by a member of the public who wanted to 3D Print a project for their child.  There was a delay in using the publicly available 3D Printers and as a favour they asked for our school to print the project and make it available.
Task: In this instance the design was completed externally and our role was simply to print the design, as it had been designed and completed externally.
Level of Difficulty: Minimum - as a print only.
Issues: None - although in the picture there is a small nick in the front right of the base, this was caused by removal from the print after printing.
Size: 25cm in height, 8cm in width, depth varies according to the design but up to 10cm at the base.
Timeframe: Nineteen hours.
Process: To increase the quality of the print Innofil 3D Print filament was used.  The was designed from an external source so the code was emailed to us.   As a result the design process differed from the regular designs on this site - as it had been created in AutoCad.
Reflection: This was an approach from an external source and it something that would probably not be repeated again, it was a favour to someone who asked rather than an original creation from the students at our school.

3D Printing Logo Designs

Above: Original design on left
Challenge: To re-create a design from a Google drawing created by another student as closely as possible to resemble the original design.
Background: A student at another New Zealand school had designed a logo for the 'International Friendship Day' project.   The school did not have resourcing for 3D Printing so we took the original student design and gave a brief to two of our students to create a 3D version of the design which we then subsequently printed and sent to the student who had designed the original.
Task: As the original design was created in Google Draw it was felt that this should translate well to Tinkercad and some of the shapes that were available from the main screen would be able to reproduce the original design.
Above: designer with design
Level of Difficulty: Easy students were able to reproduce it accurately within a ten minute timeframe as all of the featured shapes were directly created from the Tinkercad dashboard.  The only issue was that some of the shapes were not specific to the relative size in the original and perhaps they could have been more reflective of the original design.
Issues: None - an older filament was used and the machine is in need of a service, there has been a minor issue with some of the filament on the raised surfaces but this is minor and not related to the design of the print.
Size: 20cm by 15cm with a depth of 1cm.
Timeframe: Eighteen hours.
Process: The original in this case was designed by a student in Google Draw.  The teacher was emailed the original design which was then copied and printed off so the students had the original to work with, as with most every other design on this site they used Tinkercad (beta) to complete the project which was then converted to Cura for Ultimaker 2 3D Printing.
Reflection: Students were able to mimic the design and it was a way to allow them to refine some of their skills.  Producing something for another school added to the novelty value of the project.