Look inside Elektor's 3D Printing and Autodesk 123D Design Book

Misao Mizuno

ISBN 978-1-907920-45-5

The content of this book is sure to provide you with basic ideas on how to start making things at home. You will learn about the latest trends in 3D printing and gain a background to product creation. Also, by reading this book, you will gain a thorough understanding of all crucial information regarding this topic. Such information includes an amount of practical training on how to create 3D data that are essential when making things at home using Autodesk 123D Design, a free 3D CAD program. Furthermore, this book will teach you how to print objects using 3D printers, and introduce to you features of the wide-ranging 3D printing services available.

DESIGN

www.elektor.com

Don’t you think you are missing out on a great opportunity of making things at home just because you do not know where to start? So, here it is, a book that provides you with basic knowledge and information about 3D printing technologies so that you can get started.

3D PRINTING AND AUTODESK 123D DESIGN

LEARN

Elektor International Media BV

Thanks to the rapid development in 3D printing tools and services, anyone can now make things without being a member of a large organization, or without specialized facilities.

And this is definitely one of the weightiest reasons why people who are interested in making things are attracted to 3D printing technologies. On the other hand, there are still a lot of people who do not have an idea of where to start and a good many of you may not even have seen a real 3D printer except on television or in journals.

KICK-OFF GUIDE TO MAKING THINGS AT HOME

● MISAO MIZUNO

Misao Mizuno has been engaging in the CAD / CAE / PLM industries and has been helping the manufacturing industry while working at a major PLM vendor and a foreign-affiliated consulting corporation since the beginning of the 1990’s. Furthermore, he has been working actively as an advisor who helps other companies to install CAD / CAM / CAE / PLM tools while at the same time developing his own, unique products.

3D PRINTING AND AUTODESK 123D DESIGN

3D PRINTING AND AUTODESK 123D DESIGN

KICK-OFF GUIDE TO MAKING THINGS AT HOME

Misao Mizuno LEARN

DESIGN

SHARE

SHARE

LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHAR GN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHAR

Introduction 3D printers and the idea of becoming a “personal fabricator” have been gathering considerable attention since the second half of 2012. It can be said that 3D printers are now in the spot light. When 3D printers were first introduced to the market, they were advertised to be a “magical tool” which allows the designers to make anything they want at home.

They are now gathering much attention from many people including those who are not involved in industrial fabrication. In addition, 3D CADs which were very expensive and difficult to obtain in the past can now be acquired at a low price or even for free.

Because of the rapid development in 3D printing tools and services, anyone can now make things without being a member of a large organization or without having specialized facilities. And this is definitely one of the biggest reasons why people who are interested in making things are attracted to 3D printing technologies.

On the other hand, there are still a lot of people who do not have an idea of where to start and I assume that many of you have not even seen a real 3D printer except on television or in newspapers. In fact, attendees of my seminar where I teach how to create and print an iPhone case using a 3D printer often ask me various questions regarding personal fabrication.

Don’t you think you are missing out on a great opportunity of making things at home just because you do not know where to start? So, here it is, a book that provides you with basic knowledge and information about 3D printing technologies so that you can get started.

In this book, you will learn about the world’s latest trends and gain a background on product creation. Also, by reading this book, you will gain a thorough understanding of all crucial information regarding this topic. Such information includes some practical trainings of how to create 3D data that are essential when making things at home using “Autodesk 123D Design,” a free 3D CAD. Furthermore, this book will teach you how to print objects using 3D printers and introduce to you features of the wide-ranging 3D printing services available.

The content of this book can give you some “basic ideas” of how to make things at home. I am sure that many of you will have limitless amusement in making things by yourself if you take the initial step. What I really want to say here is making things on your own is really fun and exciting. I would be thrilled if by reading this book you will become motivated to make things on your own.

Isao Mizuno

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Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Introduction

00

00-01

Let’s start making things at Home! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

The dawn of “changing ideas into things” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Price reduction of 3D printers and enrichment of printing services . .

2

The era where individuals can design and create their own products has arrived . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 The reason why people are attracted to “making things” . . . . . . . . . . . . . .

4

Tools required in “making things at home”

4

Configuration of this book

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5

Chapter

01

Basic knowledge of making things and 7 3D printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

01-01

Basics of making things . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Work flow of making things (product development) . . . . . . . . . . . . . . . . . 8 • 1 Product planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • 2 Conceptual design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 • 3 Detailed design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Technical Point Column

The difference between 3D CAD data and 2D CAD data . . . . . 11

The difference between the penetration rate of 3D CAD data and 2D CAD data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

• 4 Preparation/fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 • 5 Promotion/selling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 • 6 Product support/maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Contents

“Personal product creation” us now gathering attention . . . . . . . . . . 14 • Popularization of software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

01-02

• Change in fabrication environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

• Change in consumer needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Getting started with “making things at home” . . . . . . . . . . . . . . . . . . . .

17

Tools required in “making things at home” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Knowledge required in “making things at home” . . . . . . . . . . . . . . . . . . . . . . . . 18 Column

01-03

There are many things to learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

What is 3D modeling application?

Polygonal modeling (3D CG) Surface modeling Solid modeling Technical Point

01-04

21

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23

The difference between 3D CAD and 3D CG

What is a 3D printer?

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26

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27

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29

Column

ABS and PLA

Column

Choosing appropriate personal 3D printer and 3D printing service

List of leading 3D printers

31

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32

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32

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32

Industrial 3D printers Personal 3D printers

25

26

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Various formative designing methods of leading 3D printers

Leading 3D printers makers and their products

01-06

20

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Basic knowledge about formative design in 3D printing

01-05

20

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Materials used in making things

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33

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41

Metal

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41

Resin

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42

Types of resins Wood

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42

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43

Recommendation of purchasing ready-made parts Column

Let’s learn about materials in detail

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44 44

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Chapter

02

Basic knowledge of 3D modeling 02-01

What is 3D modeling?

What is 3D data?

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45

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46

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46

Types of 3D modeling techniques

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47

Wireframe modeling - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

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Polygonal modeling

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47

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48

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49

Surface modeling Solid modeling Column

02-01

Pros and cons of sharing 3D data

First steps in designing 3D models

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50

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51

Basic Knowledge of configuration designing

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51

• Extrude

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51

• Revolve

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52

• Sweep • Loft

52

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How to design a configuration of the object specifically • Think about the main configuration first

53

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54

• Configuration should be designed by adding and subtracting 3D modeling workflow

• Step3 Utilizing the 3D data

56 56

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58

Solid modeling karnel

Technical Point

56

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• Types of file formats that can be used in 123D Design Column

55 56

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• Step2 Design the configuration based on the concept 3D data file format

. . . .

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• Step1 Developing a concept

53

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58

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Various types of file formats

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59 59

Chapter

03

Basics of 123D Design 03-01

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61

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62

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62

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66

What is 123D Design?

Features of 123D Design Autodesk 123D series

Data management using cloud service Column

03-02

How to utilize the cloud service

Installing 123D Design

71

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72

Beta version of Autodesk 123D

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Downloading and installing 123D Design

03-03

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Column

How to use the beta version (old edition) of Autodesk 123D

Column

Words and terms used in data that you are going to create

Technical Point

69

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System requirements for 123D Design Column

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72 73 73

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76

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77

Errors which might occur when using the Windows version 78

Let’s start manipulating 123D Design!

User interface of 123D Design

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79

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79

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Contents

Content of the application menu

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80

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82

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93

Content of the command menu Display menus Units

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View Cube (View point changing cube) • Perspective and Orthographic views

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97 97 98

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Chapter

04

Let’s start with creating simple 3D models!

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04-01

How to design a mug?

Configuration of the mug

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100

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100

Designing the basic figure of the mug

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100

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105

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108

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108

Hollowing out the inside of the mug Column

Context sensitive menu

Finishing the mug Column

04-01

Utilizing 3D scanners

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How to design a trinket box Plan the method of designing

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Designing the angle cut of the front of the trinket box Designing the dividers

05

114

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Designing the basic configuration of the trinket box

113 114

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• Understanding the building block

112

113

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Workflow when using 3D CAD

Chapter

99

. . . . . . . . . . . . . .

116 118 122

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Practical training Designing 3D figures to make things –How to design a penholder and a business card holder– 127

05-01

How to design a pen stand Getting started

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing criteria

Designing the holes

. . . . . . . . . . . . . . . . . .

130

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

How to design a business card holder Getting started

129 129

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing the basic configuration of the pen stand

05-02

128

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appropriate size of the business card holder

. . . . . . . . . . . . . . . . . . . . . . . . . . .

141 141 141

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Thickness of the case

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting appropriate clearances

143

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

Configuration of the cover Designing the lower case

Designing the attachment of the cover Designing the cover Column

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is offset?

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing the connection of the case and the cover Finishing the business card holder

05-03

143

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding surface decoration

148 152 154

. . . . . . . . . . . . . . . . .

156

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

160

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

163

How to create alphabet letter data using the web version of 123D Design

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Placing data stored in a cloud service into 123D Design Column

Creating products made up of several parts

163

. . . . . . . . . . . .

165

. . . . . . . . . . . . . . . . . . . . . . .

167

Chapter

06

Practical training Designing 3D figures to make things ─How to design a chair and a rabbit figure─ . . . . . . . . . . . . . . . . . . . . . . . . 169

06-01

How to design a chair Getting started

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

Designing the seat

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

Designing the legs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181

Designing the back

Assembling the chair (legs) Assembling the chair (back)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing the upper part of the chair Finishing the chair

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Choosing the texture

06-02

170

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183 187 191 195 197

How to design a rabbit figure - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Getting started

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing the face

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designing the ears, eyes and nose Assembling the face

Designing the arm Designing the leg

200 201

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

203

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

207

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211

Designing the mouth Designing the body

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217

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Contents

Assembling the whole parts Column

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220

Customize your own method of designing and become

a quick-learner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224

Chapter

07

How to print realistic materials from 225 3D data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

07-01

Printing process when using 3D printers Method1 Printing an STL file • Outputting an STL file

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Method2 Quality confirmation and adjustment of an STL file • Software that can be used to check an STL file Method3 How to print things using 3D printers Column

232

.

234

. . . . . . . .

236

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to use 3D printing services

227 229

3D Printing services affiliating with Autodesk 123D 3D Printing services in Japan

226

. . . . . . . . . . . . . . . . . . . . .

Workflow when correcting the errors of an STL file

Utilizing 3D printing services

226

. . . . . . . . . . . . . . . . . . . . . . .

Relationship between shape of models and supporting materials

Technical Point

07-02

. . . . .

226

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 241 243 246

• How to place a printing order directly from 123D Design to a 3D printing service Column

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Materials that can be used in printing services

How to save and upload an STL file

. . . . . . . . . . . . . . . . . . .

249

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252

Process from ordering to receiving of the product

Chapter

08

246

. . . . . . . . . . . . . . . . . . . .

254

Aiming to become a full-fledged personal maker

─Process from manufacturing to selling of the product─ . . . . 255

08-01

Various manufacturing methods and fabricating machines- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Cutting work Column

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is a “machining center?”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Fabricating machines which personal makers can use Column

What is a “CAM?”

. . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

256 257 257 258

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Column

What is a “CNC milling machine?”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

• Fabricating services which personal makers can use Injection molding

260

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260

• Injection molding services which personal makers can use Casting Column

. . . . . .

261

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262

What is an “undercut?”

Press molding

08-02

259

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Some words of caution when selling products Difference between “virtual” and “real” How to choose appropriate material Let’s learn about 3D CAD in detail

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before manufacturing mass-produced products Price and cost

264

265 265 265 266

. . . . . . . . . . . . . . . . . . . . . . .

267

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

268

Quality of your product

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selling and promoting your product Conclusion

. . . . . . . . . . . . . . . . .

263

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

268 269 271

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272

Downloading the sample file Each 3D data introduced in the practical training included in this book can be downloaded from the URL noted below. Please utilize it while reading this book.

Downloading the sample file www.elektor.com/3d-sample-file • Decompress the data since it is compressed in a zip file. Please note the following when using the data.

• The downloaded data should only be used for the purpose of learning the content of this book.

• Please note that the author of this book, Elektor International Media BV and SB Creative Corp. are not responsible for any damages caused by the use of the downloaded data.

All the downloadable data are copyrighted work and therefore opening all of them or a part of them to the public or utilizing them by altering them is not allowed.

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00-00

Let’s start making things at home!

Autodesk 123D Design

www.123dapp.com/design

123D Design is an entry-level CAD developed by a full-scale CAD maker named Autodesk.

Although this CAD is a free cad, it has the same, basic features that can be found in highlyfunctioned CADs used by the majority of fabricating professionals.

The feature of this CAD is limited compare to very expensive CADs that cost more than 200 thousand ~ 1 million yen but it contains enough features for people who are thinking of starting to learn about 3D printing or people who usually use 3D printers to print hobby objects. Accordingly, 123D Design is probably the best CAD for beginners. It might also be helpful for those of you who are planning to learn about 3D modeling on a full scale in the future.

The latest modern fabricating technologies and machines often require 3D data. So, without 3D data, they won’t be able to work at all. I hope that you will understand the process of making things and the importance of 3D data by reading this book. In fact, you can print your product using industrial 3D printers or carry out the cutting process (high accuracy fabricating process often done by professionals) if you create decent data using this free 123D Design. I hope the instructions included in this book will help you to move one step closer to fabricating professionalism.

Configuration of this book In this book, I will explain the basics in detail from many different perspectives in order to get you started in making things at home. Then, I will explain to you how to make 3D data by using Autodesk’s 123D Design. If you can create 3D data at will, you will be able to make anything you want. In fact, I have had people tell me that there are many people who have great ideas but do not know how to cast their ideas into shape. As a matter of course, casting ides into shape is possible if you ask data-making professionals to do this for you but 5

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that often costs a lot and I assume that many people would hesitate to pay a lot of money just to make a hobby object. Thus, I think it is crucial that you master 3D modelling before purchasing fabricating machines if you want to start making things at home. If you are able to create descent 3D data, you can choose any method of making products such as cutting, injection molding or outsourcing the work to a company which has 3D printing services.

In addition, you will learn about various know-hows of how to make full-scale and advanced products by the time you finish reading this book. I hope that this book will be a guide to those of you who are aspiring to be better personal fabricators. There is no need to spend a lot of money to start making things on your own. What I want you to do is to move your hands first and find out how interesting and fun it is to make things. I am sure that you will find yourself craving to learn more about how to make things deeply after reading this book.

Now, let’s start making things at home!

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Chapter

01

01 section

Basics of making things

Japan is known as an industrialized country. Since the beginning of the rapid growth period, many large products such as cars, home appliances, industrial machines, precision instruments, brand engineering products and many small goods like personal belongings and precise products have been created by Japanese manufacturing businesses. Small and medium-sized companies are producing various machine parts and reprocessing the materials to support Japan’s manufacturing business.

By the way, I assume that many of you do not know what kind of people are engaged in or what kind of tools are used to produce the products you are using every day unless you are involved in an industrial business. So, what I am going to do here is to explain to you the general work flow of making things. By understanding this, I am sure that you can understand why individuals and small organizations are now able to be a maker.

Work flow of making things (product development) The work flow of “making things” is as follows. 1. Consolidate the product planning. 2.

Carry out the initial conceptual design. 3. Carry out detailed design including the parts. 4.

Fabricating the product based on the design information. However, the process does not end here if you are aiming to sell the product. If you want to sell the product, you must… 5. Do the marketing and promotion. 6. Make a product support and maintenance plan from creation until the product is discarded. Besides, if you are just making something for your own, you must remind yourself that you have to support and maintain your object or you will not be able to use it for a long time.

Accordingly, the work flow of making things (product development) can be organized as seen in the diagram below.

Workflow of making things (product development)

① Product planning

② Conceptual design

③ Detailed design

④ Preparation/ fabrication

⑤ Promotion/ Selling

⑥ Product support/ maintenance

8

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01-01

Basics of making things

The work flow of making things usually starts with planning and ends with the product being fabricated as seen in the figure indicated above but you have to remember that things will not always go smoothly. 3D data is “virtual.” So, it does not mean that the data inside the PC can be fabricated properly. Moreover, there is the possibility that the product will not be profitable even though fabrication has been successful.

In such a situation, the maker has to face the reality of starting all over again that is from the production process to product planning. Such a process is often called a “design

Chapter 01

change.” Please remember that the process of making things often requires this “back and forth” process.

1. Product planning Product development starts from product planning. Some companies have a product

Basic knowledge of making things and 3D printers

planning division and some companies have all its employees participate in the product planning. In either case, the development of the product cannot be started unless the product planning is done. In product planning, you have to consider many points including what kind of product you are planning to make, what kind of people you are targeting, the price of the product and then you have to verify whether the product is marketable or not.

Especially in the case of big companies, they usually utilize all sorts of data such as a marketing data so as to forecast future prospects in the market.

Yet, it is relatively common that the product planning carried out by a big company ends up to be something innocuous because many of them prefer to avoid risks. Putting it another way, even though the degree of completion and the additional value of the product are high enough to be sold, developing something innovative which astonishes the market is now becoming increasingly difficult. Plus, there are many cases where an employee who has a great idea cannot state his/her own idea since the development of the product is carried out by a large organization.

Product planning

What kind of product is it going to be?

Who is it targeted for?

What will the price of it be?

Does it have marketability?

Data - marketing data, past performances and so on...

2. Conceptual design The actual development of the product will start after the product planning is consolidated to a certain degree. Before launching the product development, the maker has to decide on the product’s size, design and parts that are going to be used. At this stage, illustrations, sketches and 2D CAD are often used along with real scale mock-ups called “clay models” made by clay based on sketches drawn by designers. Clay models are often used when designing cars. Furthermore, Hand-made models are often used when designing small products. Some companies use 3D CADs for conceptual design from the beginning of product planning.

9

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Chapter 01

02 section

01-02

Getting started with “making things at home”

Getting started with “making things at home” Chapter 01

I think now you will have an understanding about the trend and the possibility in the field of “making things” around the world and the basic workflow of traditional product fabrication. Many of you might now be thinking “Ok, I will try to make something!” or “I will form this wonderful idea into a product and sell it!” From here on, I will explain to you how to start making things at home. You do not need to prepare initial costs. As long as you

Basic knowledge of making things and 3D printers

have your own PC, you can start making things with no money.

Tools required in “making things at home” All you have to prepare is a “3D CAD” or a 3D modeling application (software) like “3D CG” when you start making things by yourselves or with a small group of people. This means, you can tentatively start making things if you have the knowledge of how to use these software to design and fabricate products. It is better to purchase 3D printers and other sorts of machines after you are familiar with commercializing your own products which you designed by yourself and creating a number of trial products.

• All you need is a 3D modeling application (there is even a free one available) to start making things • You can avoid the risk of making a wrong decision by using 3D printing services when you are a beginner • You should consider purchasing your own 3D printer after you are familiar with making things by yourself As noted above, there are many services that can fabricate (print) your product based on the data you have created. Although the cost per product may be higher compared to when you print products using your own 3D printer, 3D printing services are still very convenient sine most of them charge just 2 or 3 thousand yen per product. Besides 3D printing services, there are also services available to fabricate your product based on 3D data through cutting work or injection molding process. Making good use of these services in accordance with your purpose is even better.

You can then consider purchasing your own 3D printer after you have sufficient knowledge of how to use them. Even reasonably priced hobby 3D printers are being sold these days.

Please note that you have to know exactly what you want to make in order to choose an appropriate 3D printer.

Tips

Examples of cutting work and injection molding services aimed at individuals are introduced in detail in Chapter 08.

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Knowledge required in “making things at home” As noted above, the only tool needed to start to make things at home is a 3D modeling application. However, you have to have knowledge about the points noted below along with knowledge of how to design 3D data by using a 3D modeling application if you want to sell your product or use a product designed yourself on a regular basis over a long period of time.

Knowledge of how to design a product using 3D modeling applications In order to start making things by yourself, needless to say, you have to have a concrete idea of your product but also knowledge of how to turn your idea into a shape which is understandable for both third parties and machines. Otherwise, your plan for product creation will end up being “pie in the sky.” This is why you have to have knowledge of how to design your product using 3D modeling application. There are many kinds of 3D modeling applications available now and the software that you are going to use will vary depending on the shape and the configuration of your product. In any case, using 3D modeling application is a MUST when making things at your own and this book especially focuses on how to design products using 3D modeling application in following chapters.

• Types of standard 3D modeling methods: p.20 • Standard 3D modeling methods using 3D modelers: p.46

Knowledge of 3D printers and other fabricating machines You need to have knowledge of 3D printers and other fabricating machines coupled with knowledge regarding 3D modeling application. Also, there are many kinds of 3D printers and the types of materials that can be used or the features of the printed object will differ depending on the model. Therefore, it is necessary to choose an appropriate 3D printer which is suitable for printing the object that you designed. It is also essential to learn about fabricating machines other than 3D printers if you want to become a full-fledged personal fabricator.

This might sound extreme but you can create almost anything by using 3D modeling application. Yet, it does not necessary mean that the object you designed on the 3D modeling applications can be physically reconstructed. For instance, objects that are too complicated and detailed cannot often be printed properly. In other words, you need to have the skill to build your own image virtually on a PC and have knowledge of how to turn your image into a shape that can be physically reconstructed.

Just to let you know, you do not necessary have to have your own 3D printer when printing your products because you have the option to utilize 3D printing services provided by a number of companies. Preferably, you should also learn as much as you can about the many kinds of 3D printing services as much as possible so that your will be able to develop your business broadly in the future. Choosing different printing services depending on your needs will surely help you to fabricate many types of products (shapes and materials) effectively and speedily.

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Chapter 02

01 section

What is 3D modeling?

In order to use the 3D printer in earnest, you have to prepare “3D data.” The operation of creating 3D data is called the “3D modeling” and the software to create 3D data is called “3D CAD” or “3D CG.” In this section, I will explain to you about 3D data before teaching you how to use 3D modeling software.

What is 3D data?

3D data can be defined as “data created on a PC which expresses the configuration of a 3D model.” Even though they look like 2D data on the PC screen, they have the positional information of X, Y and Z. Let’s take an example of an anterior image of a train. The rear and side surfaces of the train cannot be seen if the image of the train is a photo or a painting because it only has 3D positional information. On the other hand, if the image of the train is created in 3D, it can be swirled around and seen from any angle (from rear, side or even from above and below that are hard to see in real life).

The difference between 3D data and 2D data 3D data

By swirling around a model that has 3D information, you can observe the object from any angle

2D data

The frontal image looks exactly the same as the frontal image of the 3D data above but its side or rear surface cannot be seen because it does not have 3D information. The image becomes invisible when it is rotated

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02-01

What is 3D modeling?

Types of 3D modeling techniques There are several techniques to create 3D models. Each technique has its likes and dislikes and usable 3D modeling tools differ by the types of techniques that you are going to use.

Here, I will introduce to you the basic characteristic of each technique.

Wireframe modeling Chapter 02

Wireframe modeling is literary a technique of expressing the 3D model only with lineal information which allows you to get a rough overall configuration of the object (not in detail). This technique was used in initial 3D CADs. Most 3D modelers nowadays do not use this technique.

Basic knowledge of 3D modeling

3D data created by wireframe modeling

Polygonal modeling Polygonal modeling is the technique of expressing the 3D model by the aggregate of triangular patches. Although the rigorous configuration of the object cannot be expressed precisely since the object is expressed in patches, it is still possible to smoothen the surface of the object by breaking up the patches into small pieces.

The configuration of the polygonised object can be modified at one’s own will by moving the polygons around. So, polygonal modeling is often used when designing organic shaped objects such as human or animal figures. Many 3D CGs use this technique.

Furthermore, polygonised models with lesser patches called “low poly models” are often used when designing game characters which require quickness in reaction and motion.

However, low poly models are unsuitable for designing industrial products such as machine parts because their shape and dimensions cannot be expressed in a rigorous manner.

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Chapter 02

02 section

02-02

First steps in designing 3D models

First steps in designing 3D models

In this section, I am going to explain to you about the basics of the 3D modeling with a

Chapter 02

focus on 3D modeling methods using 123D Design, a solid modeler so that you can design the configuration of your product.

Basic knowledge of 3D modeling

Basic Knowledge of configuration designing The following four methods are the basic methods of object configuration in 3D modeling. Seemingly-complicated objects are all a combination of these methods.

Extrude Extrude is a designing method of extruding the sketched surface. This method and the revolve method to be described are two of the most popular configuration methods. Around 70 to 80% of the products in general are created by using these two methods. A circle becomes a circular cylinder, a circle with a whole inside becomes a cylinder hollow and a square becomes a cuboid in this method.

Object configuration using the extrude method

Create the configuration of the object by extruding the sketched surface

Cutting out the configuration of the object by extruding the sketched surface

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Revolve Revolve is a designing method of rotating the sketched surface around a certain axis. This method is also often used especially when creating components. Forming a torus is also possible if you rotate the circle sketched surface around the axis that is set a short distance away from it.

Object configuration using the revolve method

The circle sketched surface becomes a sphere if it is rotated around the axis set in the center of it.

The circle sketched surface becomes torus if it is rotated around the axis that is set a short distance away from it.

Sweep Sweep is a designing method of moving the surface along a path. This method is convenient when creating bent objects such as pipes. Although it is less often used than the extrude method and the revolve method, it is a relatively well-used configuration method.

Object configuration using the sweep method

3D model configured by the surface which moved along the path.

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Chapter 04

01 section

How to design a mug

The first thing you are going to design is a mug by combining the basic configurations which have been introduced in the previous chapters. I think that you will learn that many of the products we use on a daily basis are made up of a combination of simple configures surprisingly by performing this practical training.

Configuration of the mug You will create a mug in this section. I am sure that you will comprehend the 3D modeling method using 3D CADs by designing this simple configuration.

3D model of the mug (completed chart)

Designing the basic configuration of the mug Let’s get started by following practical steps. Designing the basic configuration of the mug is the first step to take

s tep

1

Create the vessel of the mug. The basic figuration of it is a cylinder.

Select [Primitives]  [Cylinder] and

❶ ●

enter the value of [40mm] (radius) and [80mm] (height) to the box shown at the bottom of the screen.

❷ ●

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04-01

s tep

How to design a mug

2

Set the center of the cylinder as the original point . The original point can be checked easily by selecting [BOTTOM] of View Cube.

Tips

❸ ●

Press ESC to cancel the

command selection.

s tep

3

Next, design a ring that is going to be the grip of the mug. Select [Primitives]

❺ ●

❹ ●

Chapter 04

 [Torus] and enter value of [5mm] (radius of the cross-sectional surface of the ring) to Minor Radius and [30mm] (radius of the whole ring) to Major Radius.

4

Let’s start by creating simple 3D models!

s tep

Place the center of the ring on an arbitrary point on the X-axis (the diagonally upper right extending line in the figure shown on the right). The ring

❻ ●

is set to the point of 0.150 in the figure shown on the right . The coordinate point can be checked easily by selecting [Top] of View Cube.

s tep

5

Turn the ring around to make it a grip.

Select [Transform][Move / Rotate]  and click the ring .

❼ ●

The move (rotation) guide will appear.

Select the wheel which rotates the object from the front side to the back

❽ ●

side  and enter the value of [90] to the [X Angle] input dialog .

❾ ●

●

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Chapter 05

01 section

How to design a pen stand

You are going to design the following products in this chapter and in the next chapter.

• Pen stand” that can be used on a desk • Business card holder” consists of few parts • Chair” that can be used in real life • Rabbit figure” consisting of a number of curved surfaces The goal that you should be aiming for is to design products which are different in size, configuration, use application and building block in a practical manner to become a maker who can design many kinds of configurations at will. Many of the products around us are a combination of several parts and I will also explain to you about the 3D modeling method of combining several parts together to create a single 3D model.

The unique modeling procedures explained in detail in this chapter and in the next chapter are only usable in 123D Design but the basic configuration designing methods such as the extrude, revolve and loft are also usable in most full-fledged CADs. You can therefore broaden your application range rapidly once you learn the sketch drawing methods and the 3D model designing method through the practical training introduced in this chapter.

The products that you are going to design in this chapter (except for the chair) are all introduced based on the assumption that they are going to be printed by 3D printers. This means that you will be able to print any product which you have designed by yourself as you follow the practical steps introduced in this chapter.

Now, let’s start designing full-scale products using 123D Design. The first product that you are going to design is the pen stand shown in the figure below which has a bit more complicated configuration than the mug and the trinket box you designed in the previous chapter.

Pen stand

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05-01

How to design a pen stand

Getting started Different from the edgy trinket box you designed in the previous chapter, you are going to design a stubby pen stand with web-patterned holes around its body in this chapter. Let’s think about the proper designing method of this product primarily.

Designing criteria It seems that this 3D model can be designed by making a circuit of the lengthwise sketch because it can be seen as an axisymmetric cylinder hollow but that is not the only designing method you can choose. This 3D model can be also seen as a configuration made up of four and a half flattened beer kegs cumulating one after another which means that it can be designed by cumulating sliced circle surfaces that have different radiuses in an axial direction.

As you can see, there are several ways of designing this pen stand. Which method is the best method then? Although there is no single correct answer, there are two judgmental

Chapter 05

standards (criteria) available in this case.

One is the simplicity when designing the objective configuration and second is “the ease of editing and making adjustments to the configuration.” It is not uncommon to come up with an idea of making minor adjustments to the configuration while designing the product with its completed configuration and concept in mind, but the adjustment operation will become a pain in the neck if the editing task cannot be done smoothly. It means that drawing the

PRACTICAL TRAINING

sketch precisely will sometimes result in confusion in the editing task for instance. Although 123D Design is a CAD which allows its user to edit the configuration directly, the editable configurations are limited to relatively simple configurations. There are many cases where the user cannot even edit the configuration at all when the configuration of the product is

Designing 3D figures to make things

designed in detail and has no choice but to redo the whole designing process from drawing sketches. Hence, it is better to draw a simple sketch so that the edit task can be simplified.

Now, let’s think about how to design the pen stand with the aspect noted above in mind.

With regard to the method of making a circuit of the lengthwise sketch, the editing task will be complicated since the user has no choice but to redo the drawing operation of the surface in order to change the height of the pen stand or change the length of the spaces between the beer kegs.

With regard to the method of cumulating sliced circle surfaces that have different radiuses in an axial direction, the configuration of it can be changed just by adjusting the particular circle surface and even the height of it can be changed more readily than the former method.

Consequently, we are going to design the pen stand in the following way.

• Design the main configuration by using the “sliced circle surfaces created by Loft.”

• Design the configuration of the holes by “copying them with the rotation pattern + copying them with the directional pattern.”

The configuration of the holes is relatively simple. The objective configuration of the holes 129

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can be designed by making a single hole and copying/pasting it circularly in an axisymmetric pattern. Let’s try it now.

Tips

The most appropriate method of designing a certain product can vary according to the usage of the product when there are several designing methods available. To put it another way, there is no “correct” method in designing any configuration. Although I will explain about the latter method described on the previous page, I am sure that there will be some people who think it is much easier to design the pen stand using the former method that is the method of making a circuit of the lengthwise sketch. Please choose the most comfortable method for you when you actually design your own product.

Designing the basic configuration of the pen stand Follow the following procedures to design the basic configuration of the pen stand.

s tep

1

Select [Sketch][Sketch Circle] to create a circle with the diameter of [70mm] on an operational plane surface ❶ . (Be sure to click [Exit Mode]

❶ ●

or press Esc after the circle is created).

s tep

2

Create another circle with a diameter of [60mm] on the same plane surface ❷ . ❷ ●

Attention !

Be sure not to click the first (former) circle when selecting the operational plain surface of the second (latter) circle because the first circle will become a double circled sketch if it is clicked initially. Be sure to click the area outside of the first circle.

！

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Chapter 05

02 section

05-02

How to design a business card holder

How to design a business card holder

You are going to design a practicable business card holder in this section. The business card holder is composed of two parts that are the “open/close lid” and the “business card-storing bottom case.” Even though 123D Design does not include the function to designate the location point and the direction when assembling several parts, it can handle more than two solids individually as if they are the parts of the 3D model. Since 123D Design can also show the designated part only or even hide it, we are going to use these functions to design the business card holder.

Business card holder

Chapter 05 PRACTICAL TRAINING

When the cover is closed

When the cover is opened

Designing 3D figures to make things

Getting started What do you think is the best way to design the pen stand shown in the figure above?

Appropriate size of the business card holder Needless to say, it is necessary to decide the size of the case by back calculating the size of the business card because a business card holder is a holder to hold business cards. The thickness (height) of the business card holder’s case depends on the number of business cards that you want to store in it.

There are some uniquely-shaped business card holders on the market but we are going to design an ordinary-shaped business card holder. The standard size of a business card holder in Japan is 91mm×55mm. Because business cards used in foreign countries such as the U.S. are generally smaller than 91mm×55mm, they can be stored in a 91mm×55mm business card holder without a problem.

In light of the considerations suggested above, the size of the business card holder that you are going to design in this chapter can be set up to the following descriptions.

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1. Set the measurement of the case a little bit bigger than 91mm×55mm 2. Add the side and bottom surfaces’ thickness 3. Add some space at the back side to place the pivot point The business card holder can be designed if it is configured based on the case securing enough spaces mentioned above.

Measurement of the business card holder (case) 7.5000 R5.0000

R2.5000

65.0000

10.0000

2.0000

R3.0000

67.5000

ÎŚ2.5000

2.0000

100.0000

Measurement of the business card holder (lid) R7.2000

2.0000 R4.7000 R2.7000 R3.3500 R1.550

R3.0000 2.5000

65.0000

96.0000

100.0000

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Chapter 05

03 section

05-03

Adding surface decoration

Adding surface decoration

The business card holder is now completed according to the procedures explained in the previous chapter but let’s add another twist to it. We are going to add alphabet characters on the top surface of the business card holder as shown in the figure below. Being able to customize the product freely is also an advantage of using 3D printers. Although “M.M” which is my initial is used here in the following steps, put your initial on your business card holder.

Surface decoration that is going to be added

Chapter 05 PRACTICAL TRAINING

Designing 3D figures to make things

The alphabet character data that is going to be placed on the top surface can be created using the [Sketch] command but I will explain to you how to use the character data registered in the web version of 123D Design.

First, you must register the data in the web version of 123D Design before following the following steps. Let’s start with registering the character.

How to create alphabet letter data using the web version of 123D Design The Windows version and the Mac version of 123D Design do not contain the function of designing alphabet letters but the web version of 123D Design does. Therefore, the operation can be preceded efficiently by using the web version when creating alphabet letters.

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s tep

1

Access the page of Autodesk 123D Design (refer to the following URL) and click the [Launch the App] button at the leftcenter. ❶

www.123dapp.com/design/ ❶ ●

s tep

2

Open the web version of 123D Design on the browser.

Click [T] inside the bar colored in dark blue ❷ and activate the charactercreating function.

s tep

❷ ●

3

Display the letter in a designated location on the screen ❸ . The 123D that is originally set to appear will be changed later on. The size can be adjusted by moving the displayed arrows.

s tep

❸ ●

4

After expanding the size of the letter, change the content ❹ . Enter your own initial.

❹ ●

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Chapter 06

01 section

How to design a chair

We have designed 3D models focusing around small products that can be used in our daily lives in the previous chapters but 123D Design also allows you to design relatively big products like furniture including a table and chair. You are going to design the wooden chair shown in the figure below in this chapter.

3D model of the chair

Getting started Let’s start by giving some thought to the following points. The chair you are going to design in this chapter is an adult sized chair.

• Length of the chair legs • Height of the back of the chair • Size of the seat The first thing you have to think about is the length of the chairs legs (the height from the floor to the seat). The position of one’s thighs will be higher than chair’s back if the legs are too short or one’s feet will not touch the ground if the chair’s legs are too long. In view of these considerations, the length of the chair’s legs should preferably be 45cm. Let’s design the chair’s legs based on the measurements shown in the figure on the next page. You can even set the length of the chair’s legs at your own will to design a chair of your own or design a kid-sized chair if you want.

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06-01

How to design a chair

Another thing you have to think about is the seat. Because the chair cannot be used on a routine-basis if the seat is not large enough, you have decide on the size of the seat coupled with the size of your bottom. The measurements of the seat you are going to design in this chapter are as shown in the figure below. Try measuring the measurements of the seat that you are using regularly if you are interested in designing a chair that fits your bottom perfectly.

Height of the chair (figure on the left) and the size of the seat (figure on the right) Seat

R=50mm

300mm Height of the back 500mm

50mm

475mm Seat 30mm in thickness

Height from the floor to the seat 420mm 25mm 500mm

Chapter 06

R=30mm

Let’s start designing the chair after you have learned of the rough measurements. First, you are going to design the seat.

PRACTICAL TRAINING

Tips

Although it is critical to understand the character of the material and consider the physical demands on the back and the legs in order to fabricate a practical chair, I am not going to cover

Designing 3D figures to make things 2

this topic in this book.

Designing the seat Design the seat by creating a laminated box and cutting out unnecessary quantities.

However, the operation of “sketching the needed lines for the complete configuration first and extruding the necessary area later� can be done fairly freely when using 123D Design.

It is therefore better not to sketch too many lines initially to avoid confusion. On the other hand, the operational procedure can be shortened by making a good use of only the needed sketches.

Follow the following procedure with this in mind.

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Customize your own method of designing and become a quick-learner

Column

Although this book explains the basic manipulation methods of 3D modeling and solid designing methods using 123D Design, the quality of each product introduced in this book is not the highest because this book focuses on how to design the basic configuration of each product. For this reason, I assume that some of you are craving to design more detailed products.

For those of you hoping to design more detailed products, I recommend that you try customizing your own product by you yourself utilizing the 3D modeling methods you have learned in this book. You might get bewildered or find some difficulties when configuring the products of your own since this book does not focuses on the defined procedures of how to design detailed products. However, I am sure that you can get a much better understanding of 3D modeling by trial and error. Casting your own ideas that are not introduced in this book into an actual shape is very effective for your study.

Therefore, I would like to give you some homework. It is preferable to alter the configuration of the ears of the rabbit figure made up of very thin spheres to make them look like real rabbit ears. Therefore, I designed the ears as shown in the figure below. Please try designing the configurations of ears similar to these.

Creating the ears

To give you a hint, the configuration noted above can be designed by using the [Split Solid] command and the [Subtract] option of the [Combine] command. You can remove the arbitrary solid by using the [Split Solid] command. Also, you can hollow out the inside of the solid with the predefined measurements (configuration of the solid) by using the [Subtract] option included in the [Combine] command. The detailed method of designing the configuration above is explained in the downloadable data attached to this book.

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Chapter 07

01 section

Printing process when using 3D printers

I will explain to you specifically how to print objects such as the parts of product by using 3D printer and the 3D data you have designed in the previous chapters. The basic procedure of product printing is the same in any CAD even though this chapter mainly focuses on how to print data created by 123D Design. You can therefore print your products by using any 3D printer if you remember the procedures explained in this chapter. Likewise, the explanations noted in this chapter do not confine the types 3D printers. Please keep in mind that your products can be printed with the same procedure by using any 3D printer.

Fabricating process using 3D printers Save the file as STL

Start fabricating

Take out the part

Creating the CAD data

Importing CATALYST (Preprocessing software)

Processing treatment (Full automatic)

After treatment Taking out the part and removing the supporting material

Modeling operation

Deciding layout method of the parts

Part in the making

Completed part

METHOD 1 Printing an STL file The first step of the fabricating procedure is to prepare the data in some kind of format that is going to be sent to the 3D printer. This can be executed normally by either method noted below.

• Create a data using a 3D CAD (The method explained in this book) • Execute the 3D modeling using a 3D CG to create data (this method is suited to be used when designing a character figure) • Create the basic configuration of the product by hand and scan it using a 3D scanner (p.112).

Outputting an STL file It is very easy to output an STL file using 123D Design. Try outputting an STL file by following the following procedure.

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Also, using different types of supporting materials and removing them by using alkaline water solution is possible depending on the model of dimension and uPrint.

The types of supporting materials vary depending on the maker. Supporting materials sustaining the object should be cut out by a tool so that the area where the supporting material was attached will be well-finished. On the contrary, water soluble supporting materials can be removed by soaking them in water for a while or washing them off with running water. In addition, supporting materials made of wax can be removed by melting them by placing them in an oven.

Confirm the configuration of the part after all the supporting materials are removed to check that it is printed as intended and to verify it is working properly.

Completed product (After all the parts are assembled)

Tips

Some of the personal 3D printers do not require any supporting material. You do not have

to be concerned about using supporting material when using such 3D printers.

Relationship between shape of models and supporting materials

Column

When printing a configuration shaped like a roof (overhanging configuration) which does not have any structure underneath as shown in the figure noted on the next page, 3D printers need to use supporting material to sustain it (Otherwise, the material will trickle down because it cannot be solidified). Thus, the material that supports the configuration of the object is called the “supporting material.� Supporting materials need to be removed after the object is printed. The removing method differs depending on the types of 3D printers and the material of the supporting material as described above.

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07-01

Printing process when using 3D printers

Relationship between the configuration of the 3D model and the supporting material Model material

Surface where the supporting material is not attached.

Supporting material will be placed in this area (It has to be removed after the product is printed).

Surface where the supporting material is attached.

Please note that using the surface where the supporting material is attached as the exterior surface might affect the appearance of the product.

Additionally, the length of the printing time using 3D printers is proportional to the height of the product which means that you can reduce the printing time by changing the direction of the 3D model to shorten its height (Height of flat products can be shortened by laying them on their sides).

Relationship between the height of the 3D model and the printing time When laying the 3D model on its side

Chapter 07

Z direction

When standing the 3D model up straight

How to print realistic materials from 3D data

Movement of the head

Work table

Work table

Printing time – short

Printing time – long

However, please keep in mind that it is not always a good idea to change the direction or the layout of the 3D model since there is the possibility that a number of overhanging areas will be made and you will end up having to prepare a lot of supporting materials.

You do not have to worry about this while designing the 3D model. The final direction or the layout of the 3D model should be decided after the software such as catalyst calculates the relationship between the direction of the 3D model and the printing time and the quantity of the material that is going to be used.

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Technical Point

Workflow when correcting the errors of an STL file

Because the error-correcting method of an STL file differs according to the software, it is necessary to correct the errors by following the manual attached to the software that you are using. In this section, I will explain to you briefly about the workflow of error-correcting procedure taking “netfabb,” the software which I (author) use on a daily basis, as an example.

s tep

1

I will use the configuration shown in the figure on the right as an example in this section.

This is an STL file output by a certain CAD. Although it seems like an ordinary cylinder, it cannot be printed properly ❶ because it is made up of three thin and flat surfaces (the cylinder hollow, the top surface and the bottom surface).

Also, the surfaces of it are not connected to each other. It can be said that this cylinder is a spectral, insubstantial and ghost-like object.

s tep

❶ ●

2

The 3D data of the cylinder shown above will be displayed as shown in the figure on the right after it is opened by netfabb. The “!” mark displayed in the lower right portion of the screen indicates that this data contains errors ❷ .

Technical Point

❷ ●

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How to save and upload an STL file You can also use the 3D printing service by uploading the STL stored on your PC to the website of the 3D printing service directly rather than the method of using the cloud service provided by 123 Design previously described. By using this method, you can use any kind of 3D modeler to place an order to the 3D printing service.

In this section, I will explain to you how to upload an STL file stored on your PC to shapeways on the assumption that you already have a completed, proper STL file.

s tep

1

❶ ●

Login to the website of shapeways and click [New Product] included in the [Create] menu ❶ .

s tep

2

Click the [Select 3D file] button ❷ and select the objective STL file from the displayed file-selecting screen.

s tep

❷ ●

3

Verify the unit ❸ , click the [Upload now] button ❹ and start uploading the file.

It might take a little time to upload the whole file depending on the size of the file but the file will be uploaded within no longer than few minutes.

❹ ● ❸ ●

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Chapter 08

01 section

Various manufacturing methods and fabricating machines

3D printers are gathering much attention as instruments that will bring innovation to the ways of making things nowadays but there are many ways of fabricating products other than 3D printing technology. Although it might be good enough to use 3D printers when fabricating a hobby product or a trial product, you must understand the feature and the disadvantage/advantage of each and every fabricating process. The types of fabrication process and the material that are going to be used vary according to the type or the configuration of the product.

In this chapter, I will give you a brief overview of each fabricating process while giving mention to the instruments and services that can be used by personal fabricators.

Cutting work Cutting work is one of the most popular processes of making things at the present time.

This process consists of creating a product by pruning a mass of material using a blade.

Making things with home carpentry tools or a carving knife is part of the cutting work.

Blades that can be used in various situations have been developed recently and almost any material can be processed such as wood, metal and resin.

Example of cutting work (a desk cutting machine “iModela�: Roland DG)

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08-02

Some words of caution when selling products

Conclusion Thank you for reading through this book. This book is written with the purpose of explaining the initial step of making things at home using PC to people who are interested in making things by themselves. However, it is absolutely impossible to cover all the important things just by reading this book. Remember that this book is nothing else but an introduction and I do not know what you have to learn from now on but I am sure that I have successfully introduced to you the hints of what you should learn in the future. Please try learning the knowledge that are going to be needed, acquiring needed skills and making appealing products on your own from now on.

The most exciting part of making things privately is the fact that the maker can create anything he/she wants at his/her own will without any interruption. It might not be an easy job to make things on your own but I can guarantee that you will be able to create what you really want to create if you can solve each problem in front of you step by step. Making things at your own is surely very fun, stimulating and profound and is worth putting that much effort. Trial-and-error methods are part of the product creation in the beginning.

Attractive products around us are produced after much struggle and trial-and-error and therefore I really hope that you can enjoy the whole process of making things.

The number of full-fledged personal makers might increase hereafter but when you first start making things at your own, you are all alone. However, this does not mean you have to do everything by yourself. Please remember that you always have a choice of conducting the

Chapter 08

product development by picking the brains and lending the strengths of experts in various fields and forerunners.

Lastly, it will be a great pleasure for me if by reading this book, even one person will become motivated to start making things at home.

Aiming to become a full-fledged personal maker

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Index

Number/Symbol

Assembly drawing・・・・・・・・・・・・・・・・・・ 10

123D Catch・ ・・・・・・・・・・・・・・・・・・・・・ 68

Assembly function・

123D Creature・ ・・・・・・・・・・・・・・・・・・・ 67

Autoclave・・・・・・・・・・・・・・・・・・・・・・・・ 42

123D Design・

Autodesk Alias・ ・・・・・・・・・・・・・・・・・・・ 22

123D

・・・・・・・・・・・・・・・・・・ 23, 62

Make・・・・・・・・・・・・・・・・・・・・・・ 68

Autodesk Inventor・

・・・・・・・・・・・・・・・・ 57

・・・・・・・・・・・・・・ 24, 60

123D Sculpt・・・・・・・・・・・・・・・・・・・・・・ 67

Bayblend・・・・・・・・・・・・・・・・・・・・・・・・ 43

2D CAD・・・・・・・・・・・・・・・・・・・・・・・・・ 11

Beta version・・・・・・・・・・・・・・・・・・・・・・ 73

3D CAD・・・・・・・・・・・・・・・・・・・・・・・・・ 11

Blade-1・ ・・・・・・・・・・・・・・・・・・・・・・・・ 40

3D CG・・・・・・・・・・・・・・・・・・・・・・・・・・ 20

Boolean・・・・・・・・・・・・・・・・・・・・・・・・・ 90

3D Touch・・・・・・・・・・・・・・・・・・・・・・・・ 34

Box・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 83

3ds Max・・・・・・・・・・・・・・・・・・・・・・・・・ 20

Browse My Computer・ ・・・・・・・・・・・・・・ 82

3D scanner・

・・・・・・・・・・・・・・・・・・・・・112

Browse The Gallery・・・・・・・・・・・・・・・・・ 82

3D data・・・・・・・・・・・・・・・・・・・・・・・ 11, 46

Business card holder・・・・・・・・・・・・・・・ 141

3D printer・ ・・・・・・・・・・・・・・・・・・・・ 12, 26

Butadiene・

3D printing service・・・・・・・・・・・・・・・・ 241

CAD・

3D modeler・ ・・・・・・・・・・・・・・・・・・・ 17, 20

CAE・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 10

3D

modeling・ ・・・・・・・・・・・・・・・・・・・・ 46

CAM・

・・・・・・・・・・・・・・・・・・・・・・ 29

・・・・・・・・・・・・・・・・・・・・・・・・・・ 25

・・・・・・・・・・・・・・・・・・・・・・・・・ 258

Carbon fiber・・・・・・・・・・・・・・・・・・・・・・ 42

A•B•C

Casting・ ・・・・・・・・・・・・・・・・・・・・・ 12, 262

ABS resin・・・・・・・・・・・・・・・・・・・・・・・・ 29

Catalyst・・・・・・・・・・・・・・・・・・・・・・・・ 232

ABS-like・・・・・・・・・・・・・・・・・・・・・・・・ 30

CATIA V5・・・・・・・・・・・・・・・・・・・・・・・・ 60

ACIS・ ・・・・・・・・・・・・・・・・・・・・・・・・・・ 59

Ceramics・・・・・・・・・・・・・・・・・・・・・・・ 249

Acryl・・・・・・・・・・・・・・・・・・・・・・・・・・・ 43

Chair・・・・・・・・・・・・・・・・・・・・・・・・・・ 170

Acrylonitrile・ ・・・・・・・・・・・・・・・・・・・・・ 29

Chamfer・

Acrypet・ ・・・・・・・・・・・・・・・・・・・・・・・・ 43

Circle・・・・・・・・・・・・・・・・・・・・・・・・・・・ 83

Adding・・・・・・・・・・・・・・・・・・・・・・・・・・ 91

Circular arc・

Altech・ ・・・・・・・・・・・・・・・・・・・・・・・・・ 35

Circular Pattern・

Alumide・・・・・・・・・・・・・・・・・・・・・・・・ 249

Clay model・・・・・・・・・・・・・・・・・・・・・・・・ 9

Aluminum

alloy・ ・・・・・・・・・・・・・・・・・・ 41

・・・・・・・・・・・・・・・・・・・・・・・ 86

Clearance・

・・・・・・・・・・・・・・・・・・・・・ 84 ・・・・・・・・・・・・

87, 136, 190

・・・・・・・・・・・・・・・・・・・・・ 143

・・・・・・・・・・・・・・・・・・・・・・・・ 43

Cloud service・・・・・・・・・・・・・・・・・・・・・ 64

Application menu・ ・・・・・・・・・・・・・・・・・ 79

CNC Utility・・・・・・・・・・・・・・・・・・・・・・・ 80

Assembly・・・・・・・・・・・・・・・・・・・・・・・・ 10

Combine・ ・・・・・・・・・・・・・・・・・・・・・・・ 90

Amiran・

272

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Index

Command menu・・・・・・・・・・・・・・・・・・・ 79

Fiber Reinforced Plastics・ ・・・・・・・・・・・・ 42

Computer Aided Design・・・・・・・・・・・・・・ 25

Figure・ ・・・・・・・・・・・・・・・・・・・・・・・・ 199

Engineering・ ・・・・・・・・・ 10

File format・・・・・・・・・・・・・・・・・・・・・・・ 59

Computer Graphics・・・・・・・・・・・・・・・・・ 25

Fillet・ ・・・・・・・・・・・・・・・・・・・・・・・・ 84, 86

Conceptual design・

Computer Aided

・・・・・・・・・・・・・・・・・ 9

Fine Detail Plastic・・・・・・・・・・・・・・・・・ 249

Cone・・・・・・・・・・・・・・・・・・・・・・・・・・・ 83

Firstcut・ ・・・・・・・・・・・・・・・・・・・・・・・ 260

Construct・・・・・・・・・・・・・・・・・・・・・・・・ 84

Fit・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 95

scanner・ ・・・・・・・・・・・・・・ 112

Flipped patche・ ・・・・・・・・・・・・・・・・・・ 229

Context sensitive menu・・・・・・・・・・・・・ 108

Fortus・ ・・・・・・・・・・・・・・・・・・・・・・・・・ 36

Copper・

Frosted Detail Plastic・・・・・・・・・・・・・・・ 249

Contact 3D

・・・・・・・・・・・・・・・・・・・・・・・・ 42

Core-cavity・

・・・・・・・・・・・・・・・・・・・・ 260

FRP・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 42

Cube・・・・・・・・・・・・・・・・・・・・・・・・・ 34, 97

Full Color Sandstone・・・・・・・・・・・・・・・ 249

Cutting work・

Fuse deposition molding・ ・・・・・・・・・・・・ 28

・・・・・・・・・・・・・・・・・ 12, 256

Cylinder・・・・・・・・・・・・・・・・・・・・・・・・・ 83

G•H•I D•E•F

Geometric information・

・・・・・・・・・・・・・ 23

Delpet・・・・・・・・・・・・・・・・・・・・・・・・・・ 43

Gold・ ・・・・・・・・・・・・・・・・・・・・・・・・・・ 42

Design change・ ・・・・・・・・・・・・・・・・・・・・ 9

GrabCAD・ ・・・・・・・・・・・・・・・・・・・・・・・ 58

Detailed design・・・・・・・・・・・・・・・・・・・ 10

Grouping・・・・・・・・・・・・・・・・・・・・・・・・ 89

materials・・・・・・・・・・・・・・・・・・・ 36

High-density polyethylene・・・・・・・・・・・・ 43

Digital

Dimension・ ・・・・・・・・・・・・・・・・・・・ 36, 232

HI-ZEX・

・・・・・・・・・・・・・・・・・・・・・・・・ 43

Direct metal・・・・・・・・・・・・・・・・・・・・・・ 35

i.materialise・・・・・・・・・・・・・・・・・・・・・ 243

DirectX・

・・・・・・・・・・・・・・・・・・・・・・・・ 78

Iges format・ ・・・・・・・・・・・・・・・・・・・・・ 60

Display menu・・・・・・・・・・・・・・・・・・・・・ 79

iGUAZU・ ・・・・・・・・・・・・・・・・・・・・・・・・ 34

Draft・・・・・・・・・・・・・・・・・・・・・・・・・・ 263

Industrial 3D printer・・・・・・・・・・・・・・・・ 32

Drawing・・・・・・・・・・・・・・・・・・・・・・・・・ 11

In perspective・

Drilling machine・・・・・・・・・・・・・・・・・・ 257

Injection molding・ ・・・・・・・・・・・・・・ 12, 260

Duracon・・・・・・・・・・・・・・・・・・・・・・・・・ 43

Inkjet printing process・

Duranex・

・・・・・・・・・・・・・・・・・・・ 98

・・・・・・・・・・・・・ 29

・・・・・・・・・・・・・・・・・・・・・・・ 43

Install・ ・・・・・・・・・・・・・・・・・・・・・・・・・ 74

DWG format・・・・・・・・・・・・・・・・・・・・・・ 60

Instructables・ ・・・・・・・・・・・・・・・・・・・・ 71

Elastic deformation・・・・・・・・・・・・・・・・・264

INTER-CULTURE・ ・・・・・・・・・・・・・・・・・ 244

Elastomer・ ・・・・・・・・・・・・・・・・・・・・・・ 43

Intermediate file・・・・・・・・・・・・・・・・・・・ 59

Ellipse・・・・・・・・・・・・・・・・・・・・・・・・・・ 83

Intersect・ ・・・・・・・・・・・・・・・・・・・・・ 90, 91

EOSINT・・・・・・・・・・・・・・・・・・・・・・・・・ 36

Iron・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 42

EOS・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 36 Extend・・・・・・・・・・・・・・・・・・・・・・・・・・ 84 Extra super

duralumin・・・・・・・・・・・・・・・ 41

J•K•L Join・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 91

Extrude・・・・・・・・・・・・・・・・・・ 51, 84, 85, 117

Kevlar fiber・

FDM・

KitMill series・・・・・・・・・・・・・・・・・・・・・ 259

・・・・・・・・・・・・・・・・・・・・・・・・・・ 32

Fiberglass・

・・・・・・・・・・・・・・・・・・・・・・ 42

・・・・・・・・・・・・・・・・・・・・・ 42

Kurarastec・・・・・・・・・・・・・・・・・・・・・・・ 43 273

3D_272_277_index_UK_EL.indd 273

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Misao Mizuno

ISBN 978-1-907920-45-5

The content of this book is sure to provide you with basic ideas on how to start making things at home. You will learn about the latest trends in 3D printing and gain a background to product creation. Also, by reading this book, you will gain a thorough understanding of all crucial information regarding this topic. Such information includes an amount of practical training on how to create 3D data that are essential when making things at home using Autodesk 123D Design, a free 3D CAD program. Furthermore, this book will teach you how to print objects using 3D printers, and introduce to you features of the wide-ranging 3D printing services available.

DESIGN

www.elektor.com

Don’t you think you are missing out on a great opportunity of making things at home just because you do not know where to start? So, here it is, a book that provides you with basic knowledge and information about 3D printing technologies so that you can get started.

3D PRINTING AND AUTODESK 123D DESIGN

LEARN

Elektor International Media BV

Thanks to the rapid development in 3D printing tools and services, anyone can now make things without being a member of a large organization, or without specialized facilities.

And this is definitely one of the weightiest reasons why people who are interested in making things are attracted to 3D printing technologies. On the other hand, there are still a lot of people who do not have an idea of where to start and a good many of you may not even have seen a real 3D printer except on television or in journals.

KICK-OFF GUIDE TO MAKING THINGS AT HOME

● MISAO MIZUNO

Misao Mizuno has been engaging in the CAD / CAE / PLM industries and has been helping the manufacturing industry while working at a major PLM vendor and a foreign-affiliated consulting corporation since the beginning of the 1990’s. Furthermore, he has been working actively as an advisor who helps other companies to install CAD / CAM / CAE / PLM tools while at the same time developing his own, unique products.

3D PRINTING AND AUTODESK 123D DESIGN

3D PRINTING AND AUTODESK 123D DESIGN

KICK-OFF GUIDE TO MAKING THINGS AT HOME

Misao Mizuno LEARN

DESIGN

SHARE

SHARE

LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHAR GN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHARE ● LEARN ● DESIGN ● SHAR