1. An Overview and Applications for Amateur Radio Paul Cowley W0YR
3D Printing
An Overview and Applications for Amateur Radio
Paul Cowley W0YR

2. Basics of 3D Printing
3D Printing creates a physical object from a three-dimensional digital model
Additive manufacturing process
Can employ different additive techniques, processes, and materials including:
Material extrusion (Fused Deposition Modeling aka Fused Filament Fabrication is the most common process today)
Light polymerization (Consumer-grade Stereolithography is starting to emerge as a viable process)
Powder bed (Currently expensive. Typically use laser or heat sintering, mostly used for metals and ceramics)

3. Fused Filament Fabrication (FFF)

4. Types of FFF Printers Cartesian Printers (most common type)
Print head typically moves on X, Z axes
Printer bed typically moves on Y axis
Advantages
Higher print resolution
Lots of technical support available
Less expensive than competing designs
Consumer-friendly design that is simple to understand
Disadvantages
Slower print speeds than Delta printers
Weight is greater than Delta printers
Often limited capabilities when printing tall objects

5. Types of FFF Printers Delta Printers (somewhat common)
Print head is held by three supports in a delta configuration
Advantages
More efficient use of printer bed area
Faster than Cartesian printers due to lighter print mechanism (reduced inertia)
Disadvantages
Circular build area
Must be physically much taller than Cartesian printers for same build volume
Harder to print objects with large flat/horizontal surfaces
Currently less-precise than Cartesian printers (lower print resolution)

6. Types of FFF Printers Polar Printers (very uncommon)
Use a polar coordinate reference
Advantages
None?
Disadvantages
Different than mainstream units, so available support is limited

7. Some Available FFF Materials
PLA (Polylactic Acid)
Easy to print, low warping during print, hard but potentially brittle material
PETG (Polyester Terepthalate – Glycol-modified)
Slightly flexible, very tough and durable, suitable for food contact
ABS (Acrylonitrile Butadiene Styrene)
High impact strength, UV-resistant, little/no warping during print, releases potentially harmful vapors during print
ASA (Acrylonitrile Styrene Acrylate)
Strong UV-resistance, high wear and impact resistance, releases potentially harmful vapors during print
PC (Polycarbonate)
Very tough, heat resistant to ~140°C, BPA-free
Nylon
Strong and tough material, requires special filament drying and handling procedures

8. Amateur Radio Applications

9. Amateur Radio Applications
Design and build custom enclosures for equipment or projects
Design and build custom antenna parts
Insulators, coil forms, mounts,
Design and build custom tools and equipment
Equipment stands, mounting brackets, soldering tools, vises, wrenches, etc
Repair or modify existing objects
If you can dream it up, you can probably 3D print it!

10. A Few Sources for Designs

11. 3D Printing Workflow
Create the design in 3D CAD software and export mesh file (typically in .STL or .OBJ file format)
Fusion360 (very powerful professional cloud-based CAD/CAM software – free for hobbyists)
TinkerCAD (simple, free, browser-based program)
Blender (free and open-source software, geared more toward graphic designers)
SketchUp (limited feature set is available free, paid subscriptions offer more features)
OpenSCAD (free parametric code-driven 3D CAD software)
Import mesh file into “slicer” software to convert 3D model into layer-by-layer G-Code (RS-274 protocol) using appropriate parameters for your design, material, and printer
Cura (free)
KISSlicer (free / $35 pro version – multiple extruder support)
Slic3r (free, open-source)
OctoPrint (free, open-source)

12. Fusion360 Screenshot

13. OpenSCAD Screenshot

14. 3D Printing Workflow Import compiled G-Code into printer
G-Code commands the printer movements, extrusion, other parameters
Example G-Code commands

15. Example G-Code

16. Hands-On Demonstration
Start with Thingiverse design
Customize and export .STL file from Thingiverse Customizer
Import .STL file into Slic3rPE (Slic3r Prusa Edition)
Export G-Code for Prusa i3 MK3
Print!

17. Alternatives to Owning a 3D Printer
Create or download your design and have a third-party print and ship to you
Wider array of materials and processes than most hobbyists
You DO pay for the convenience!
Shapeways
Xometry
Protolabs
3D Hubs
i.materialise
Sculpteo
***DISCLAIMER: I have not personally used ANY of these services!

18. Questions?