Printer benchmark and manifold redesign
A benchmark part that found the limits of the university's FDM printers, and a hydraulic manifold redesigned to print with minimal support.
A benchmark part designed in Fusion 360 with eight features testing overhangs, bridges, angled beams, holes and engraved text. It was sliced in Z-Suite and printed in Z-ABS with a 0.4 mm nozzle, 0.19 mm layers and 20% infill.
We also redesigned a hydraulic manifold in SolidWorks so it could be printed with as little support material as possible.
What I did
- Created the benchmark model and prepared it in Z-Suite.
- Inspected each feature after printing to find where the printer failed.
- Contributed to the manifold redesign.
What the print showed
- Finding:
Most unsupported features failed in some way: vertical holes stayed clean only up to about 6 mm, horizontal holes under 1 mm collapsed, thin overhangs drooped and engraved text on rough surfaces was hard to read.
Response:Recorded the limits as design rules for the printer.
- Finding:
The original manifold's internal channels needed heavy support.
Response:Angled the channels to less than 45° from vertical and added walls where angling was not possible, cutting the supports needed.
From the bench
Overhang test features drooping at shallow angles
Hole-size test row
Printed hydraulic manifold redesigns