Vacuum Forming

Vacuum Forming

Intro/Background

Modeling Tips

Introduce Vacuum Former

Heat press (Fancier Studio)

Temp

Time

Material

Thickness

Look up different options

Do and Don'ts

Specs

Set up

Use

Tips throughout

Removing Mold

Clean up

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital STL file. It uses 3D digital models to create solid fixtures by printing layer upon layer of plastic material. 3D printing has been around since the mid 1980’s. It has only became practical in the past seven to 8 years as 3D printers have come down in price. 3D printers are good for rapid prototyping. Currently the University of Idaho has four 3D printers available for use such as the MakerBot Replicator 2, two Sindoh 3DWOXs, and the Mark 2 MarkForged.

Vacuum Forming Machines Available
The available mechanical engineering vacuum former is located in the Metrology Lab (Room 123) inside the Gauss Johnson Engineering Lab. The sign up process to use these machines is based on a first come first serve basis. For more information on how to use these machines find a graduate student and/or go to the IEW office (GJ 113). Listed below are a few examples of graduate students that could be contacted.

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MakerBot
The MakerBot was purchased by the University of Idaho in 2012. Some characteristics of the Makerbot include:
 * Build Volume - 11.6" x 7.6" x 6.5" (29.5cm x 19.5cm x 16.5cm)
 * Filament Material(s) - PLA

More information on this printer can be found below:
 * Part Design (MakerBot)
 * Code Generation (MakerBot)
 * Machine_Setup/Maintenance (MakerBot)
 * [MakerBot Filament]
 * [MakerBot Filament]

More information on this printer can be found below:
 * [[File:Sindoh_3DWOX_Information_Sheet.pdf ]]
 * Video-Hints and Tips
 * Video-Hints and Tips #2
 * SINDO FAQs

Mark 2 MarkForged

 * Easy to Use - Printing a part to be strong or flexible is intuitive using the touchscreen interface.
 * Versatile - This printer can print 12.6" x 5.2" x 6" (320mm x 132mm x 154mm) parts.
 * Filament Material(s) - Onyx (plastic)
 * High-Strength Printing - Reinforcing your parts with composite fiber while 3D printing them, this printer achieves high strength, stiffness, and durability in its printed parts.
 * Range of Materials - In addition to printing Onyx, this printer is capable of printing Carbon Fiber, Fiberglass, and Kevlar.

More information on this printer can be found at https://markforged.com/

Recommended Settings

 * Select "Standard" resolution
 * Infill to 20%
 * Set "Number of Shells" to 3
 * Select "Raft" to help keep your part from warping. Typically for use with large parts or flat parts
 * Turn on "Supports" if your part cannot be oriented in such a way to prevent overhangs.
 * Click "Print" to begin exporting your model
 * Click "Export Now" and save to your flash drive
 * Place your flashdrive in the 3D printer and select "Print" from the file you just saved.

Pros and Cons of ABS and PLA

 * Acrylonitrile Butadiene Styrene (ABS)
 * Pros
 * Low Cost
 * Good impact and wear resistance
 * Less oozing and stringing gives models smoother finish
 * Good heat resistance
 * Cons
 * Heavy warping
 * Needs heated bed or heated chamber
 * Produces a pungent odor while printing
 * Parts tend to shrink leading to dimensional inaccuracy


 * Poliactic Acid (PLA)
 * Pros
 * Low Cost
 * Stiff and good strength
 * Good dimensional accuracy
 * Good shelf life
 * Cons
 * Low heat resistance
 * Can ooze and may need cooling fans
 * Filament can get brittle and break
 * Not suitable for outdoors (sunlight exposure)

'''For more information on materials visit the website: https://www.simplify3d.com/support/materials-guide/pla/'''

Troubleshooting
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Print Not Sticking to Build Plate
{| A print can fail if the base does not adhere properly to the base plate. There are a few things that can cause this:
 * 1) The base plate is not level. It could be possible that the base plate is not level. If the base plate isn't level your part may come out lopsided or won't stick properly. See Leveling Base Tray for instructions on how to level the base plate.
 * 2) Bubbles or Other Defects in Tape There is tape on the base plate in order to make maintaining the MakerBot easier. If there are any defects in the surface such as bubbles or significant wear, the part will have trouble sticking. See Maintaining Tape for more information.
 * 3) Complex Geometry Complex geometry on the bottom side of a part can cause issues with adhering to the base plate. Try simplifying the part geometry or adding a raft to avoid this issue.

Stringing or Oozing
More information on troubleshooting can be found at https://www.simplify3d.com/support/print-quality-troubleshooting/

Naming Convention for STL Files
For appropriate accounting, save your STL files in the following formats below. Make sure the print operator name is included because often the people signed in are not the ones that should be charged. This information is collected monthly from the printer and sent to Molly in the engineering department (mollym@uidaho.edu). If there is confusion in charges contact her.

Class Project Example:

(Class, Student Name) "Project"

Vacuum Forming Policy
The Mechanical Engineering Department maintains the vacuum former for sole use by faculty, staff, and students. The use of the vacuum former shall be consistent with the purpose of the department, which includes facilitating research and learning. In accordance with these purposes, the department has developed policy and procedures for use of the printers:

1.	Administration. All projects (i.e. components) to be printed shall require permission from a faculty member. All projects must originate from U of I classroom, lab, or research. To clarify, personal projects are prohibited.

2.	Certain Uses Prohibited. Regardless of viewpoint, certain uses of the printers are prohibited and violate this Policy:

(a)	Printing any object that is unlawful, threatening, abusive, tortuous, obscene, and racially, ethnically or otherwise objectionable;

(b)	Printing any object that is intended to physically harm, or attempt to harm, an animal or person in any way. This includes any type of weapon (i.e. knives, firearms, etc.) or parts of a weapon (i.e. blades, gun triggers, etc.)

(c)	Printing any object that infringes upon a patent, trademark, trade secret, copyright or other proprietary rights of any party unless consent from the rights-owner has been obtained; The Copyright Law of the United States governs the making of photocopies or other reproductions of copyrighted material. The deparment reserves the right to deny use of printers if, in its judgement, use of the printers would violate Copyright Law.

(d)	Printing any object or any part of an object that is regulated. For example: Undetectable Firearms Act of 1998 which specifically bans plastic firearms.

3.	Usage Subject to Refusal or Revocation. The vacuum former is provided to further the purposes of the department. In accordance with this policy, the department may refuse usage of the vacuum former at any time. Failure to abide by this policy may result in revocation of the user’s forming privileges.