No one likes a know-it-all. Most of us realize there’s no such thing–how could there be? The world is far too complicated for someone to understand everything there is to know. So when you come across a know-it-all, you smile to yourself as they ramble on because you know better. You understand that the quest for knowledge is a never-ending one, and you’re okay with that. You have no desire to know everything, just the next thing. You know what you don’t know, you’re confident enough to admit it, and you’re motivated to do something about it. At Idiot’s Guides, we, too, know what we don’t know, and we make it our business to find out. We find really smart people who are experts in their fields and then we roll up our sleeves and get to work, asking lots of questions and thinking long and hard about how best to pass along their knowledge to you in the easiest, most-accessible way possible. After all, that’s our promise–to make whatever you want to learn “As Easy as It Gets.” That means giving you a well-organized design that seamlessly and effortlessly guides you from page to page, topic to topic. It means controlling the pace you’re asked to absorb new information–not too much at once but just what you need to know right now. It means giving you a clear progression from easy to more difficult. It means giving you more instructional steps wherever necessary to really explain the details. And it means giving you fewer words and more illustrations wherever it’s better to show rather than tell. So here you are, at the start of something new. The next chapter in your quest. It can be an intimidating place to be, but you’ve been here before and so have we. Clear your mind and turn the page. By the end of this book, you won’t be a know-it-all, but your world will be a little less complicated than it was before. And we’ll be sure your journey is as easy as it gets. Mike Sanders Publisher, Idiot’s Guides This book is dedicated to my lovely wife Sarah, who has always stood by me and supported me. Without her, I could never have done this. ALPHA BOOKS Published by Penguin Group (USA) Inc. Penguin Group (USA) Inc., 375 Hudson Street, New York, New York 10014, USA • Penguin Group (Canada), 90 Eglinton Avenue East, Suite 700, Toronto, Ontario M4P 2Y3, Canada (a division of Pearson Penguin Canada Inc.) • Penguin Books Ltd., 80 Strand, London WC2R 0RL, England • Penguin Ireland, 25 St. Stephen’s Green, Dublin 2, Ireland (a division of Penguin Books Ltd.) • Penguin Group (Australia), 250 Camberwell Road, Camberwell, Victoria 3124, Australia (a division of Pearson Australia Group Pty. Ltd.) • Penguin Books India Pvt. Ltd., 11 Community Centre, Panchsheel Park, New Delhi—110 017, India • Penguin Group (NZ), 67 Apollo Drive, Rosedale, North Shore, Auckland 1311, New Zealand (a division of Pearson New Zealand Ltd.) • Penguin Books (South Africa) (Pty.) Ltd., 24 Sturdee Avenue, Rosebank, Johannesburg 2196, South Africa • Penguin Books Ltd., Registered Offices: 80 Strand, London WC2R 0RL, England Copyright © 2015 by Penguin Group (USA) Inc. All rights reserved. No part of this book may be reproduced, scanned, or distributed in any printed or electronic form without permission. Please do not participate in or encourage piracy of copyrighted materials in violation of the author’s rights. Purchase only authorized editions. No patent liability is assumed with respect to the use of the information contained herein. Although every precaution has been taken in the preparation of this book, the publisher and author assume no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of information contained herein. For information, address Alpha Books, 800 East 96th Street, Indianapolis, IN 46240. IDIOT’S GUIDES and Design are trademarks of Penguin Group (USA) Inc. eISBN: 9781615647453 Library of Congress Catalog Card Number: 2014951305 17 16 15 8 7 6 5 4 3 2 1 Interpretation of the printing code: The rightmost number of the first series of numbers is the year of the book’s printing; the rightmost number of the second series of numbers is the number of the book’s printing. For example, a printing code of 15-1 shows that the first printing occurred in 2015. Printed in the United States of America Note: This publication contains the opinions and ideas of its author. It is intended to provide helpful and informative material on the subject matter covered. It is sold with the understanding that the author and publisher are not engaged in rendering professional services in the book. If the reader requires personal assistance or advice, a competent professional should be consulted. The author and publisher specifically disclaim any responsibility for any liability, loss, or risk, personal or otherwise, which is incurred as a consequence, directly or indirectly, of the use and application of any of the contents of this book. Most Alpha books are available at special quantity discounts for bulk purchases for sales promotions, premiums, fund-raising, or educational use. Special books, or book excerpts, can also be created to fit specific needs. For details, write: Special Markets, Alpha Books, 375 Hudson Street, New York, NY 10014. Publisher: Mike Sanders Executive Managing Editor: Billy Fields Senior Acquisitions Editor: Brook Farling Development Editor: Kayla Dugger Production Editor: Jana M. Stefanciosa Cover Designer: Laura Merriman Book Designer: William Thomas Indexer: Brad Herriman Layout: Brian Massey Proofreader: Virginia Vasquez Vought DIGITAL OPERATIONS, LONDON Digital Producer: Alex Valizadeh Senior Digital Producer: Miguel Cunha DIGITAL OPERATIONS, DELHI Head of Digital Operations: Manjari Rathi Hooda Producer: Rahul Kumar Assistant Editor: Etika Kapil DTP Designer: Manish Bhatt Operations Assistant: Tauhid Nasir Contents Part 1: What Is 3D Printing? 1 The Goal of 3D Printing For Businesses Rapid Prototyping Manufacturing For the Hobbyist The Maker Culture A Tool in Your Arsenal Common Misconceptions Materials You Can Use A Replicator in Every Home The Time It Takes What It Can Print Finishing 2 The History and Future of 3D Printing 3D Printing Is Born Hull’s and 3D Systems’ Contributions The Invention of FDM Printing The Development of Other 3D Printing Processes The RepRap Project Initial Intentions The Importance of Open Source Rapid Development Refinement, Availability, and Your Wallet Maturation of Technology Availability of Parts The Race to the Lowest Price 3 Manufacturing with 3D Printers and CNC Mills The Simple Principle Behind 3D Printing Slicing and Creating Layers for Your Model Extruding Filament CNC Milling and How It Works Subtracting with CAM Software Milling the Material Pros and Cons of 3D Printers vs. CNC Mills Cost Part Geometry Material Matters Surface Finish Using the Right Tool for the Job 4 Types of 3D Printers Stereolithography Digital Light Processing Powder Bed Printing MultiJet Printing Selective Laser Sintering Fused Filament Fabrication Part 2: All About the Hardware 5 The Frame Cartesian Layouts Ways Cartesian 3D Printers Are Constructed Cartesian Layout Considerations The Importance of Frame Construction Rigidity and How It Affects Quality and Reliability What Makes a Good Frame Size Matters 6 Movement Components Components for Smooth Linear Motion Rails and Smooth Rods Bearings Stepper Motors Belts and Pulleys Weight-Bearing Components for Converting Motion Lead Screws Threaded Rods Attachment and Connection Components Couplers Nuts 7 The Extruder What Is Extrusion? The Cold End Direct Feed Bowden Direct Drive vs. Geared The Hot End Thermistor Heating Element Physical Design and Makeup The Nozzle Print Fans Using Multiple Extruders For Support Material For Filaments with Different Properties 8 The Build Platform Build Platform Materials Heated Beds Heated Build Chambers and Enclosures Surface Treatments Painter’s Tape White Glue Polyimide Film PET Film ABS Juice Hairspray 9 Control Components End Stops Mechanical End Stops Optical End Stops Other Kinds of End Stops Control Boards Arduinos and Proprietary Control Boards Changing or Upgrading Control Boards SD Card Support Using an SD Card Benefits of SD Cards LCD Controllers 10 Choosing a 3D Printer Open or Closed? What Does It Mean to Be Open Source? Why It Might Matter to You Assembled, Kit, or DIY? Assembled 3D Printers 3D Printer Kits Building a DIY 3D Printer Determining Your Needs Print Volume Print Resolution Filament Prices Printers with Unusual Designs Part 3: Setting Up and Printing 11 Software Setup and Printer Control Firmware Explained Choosing Host Software Choosing Slicing Software Connecting to Your Printer Controlling Your Printer G-Code Printing with G-Code Performing Functions Manually with G-Code 12 Leveling the Bed and Adjusting the Z Height Why Does Your Bed Need to Be Leveled? Manual Leveling Auto-Leveling How to Adjust Your Z Height Setting the Z Height Manually or Automatically Knowing the “Correct” Z Height 13 Slicing and Printing Configuring Your Slicing Software Slicer Settings Explained Printer Settings Filament Settings Print Settings Preparing for and Running a Print Host Preparation Running a Print 14 Troubleshooting Your Prints What’s the Problem? Extrusion Problems Overextrusion Underextrusion Jamming Poor Dimensional Accuracy Temperature Problems Hot End Is Too Hot Hot End Is Too Cold Cracking of Part Due to Cooling Discoloration of Filament Due to Heat Adhesion Problems Warping Part Comes Loose Part Breaks During Removal Other Printer Problems Blobs Stringing Drooping Ghosting Project 1: Carabiner Preheat the Extruder and Heated Bed Load the .STL File Slice the Model Load the Filament Extrude Some Filament Start the Print Watch the First Layer Let the Part Cool Remove the Part Project 2: Pencil Holder Load the .STL File and Resize the Model, If Necessary Preheat the Extruder and Heated Bed, and Load the Filament Modify the Slicer Settings to Make the Model a Cup Slice the Model Start the Print Watch the First Layer Remove the Part Project 3: Robot Load the .STL File Preheat the Extruder and Heated Bed, and Load the Filament Modify the Slicer Settings for Supports Slice the Model