Formlabs Ceramic Printing Progress

With each print job, new things come to light that help us learn what it takes to reliably print with the experimental ceramic resin on the Formlabs Form 2.

With the first successful print completed, with just one earring.  It was time to complete the pair and add a second pair to see how more than one earring printed.  So, the second print job included three earrings.  All of them were oriented as was the first.

Fortunately, the print was successful.  So, at this point I have been able to print 2 pairs of sample earrings.  This was encouraging!

FormLabs Ceramic Progress... four sets completed.

But, it was more than that.  It gave me multiple items to study closely.

The first thing that became clear is that while it is doable, removing all these supports cleanly is going to take time and time is money.  I had to find a way to print the items upright, or as near to upright as possible so that areas impacted by supports are minimized, while still providing the adherence required for successful printing.

One key, of course, is robust support creation.  But, the other key, was not so obvious.  But, it had been in front of me every time I had been successful up to the point of finishing a raft.  That key is preventing "cupping".  Think of "cupping" by visualizing the tentacles on an octopus or squid.  Our designs can form the suction cup features that make it difficult to separate a newly printed layer from the bottom of the resin vat.  In fact, the suction can be so great that it breaks supports completely causing catastrophic failure.

As I studied the successful prints carefully, something caught my eye.  What you cannot see in this image is that there are little holes around the circumference of the rafts generated by the Formlabs software.  They are SO tiny that it is even difficult to see them when you look closely while holding one in your hand.  Yet, they are important clues.  They are relief holes that allow air to escape which prevents cupping from happening at a level that causes the parts to fail.

I had been warned about "Cups" by the Formlabs software in previous prints.  But, now that message took on new meaning and I decided to investigate more deeply.  Before attempting to print again, I realized I had to create those same little escape holes in my entire part.

I have done so and now have just begun a new print job with four earrings.  Each earring design includes internal venting tunnels.  We'll see how it goes.  We'll have to wait some hours to find out.  But, I can tell you this, I am encouraged enough to purchase a new cartridge of ceramic material so that I can continue testing.  There IS light at the end of the tunnel.

UPDATE 1:  Support removal is unique for Ceramic Prints

I will write more about this topic in the near future.  We've been dealing with supports for years with a wide variety of techniques.  Using SLA plastic support removal tools and techniques is NOT going to have the same outcome with ceramic prints. Ceramic prints in their "green" state crumble easily.  So, using snips without damaging a part is more difficult than when removing plastic supports.  We're thinking that something like a rotary tool with a Dremel 561 Multipurpose Cutting Bit might be effective.  We'll see.  More later...

Dremel 561 Cutting Bit

UPDATE 2:  "Tunnel" method works! 

"Tunnel" Test Print

This was a quick snapshot taken with my camera just as the print completed.  Raft and supports were part of the design.  Raft is a hex design so that multiple groups can be easily placed into the print area.

But, I will have to delay getting better pictures for a bit due to our full teaching schedule through Saturday.  This is 3D ThinkLink Immersion Lab week for 6 cadets from Maryland, DC and South Carolina.  Keeping 6 cadets busy designing and printing on single color FDM, Color Mixing FDM, powder/binder full color and SLA takes full concentration.  Besides, it is a LOT of fun!

BTW, the print that finished this afternoon just about emptied my first ceramic cartridge; but, more is on the way.

Even though it might not arrive this week, we'll let the cadets design something for ceramic to be printed and fired before their graduation ceremony where we can present it to them.  In the meantime, we do have "tough" resin so they can see the result of their design from an SLA printer. They will be the first group to be introduced to both powder/binder and SLA during their 3D immersion experience.