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We have a couple of machines available in our lab. Ultimaker 2 and Stratasys Dimensions SST 1200. Stratasys Dimensions SST 1200 This is a bigger machine. It uses ABS plastics to make models and also has a solubleThe technology employed is FDM Technology and can give a finer resolution print and at aYou can see that the machine is closed up and has strict temparature and humidity controlThe machine can print with layer thickness as small as 0.254 mm( 0.010 in ). planned to use ultimaker for my printing purpose. Ultimaker is a cheap and comparitively lightweight 3d printer. build volume of 223 X 223 X 205 mm. The technology used is Fused Filament Fabrication where the printing material is headed to a liquid form and is extruded in layers to form the model. The size of the nozzle of the print head is 0.4 mm, the tempareture is 180 to 260 degree celcius. Though we can use wide range of material in this machine, the recommended thickneds is 2.85 mm. Layer resolution is up to 20 microns

with a print speed ranging from 30- 300 mm/sec and traveling speed ranging from 30 to 350 mm/sec This is the software used to convert 3d models in different format like ply, stl, obj into machine unserstandableThis software is more advanced than a tpical gcode converter as it has features to view and position the model, scale, rotate etc. The ultimaker settings can be set using this software. We can set the layer and support material properties in this software. Another highlight of this software is that when we load the model it shows an estimate time and amount of material required for the print operation. This is very much helpful and also helps avoid insufficient material problems while printing. Sample taken from thingverse A testing design as in figure was pulled out from thingvere and it was printed in ultimaker to test the results. The followig tests where included in this file The actual and printed size comparisons are shown below.

1. Creating the gear, starting with a couple of circles 2. Creating the groove 3. Duplicating the groove to create the gear 4. Extruding the sketch 5. Making the hole at the center Gear placed inside the casing Detached view for better comprehension. 7. Import it into CURA for 3d printing, Place the model properly, transform it if necessary. Now change the print settings and generate gcode. This is gcode file is copied into a memory card and transferred into the ultimaker to print. Front and back side of the printed model Unfortunatly for me the printing did not work well and the printed model was alli was not able to move the gear. Though i have provided allowance at places, as i scaled down the model to one fourth its original size, the allowance was too small and the plastic which needed to stay separated fused on to each other. My placement of the model for printing was wrong. I placed it in such a way that the gear opening was on the bottom.

But now i realize, it would have worked if i did it upside down. First when we started the machine to print, the extrusion was not happening, seems like the material has clottedTo fix that we had to pull out the filament and cut the clotted portion and reinsert it. This worked fine but unfortunately when we reinserted the filament to the tube. moter was not pulling it in. After consult with the lab technician it was found that a small bit of the filament was stuck in the stepper. Later we had to remove that to make the machine work fine. The point to appreciate is the maintainability of the ultimaker machine 1. Creating the basic shape 2. Creating the cuts 3. Creating the holder Final rendering of the whistle Different views of the printed model This time the printing worked well and the only issue was that of the support material. The inside of the model was filled with support material which i had to manually remove and that was a tedious process.

Removing support material is a challenge if you print these kind of models in a priniter like ultimaker. should have worked better if i printed this in Stratasys Dimensions SST 1200 where the support can be dissolved away. Scanning with Kinect Scanner I used the software Skanect for 3d scanning. Skanect is a propiratory software i could only get a free version with limited features. The limitation include the model resolution. version of the software only lets you save a low resolution model. Also you cant export a texture in the freeWe had the kinnect and a camera stand but fixing the kinnect on the stand was a mess. Thanks to Rahul and Syed who 3d printed a the kinnect holder for the stand we had , they also tweked an office chair to make the scanning easy. This it our scanning setup, we use the kinnect and a modified revolving chair for the process. Scanning with skanect is very easy,the following link from instructables will get you started

Correcting the scans in blender The model generated by skanect often have some additional things such as a nearby wall or stand.So its often necessory to remove the unwanted parts from the model before going ahead with printing it. I use blender for this process. I opened up the model in blender and then selected the unwanted vertices/faces in edit mode and then deleted them. Now i had the model alone ready to print. Original blender file of standing pose Original stl file of standing pose Original blender file of sitting pose Original stl file of sitting pose 3d Printing the scanned model The scanned model which was further refined with blender was exported to curaI also applied a sub-surf modifier to smooth the model and also added a base to the model as you can see in the following image. The files are attached below. Final model used to print Original stl file of sitting pose with base Model in cura: The model was placed in a lying pose so that there wont be support for the