3D printing step files

All modern CAD (Computer Aided Design) programs allow you to export your own file format to STL. The 3D model is then converted into machine language (G-code) through a process called "slicing" and the model is then ready to be printed.

In this article, you will learn the basic steps required to properly export your models for 3D Printing.

Step 1: Resolution STL

The STL file format uses a series of linked triangles to recreate the surface geometry of a solid model. Increasing the resolution will use more triangles, better approximating the surfaces of the 3D model, but also increasing the size of the STL file.

If you export the file at too low a resolution, the model will have visible triangles on its surface when printed. In most cases this is not desirable, but they can be used to create "low poly" models with a digital look.

Increasing the resolution above a certain point is also not recommended, as it does not bring any additional benefit: very small details cannot be 3D printed, so the file size will be increased unnecessarily, making subsequent processing difficult.

Step 2: Export Options

You can change the resolution of STL files by changing the format options in the software. If you're unsure, choosing a preset is the safest option to create an STL file that fits 3D print .

Each CAD package has different STL resolution options, but most use two main parameters: chord height and angle.

Chord height is the maximum distance between the surface of the original 3D model and the surface of the STL file that the software can use. Using a lower chord height will help show the curvature of the surface more accurately.

The recommended value for the chord height is 1/20 of the thickness of the 3D printed layer and not less than 0.001 mm (1 micron). This will always produce an STL file with perfect accuracy for most 3D printing applications. Exporting at a lower tolerance will not affect print quality as most regular 3D printers are not capable of reproducing such a high level of detail.

Angular tolerance limits the angle between the normals of neighboring triangles. The default value is often 15 degrees. Some programs also specify this tolerance as a value between 0 and 1. If a smoother surface does not require a higher setting, the default value of 15 degrees (or 0) is recommended.

Step 3: Export STL files from your CAD software

Let's see how you can quickly and easily convert your file to STL format in different programs.

AutoCAD:

Important: STL export is only possible for whole 3D objects

1. Enter “FACETRES” on the command line
2. Set parameter FACETRES to 10.
3. Enter command “STLOUT”
4. Specify objects to export
5. Press Y or Enter at the Create a binary STL file? [Yes/No]
6. Specify a file name
7. Save the file.

Autodesk 3ds Max (3D Studio Max)

1. Open the File > Export tab)
2. Select file type - StereoLitho *.stl
3. Enter file name
4. Save file
5. Select type Binary
6. Press OK

Autodesk Inventor / Mechanical Desktop

Important: you can export both individual parts and whole parts of the model

1. Open Manage tab > Update panel > Rebuild All
2. Then open File > Save as > Save Copy As
3. Select STL file format
4. Enter file name
5. Set the following parameters: Format - binary (Format > Binary), units - mm or inches (Units > mm, inches), resolution - high (Resolution > High)
6. Save file

Google Sketchup

If you are using Sketchup Standard and not Pro, you will need to install a special extension to export to STL. You can find the appropriate extension for your version of Sketchup here. Download the extension, go to Sketchup > Window > Preferences > Extensions > Install Extension to install it.
To export to STL after installing the extension, follow the instructions below:

1. Go to Sketchup > Tools > Export to DXF or STL
2. Select the desired object to export. If you do not select an object, then the model will be exported completely.
3. Select the unit of measurement for the exported object: meters, centimeters, milimeters, inches, feet
4. Select the geometry of the exported object: polyface mesh, polylines, triangular mesh, lines, stl
5. Select where you prefer to save the exported file.

Attention: if you export a circle with this plug-in, then when you view it in some other programs, you will notice that when you increase it, it consists of short segments.

Blender

1. Open File > Export > STL
2. Enter file name
3. Specify file locations
4. Press the Export STL button

Pro ENGINEER

1. Open File > Save a Copy
2. Select STL type and press OK
3. Set Coordinate System Standard
4. Select file format Binary
5. Set the following parameters Chord Height to 0 (set the minimum allowable Pro/E values)
6. Angle Control leave the default
7. Enter a file name and press OK

Rhino

1. Open the File > Export Selected or File > Save As tabs
2. Select objects to export
3. Set file type to Stereolithography (*. stl)
4. Enter file name
5. Save file
6. In the STL Mesh Export Options window, set the Enter Tolerance to 0.02 mm (0.0008 inches), then click OK.
7. Set the file format to Binary
8. Uncheck the Uncheck Export Open Objects option
9. And press OK again

Solidworks

1. Go to File > Save As…
2. Set the file type to STL(*.stl)
3. Open the Options tab
4. Set the output file format to Binary
5. Unit: > Millimeters or Inches
6. Resolution-Good (Resolution > Fine)
7. Press OK
8. Enter file name
9. Save

SolidWorks Student Design Kit

1. Open File > Save As…
2. Set file type eDrawings(*.eprt)
3. Open the Options tab
4. Check the box Allow export to STL for Parts & Assemblies
5. Press OK
6. Enter file name
7. Save file
8. Open the file in eDrawings
9. Open the tabs File > Save as… > and set the file type to STL (*. stl)
10. Save file

Rules of thumb

• Export with 0.001 mm chord height and 15 9 angular tolerance0243 o for best results 3D printing .
• Avoid exporting unnecessary large STL files.

Preparing models for 3D printing: Materialize Magics features

3D basics

Software

Author: Kirill Romanov

Author: Kirill Romanov

Materialize Magics: An all-in-one 3D printing program | What is included in the software | Magics RP Base Module Capabilities | Additional modules | Benefits of Magics

How models are prepared for 3D printing

Additive manufacturing starts with the modeling of objects, which is carried out in various programs such as CATIA, SketchUp, SolidWorks, Inventor, Siemens NX and others. In order to print a product, it is necessary to prepare its digital model, and this process can take up to 32% of the time of the entire additive manufacturing cycle, depending on the technology and complexity of the object.

To manufacture a part on a 3D printer, first of all, you need to get an STL file. To do this, we convert a rigid body to a polygonal model, and then perform the operations of correction, enhancement, editing, platform preparation, nesting, generation of supporting structures, measurements and analysis.

The next stage is slicing (separation into layers), which consists in creating a control program for a 3D printer. The model is divided into layers with a certain step, and on each layer we get a closed contour, along which the extruder or printer's laser beam will pass. Each layer is usually a 2D DXF image.

Applying Materialize Magics Software to the Additive Manufacturing Cycle

Next, the object is printed and undergoes the necessary post-processing. The stages of work from converting to STL to slicing are performed in specialized software, which will be discussed in our review.

Attention! In the context of sanctions, VoxelDance will become a worthy analogue of the software of manufacturers who have left the Russian market. These are universal solutions for preparing models for 3D printing at a bargain price. Check out the overview and demonstration of work in the software product.

Materialize Magics: Universal 3D Printing Software

The most flexible and comprehensive solution for these purposes is offered by Materialize, which has developed the Magics software product for 3D printing professionals. It allows you to create individual layers of components with high speed and accuracy based on 3D CAD data or 3D scan data. The software provides a full cycle of additive manufacturing - from data import (in STL and other formats) and quality analysis to platform preparation and post-processing.

Materialize Magics is unique in that it comes with the widest range of features available today. This is a kind of constructor, flexible and adaptable to almost any task of additive manufacturing. The software works with all types of 3D printers, and many manufacturers are building Magics into their hardware.

What's in the

Base module RP

1. Has a wide range of special functions for editing models.
2. Works with a large number of import file formats.
3. Quickly, accurately and geometrically correct errors in uploaded files.
4. Keeps the original color, textures and textures of objects after the "treatment" of the downloaded files, depending on the settings.
5. Provides convenient configuration of processes at all stages of preparation for printing.

Additional modules for specific functions

For example, the Import Module allows you to import many different formats; Structures allows you to design and print honeycomb structures and layers; Slice is used to transfer objects at the layer level in CLI, F&S, SLC, SSL formats; Tree Support is a set of supports, and so on.

Let's take a closer look at the capabilities of these software products.

Magics RP

The most important modeling step for a 3D printer is correcting errors. RP allows you to automatically correct errors in polygonal models, such as inverted normals, holes, open boundaries, noise, self-intersections of triangles, overlaps, etc.

Software functions:

1. One-click auto-correction of the most common geometry problems;
2. a step-by-step fix wizard to selectively fix certain categories of bugs;
3. manual patching tools to restore the most difficult areas.

1. Model editing:

• empty parts (walling) to save material, reduce weight and build speed;
• perforation to extract unused material;
• adding thickness to thin walls or modifying a part using the Offset & Extrude tool;
• converting a thin-walled surface to a solid model using Surface to Solid.

A large-scale SLA-printing project for mammoth bones. Emptying the model reduced material costs by 80%

Since some 3D printers have data upload limits, the following functionality is used to lighten the weight of the file:

• reduction of triangles;
• smoothing sharp edges;
• global rebuilding of the polygonal mesh.

2. Marking:

• Easily add text and images (DXF) to parts as markings.

3. Slicing (to separate the model and print it in parts if it does not fit in the printer chamber):

• notched cuts to reinforce the assembly;
• automatic creation of guide pins for assembly.

Using Magics, Nissan Motor Corporation has reduced the time it takes to process a 3D model and model assembly elements by 85%.

4. Boolean operations:

• just like in any CAD, the software makes it possible to perform Boolean operations, and directly in the STL file.

5. Platform preparation:

• platform visualization;
• automatic placement of objects on the platform;
• comparison of the positions of the model by various parameters;
• placement of the model, taking into account surfaces without supporting structures;
• a large library of 3D printers that you can replenish yourself.

6. Import:

• 3D printing software allows you to import polygonal models in all the most common formats - STL, OBJ, PLY, VRML - and many others.

Import Module

Using this module, you can additionally import CAD formats such as CATIA, NX, SolidWorks, while they are immediately converted to an STL file.

Slice Module

Creating a control program for a 3D printer includes features such as:

• preview of each print layer;
• saving settings for each machine;
• construction of a graph of the distribution of layers, which shows the dependence of the height on the area of ​​a given section.

Structures Module

This 3D printer modeling software allows you to create different structures inside the model for:

• reduction in weight, amount of material used and build time;
• giving greater strength compared to the devastated part;
• Prevent warping and build errors during printing by reducing the area/volume that is exposed to heat.

SL Corporation performs 3D printing of mounting fixtures. Due to the creation of structures inside the part, the weight of the product has decreased by 40%

Sinter Module

Specially designed for SLS printing and provides automatic placement of parts in a given build chamber volume:

• maximum use of the volume of the 3D printer building chamber when placing parts;
• creation of boxes for fragile or groups of small parts.

SG Module

Performs the function of building supporting structures for printing complex objects using various technologies (FDM, SLA, DLP):

• when changing the orientation, you can see where the supports will be built in real time;
• the serrated shape ensures the generation of strong yet easily removable supporting structures;
• perforated supports help save time and material;
• you can save a support profile with the specified parameters and use it for other products;
• The list of surfaces allows you to analyze and optimize support if necessary.

Tree Support Module

With the help of this software, tree-like supports are built, i.e. structures with a "trunk" and "branches". Tree Support provides the following benefits:

• ability to build supports in semi-automatic mode;
• improved surface quality by minimizing contact points;
• prevention of deformation of the product due to heat removal;
• easy removal of supporting structures by creating break points;
• lack of powder inside the supports;
• determination of the optimal cross-sectional diameter of the tree support depending on the material.

SG+ Module

A special modeling program for a metal 3D printer allows you to:

• to build three-dimensional supporting structures in order to avoid detachment from the platform and deformation of the product;
• create conical supports in critical places to improve heat dissipation;
• automatically generate angular and tree support.

Simulation Module

Designed to simulate the printing process with metal and visual display of various mechanical deformations or conduct thermal simulation.

Simulation of risks in 3D printing:

• simulation of mechanical deformations of a part and supports;
• definition of overheating zones;
• compiling the field of internal stresses of the metal on each layer and on the product as a whole;
• definition of zones with high shrinkage;
• visualization of results;
• obtaining a product with compensating dimensions.

The software also evaluates printing risks, such as broken support structures, recoater collisions, shrinkage, overheating, and helps prevent scrap.

In addition to Magics, Materialize offers 3D printing programs as separate base modules.

1. 3-matic is designed for modeling in STL-format (standard triangulation) and makes it possible to perform topological optimization at the microstructure level, including with the help of many CAE programs.

2. e-Stage enables fully automated generation of support structures and reduced post-processing costs. Creates contact points with minimal area support, making it easier to remove. The software is available in two configurations: for photopolymers (SLA) and metals (SLM).

Benefits of Materialize Magics

1. Speed, optimization and high reliability of all processes.

2. A set of practical and efficient solutions for preparing platforms, building support structures using any 3D printing technology.

3. Wide functionality for editing models (adding logos, textures, images).

4. Ability to perform complex cuts (for example, with built-in connecting pins), Boolean operations, etc.

5. The presence of an extensive library for almost any equipment with prescribed and customizable parameters.

6. Analysis and correction (quick correction, preparation and optimization of the polygon mesh with the best preservation of texture, color and quality, analysis of possible problems).

7. A wide range of tools for conducting additive manufacturing business processes.

8. Intuitive, easily customizable interface with technical support from the developer in Russian.

: our experienced experts will advise you on purchasing Magics, 3D modeling and other aspects of 3D technology.

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