Printing large objects with a smaller 3D printer can be a challenge, especially when you’re working with limited build volume. However, with the right techniques and strategies, it’s entirely possible to create larger prints without compromising on quality. In this article, we’ll explore the best ways to print large objects on a smaller 3D printer, including design techniques, slicing methods, and hardware modifications.
Why Print Large Objects on a Smaller 3D Printer?
While some 3D printers come with an ample build volume capable of printing large objects in one go, many users are limited to smaller printers. This doesn’t mean you can’t print big objects; it simply means you need to think creatively. Here’s why people opt to print large objects on smaller printers:
- Cost-effective: Smaller 3D printers are generally less expensive and more accessible.
- Space-saving: For users with limited space, a smaller printer is often more practical.
- Upgrading Options: If you already own a smaller 3D printer, printing large objects might be more cost-efficient than upgrading to a larger one.
By breaking down the design process and exploring creative solutions, you can successfully print large objects on a smaller 3D printer.
1. Divide the Model into Smaller Parts
One of the most effective ways to print large objects on a smaller printer is to split the model into smaller, more manageable parts. Once the parts are printed, they can be assembled to form the full object.
Steps to Divide Your Model:
- Use 3D Design Software: Most 3D modeling software, such as Tinkercad, Fusion 360, or Meshmixer, allows you to split models into smaller sections.
- Design for Assembly: When dividing the model, ensure that the parts fit together easily. You can use connectors like dovetail joints, pins, or interlocking tabs to ensure the pieces fit securely.
- Consider Orientation: Think about how each part will be oriented on the print bed. Ideally, orient parts to minimize overhangs and reduce the need for support material.
Once you’ve divided the model, use your slicing software to prepare each part for printing. After printing, you can assemble the parts together using glue, screws, or other methods.
2. Use Modular Design
Modular design is another effective technique that allows you to print large objects by designing them in multiple smaller, independent modules. This method is perfect for objects that can be separated into logical, functional components.
Benefits of Modular Design:
- Easier Printing: Smaller modules fit within the build volume, and each one can be printed separately.
- Customization: You can design the modules in a way that allows you to easily customize or replace parts later on.
- Strong Assemblies: When using modular designs, you can incorporate strong joining techniques like threaded bolts or snap-fits, ensuring that the final assembled object is sturdy.
Examples of modular designs include storage boxes, furniture, and large mechanical parts that can be divided into functional sections.
3. Scale Down and Print in Parts
If the large object you’re printing doesn’t need to be an exact scale, consider printing it at a smaller size. This approach allows you to print all parts in one go and then scale them up later.
- Use Slicing Software: You can scale down the model in your slicing software before printing. Make sure to maintain the proportions to avoid issues with fitment when assembling parts.
- Post-Processing: If the object requires a specific size, you can use post-processing techniques, like sanding or adding extensions, to scale it back up after assembly.
While this method may not work for every project, it’s an efficient way to create larger models that fit within your printer’s capacity.
4. Make Use of the Printer’s Build Plate with Strategic Placement
If your 3D printer has a smaller build plate, you can still print larger objects by maximizing the available space through strategic placement. The key is to orient the model in such a way that you minimize wasted space and utilize the build volume efficiently.
Tips for Placement:
- Orient Objects for Maximum Space: Place the parts on the build plate in a way that minimizes gaps between them. Use the slicing software to arrange the parts efficiently.
- Use Overhangs Wisely: Some objects can be printed in a way that overhangs are minimized, allowing for more space to place other parts. Keep in mind that overhangs may require additional support structures.
- Print in Layers: If the object is very tall, you can print in vertical sections to fit them on the build plate, as long as you have enough height on the Z-axis.
5. Utilize Support Structures to Increase Print Size
Support structures are essential when printing large objects in parts. They provide the necessary stability during the printing process and help prevent warping. While some printers require support structures by default, you can manually add them in slicing software to ensure your parts print successfully.
Support Material Strategies:
- Generate Support in Software: Most slicing programs, like Cura or PrusaSlicer, automatically generate supports when needed. You can tweak the settings for more or less support material based on the model.
- Use Breakaway Supports: Some filaments or 3D printers support breakaway supports, which are easy to remove after the print.
- Soluble Supports: For complex models, consider using soluble support filaments like PVA, which dissolve in water and leave no trace of support material on the print.
By carefully designing your model and using support structures, you can print larger objects even if they are taller than your build plate’s capacity.
6. Consider Printing with a Lower Layer Height
When working with smaller parts for a larger print, reducing the layer height can result in better print quality and smoother fits when assembling the pieces. A lower layer height (e.g., 0.1mm) ensures that the parts come out with finer details, which can be particularly important for creating well-fitting joints in modular designs.
Layer Height Tips:
- Precision: A smaller layer height allows for more precise details, making the assembly process easier and more accurate.
- Print Time: Be mindful that printing with a lower layer height can increase print time. However, the improved quality often makes this extra time worth it, especially for parts with fine details.
7. Optimize for Print Speed
If you’re printing a large object in parts, optimizing for speed without sacrificing quality can save time. This involves adjusting print settings such as layer height, print speed, and infill density.
Print Speed Considerations:
- Layer Height: Choose an optimal balance between speed and detail. Larger layer heights (e.g., 0.3mm) speed up the process but might sacrifice fine details.
- Infill Density: Reduce the infill density for non-critical parts to save material and printing time.
- Wall Thickness: Increase the wall thickness to ensure strength without requiring dense infill. This allows faster prints while still maintaining structural integrity.
By optimizing for speed, you can complete the individual parts faster and reduce the overall printing time for your large object.
8. Post-Processing and Assembly
Once all the parts of your large object are printed, you can move on to post-processing and assembly. The method of joining the parts depends on the type of model and how you designed the parts.
Common Assembly Methods:
- Glue: Use strong adhesives like cyanoacrylate (super glue) or epoxy for joining parts.
- Screws and Bolts: For added strength and adjustability, you can use screws, bolts, or threaded inserts to assemble your parts.
- Snap-Fits: If your design supports it, snap-fit connectors allow you to assemble the parts without additional tools.
Post-processing can also involve sanding, painting, or polishing the assembled model to achieve the desired finish.
Conclusion
Printing large objects on a smaller 3D printer is entirely achievable with the right approach. By dividing your model into smaller parts, using modular designs, optimizing print settings, and employing creative post-processing methods, you can overcome the limitations of your printer’s build volume.