Homework F3: 3D Printing

For this project, I used the Original Prusa i3 MK3S+ printer at the Kaplan Cellular Agriculture Lab located in the Science and Technology Center at Tufts University. The material I selected was Prusament PLA, a biodegradable thermoplastic ideal for producing stable, detailed prints. I used the National Institute of Allergy and Infectious Diseases (NIH) Heart Library to obtain my desired 3D print.

My primary goal was to optimize the stability of the print on a flat surface while minimizing material usage without compromising structural integrity. To achieve this, I applied organic supports in critical areas, particularly around the brain stem, where the thinner layers were at risk of collapsing. These organic supports are branched, making them easier to peel off after the print is complete. I strategically limited the placement of these supports to the build plate, reinforcing only the parts of the model that required additional stability.

Additionally, I reduced the infill percentage from 100% to 10%, which significantly reduced the printing time from 2 hours and 40 minutes to 2 hours and 20 minutes. This change also minimized material usage while maintaining the necessary strength of the model. Furthermore, I scaled down the original MRI brain scan model to 33.82 mm (x), 26.54 mm (y), and 27.76 mm (z), optimizing both the material consumption and the overall print duration.

Initially, I encountered an issue where the first couple of layers were sliding off the build plate during the printing process. After troubleshooting, I determined that the build plate was too oily, likely due to fingerprints or residual dirt. To resolve this, I cleaned the plate using a standard table spray cleaner, which improved adhesion and successfully resolved the issue. Another challenge was taking the supports off without damaging the print. Since the supports were strongly attached to the model I used a screwdriver to chop off the branch-like structures and was able to isolate the brain.

Additionally, I reduced the infill percentage from 100% to 10%, which significantly reduced the printing time from 2 hours and 40 minutes to 2 hours and 20 minutes. This change also minimized material usage while maintaining the necessary strength of the model. Furthermore, I scaled down the original MRI brain scan model to 33.82 mm (x), 26.54 mm (y), and 27.76 mm (z), optimizing both the material consumption and the overall print duration.

Initially, I encountered an issue where the first couple of layers were sliding off the build plate during the printing process. After troubleshooting, I determined that the build plate was too oily, likely due to fingerprints or residual dirt. To resolve this, I cleaned the plate using a standard table spray cleaner, which improved adhesion and successfully resolved the issue. Another challenge was taking the supports off without damaging the print. Since the supports were strongly attached to the model I used a screwdriver to chop off the branch-like structures and was able to isolate the brain. Finally, I achieved a successful, highly detailed small-scale brain 3d printed product!

One example of an object that is difficult to fabricate using traditional technologies is the small-scale brain model derived from an MRI scan. This model includes detailed curves, folds, and complex internal structures that would be nearly impossible to replicate using subtractive manufacturing methods like casting, molding, and machining. 3D printing allows for the precise reproduction of these organic shapes. Other examples include bifurcating blood vessels and complex vasculature, which have non-linear, organic shapes and internal hollow cavities that are challenging for traditional fabrication techniques. Additionally, tailoring prosthetics or implants to match an individual patient’s anatomy can be time-consuming and costly with conventional methods, whereas 3D printing enables rapid, custom fabrication based on digital models from medical scans.