In this section an example of modelling for 3D printing is depicted. A cam gear mechanism is modelled using fusion 360, and
printed using Ultimaker 5S 3d printing machine.

First we start by the modelling of the cam gear mechanism which is derived by human hand

The design consists of 5 parts which need to be modelled individually

Cam Gear
We start by sketching the profile of the cam gear using the ellipse tool, then sketching the material optimisation profiles.

Then using the extrusion tool the final profile of the gear can take shape with a material thickness of 2 mm.


Reciprocator Guide
We start by sketching the profile of the reciprocator guide using the Rectangular tool, then sketching the spindle holder .

Then using the extrusion tool the final profile of the guide can take shape with a material thickness of 5 mm.

notice that the spindle holder is supposed to allow the spindle to rotate freely so a tolerance of 1 mm is applied to the slot.
Lever (Handle)
We start by sketching the profile of the reciprocator guide using the rectangular and circle tools, then sketching the material optimisation profiles .

Then Extruding the profiles using the extrusion tool with a material thickness of 3 mm

Reciprocator
Using the sketch tool we can derive the profile with the rectangular and circle tools, then sketching the material optimisation profiles.


Extruding the profile with 3 mm thickness.

Spindel
By using the sketching tool we can create the profile of the spindle using the rectangular tool, then adding the material optimosation profile.


The spindle is going to be having to deal with the load coming from human hand input, so adding a truss support profile is essential to avoid fracture.
Using the extrude tool by a thickness of 2.9 mm, we can conclude the final profile of the spindle.

notice that the spindle is supposed to be form fitted in the cam gear slot so the thickness of the spindle profile should be less than the cam slot.
The final assembly should be having this profile.


The motion analysis of the mechanism should behave like follows.

3D printing
In order to transform the fusion 360 files into readable additive manufacturing machines language we need to use a slicing program to transform
the fusion 360 files into G-Code, which slices the solid models into multible slices in xyz coordinates
we use the program Ultimaker Cura 4.8.0 for preparing the print.

After saving our individual parts as STL files we can import them into Ultimaker Cura 4.8.0 and place them correctly on the printing plate so that
no overhang is allowed as the printing is done bottom up direction and the material need to be supported.

By using these printing configurations we can prepare the parts for printing



Notice that for such a mechanical part a relatively high layer hight is recommended to optimise toughness and overcoming plastic elasticity.
After final checking for the printig specs we can press slice, the program starts to transform the solid parts into G-Code slices and opting out
a time estimation of the print and a G-Code file. We save the file to our USB stick and the file is good to go to the Ultimaker S5.

The ultimaker printing machine is qualified with a USB stick input slot which we can use it directly and choosing the file form the window and
pressing Print.

The final print will be looking like follows

Conclusion