szmz/teaching

3d printed Stencil

First create a vector format stencil file either type of:

  • halftone vector stencils (downloadable in .svg format):
    https://halftone.xoihazard.com/
    (or: https://vectorizer.oscaralexander.com/)
    tips:
    • the grid should be hexagonal, size not smaller than 18, radius 1
    • shape should be triangular or square, scale >~0.77, strength 0.5-0.65
    • but most importantly:
      • the raster elements should always have thick borders between each other
      • the smalest triangular/square elements should be bigger than 1mm in diameter (the bigger is the safer)

Next create a 3d model for 3d printing in Blender or any 3d modeling program:

  • create a flat sheet with 0.4-1mm thickness (z dimension), depending the elasticity you need
  • import the svg and finetune it
  • select all the curves, convert to mesh, then join them to one mesh
  • in edit mode extrude the mesh in z, thicker than your sheet
  • place the mesh within the body of the sheet
  • add a BOOLEAN DIFFERENCE modifier to the sheet with the curves-mesh, it should perforate the flat sheet

Lastly import the model to your slicer software and print it. Note that first layer speed should bee slow, especially when there are fine details present in the stencil. Some recommendations in print settings:

  • use a 150% thick first layer. Eg. if your layer height is 0.2mm, set your first layer height to 0.3
    (in Orca Slicer: Quality>First Layer Height=0.3mm
    in Cura: Quality>Initial Layer Height=0.3mm )
  • use only 1 perimeter
    (in Orca Slicer: Strength>Wall loops=1
    in Cura: Walls>Wall Line Count=1 )
  • use 125% extrusion width on the 1st layer: if extrusion width is 0.4mm, use 0.5 on the first layer
    (in Orca Slicer: Quality>Line width>First layer=0.5
    in Cura: Quality>Initial Layer Line Width=125%)
  • use very small elephant foot compensation ~ 0.05mm
    (in Orca Slicer: Quality>Precision>Elephant foot compensation=0.05
    in Cura: Walls>Initial Layer Horizontal Expansion=0.05 )

3D Printed Stencil: How to Make Your Own