Manufacturing Configuration for dvi3v Hardware
v3.9.2.208

This document describes the actual manufacturing configuration used to fabricate the dvi3v camera stand hardware.

The configuration is extracted from .3mf files which contain the complete slicer settings used for production prints.

Each hardware component has a corresponding .3mf file containing:

• Complete slicer configuration (PrusaSlicer 2.9.4)
• Print orientation on bed
• Material settings (PETG)
• Layer heights, speeds, temperatures
• Infill patterns and densities

• Base-left_enfolding.3mf - Left base component
• Base-right_enfolding.3mf - Right base component
• Base-union.3mf - Union truss connector
• Base-screw.3mf - M6 screw model
• CameraBase.3mf - Camera mounting platform
• VerticalBar.3mf - Vertical support bar

• Slicer: PrusaSlicer 2.9.4
• Printer: COREONE (or COREONEL)
• Nozzle: 0.6mm high-flow
• Bed: 250mm × 220mm

Similar settings to VerticalBar:

• 0.2mm layers
• PETG material
• 15% gyroid infill
• 2 perimeters

• Speed: 45mm/s
• Acceleration: 500mm/s²
• Ensures reliable bed adhesion

• Perimeters: 70mm/s
• External perimeters: 50mm/s (slower for quality)
• Infill: 100mm/s (fast, less critical)
• Bridge: 30mm/s
• Default acceleration: 3000mm/s²

• First layer: 500mm/s²
• Perimeters: 2500mm/s²
• External perimeters: 1500mm/s²
• Infill: 6000mm/s²
• Bridge: 1500mm/s²

Note: Dynamic acceleration based on layer height (G-code modifies above layer 150mm)

• Cooling: Enabled
• Disable fan first layers: 3
• Bridge fan speed: 60%
• Regular fan: Auto (dynamic)
• Logic: Consistent surface cooling

• Dynamic fan speeds: Enabled
• Dynamic overhang speeds: Enabled
• Allows adaptive cooling based on geometry

Printed diagonally on bed to accommodate height:

• Component exceeds 220mm Y dimension
• Rotation: ~45° to fit within 250×220mm bed
• Ensures full part can print without splitting

• Left/Right: Flat on bed (designed orientation)
• Union truss: Flat on bed
• Screw: Upright (threaded axis vertical)

• Flat on bed with camera opening upward
• No supports needed due to design

• Layer height: 0.2mm
• Balance between:
  • Dimensional accuracy (good)
  • Print time (moderate)
  • Strength (excellent - more layer bonding)
• Typical print time: ~4-6 hours for VerticalBar

• Layer height: 0.32mm
• Advantages:
  • Faster printing (~40% time reduction)
• Disadvantages:
  • Less dimensional accuracy
  • Weaker layer bonding
  • Visible layer lines
• Reason for change: Wobbling issue indicated insufficient structural rigidity at coarser layers

• PLA was mentioned in test object specs (black, matte)
• Actual jig uses PETG for structural components
• Rationale: Higher strength requirements for camera support

• Original design suggested "structural" profile
• 0.32mm speed profile caused wobbling
• 0.2mm provides:
  • Better layer adhesion
  • Improved dimensional accuracy
  • Necessary rigidity for tall vertical structure

• Lower than typical 20% for non-structural parts
• Gyroid pattern provides:
  • Isotropic strength (equal in all directions)
  • Material efficiency
  • Adequate rigidity for this application
• Saves material and print time vs solid infill

• Standard for this nozzle size (0.6mm)
• 2 × 0.62mm = 1.24mm wall thickness
• Adequate for this geometry
• More perimeters would increase print time without significant strength gain

• Geometry designed to be support-free
• Fillets and angles avoid >45° overhangs
• Support removal can damage surface finish
• Support-free design is superior engineering

• Extended height (200mm junction + extension) exceeds Y bed (220mm)
• Diagonal rotation fits within 250×220mm bed
• Alternative would be:
  • Splitting into multiple parts (adds assembly complexity)
  • Larger printer bed (e.g., Prusa XL with larger platter)
• Diagonal orientation maintains single-piece integrity

All camera stand structural components use PETG:

• Base (left, right, union, screw)
• VerticalBar
• CameraBase

Rationale:

• Mechanical requirements: rigidity, strength, durability
• Temperature resistance (hot environments, sunlight)
• Impact tolerance (repeated handling, assembly)
• Layer adhesion for tall prints (VerticalBar)
• Less brittleness than PLA

All test objects use black matte PLA:

• Geometric shapes (circles, squares, rectangles, triangles)
• Reference patterns
• Calibration objects

Rationale:

• Dimensional accuracy (PLA shrinks less than PETG)
• Matte black surface minimizes reflections
• High contrast with white A4 paper background
• Easy to print (lower temperatures, no warping)
• Less expensive for consumable test objects
• Sufficient strength for non-structural test pieces

• Red base (structural PETG)
• Natural/white structures (CameraBase, VerticalBar in PETG)
• High contrast aids computer vision in photographs

All jig .3mf files are stored in:

hardware/
  Base-left_enfolding.3mf
  Base-right_enfolding.3mf
  Base-union.3mf
  Base-screw.3mf
  CameraBase.3mf
  VerticalBar.3mf

Same directory as corresponding .scad files for easy access.

All test object .3mf files are stored in:

TestInstrumentation/GeometricShapes/
  Circle25mm/Circle25mm.3mf
  Circle50mm/Circle50mm.3mf
  Circle75mm/Circle75mm.3mf
  Square25mm/Square25mm.3mf
  Square50mm/Square50mm.3mf
  Square75mm/Square75mm.3mf
  Rectangle50x100mm/Rectangle50x100mm.3mf
  Triangle80mm/Triangle80mm.3mf

These .3mf files contain the actual print settings used, documenting the exact manufacturing process for reproducibility.

1. Open .3mf file in PrusaSlicer
2. All settings automatically loaded
3. Can modify if needed
4. Slice and send to printer

.3mf files are ZIP archives containing:

• 3D/3dmodel.model - Geometry (STL-like)
• Metadata/Slic3r_PE.config - Complete slicer settings
• Metadata/thumbnail.png - Preview image

Extract configuration:

unzip -p component.3mf Metadata/Slic3r_PE.config > settings.txt

CRITICAL: For multi-tool printers (e.g., Prusa XL with multiple extruders), always identify which tool was actually used before documenting settings.

1. Open .3mf file
2. Import new STL
3. Settings automatically applied
4. Adjust if geometry significantly different