For this project we had to design birdhouses within a tight budget. The deadline was also quite tight, so we had to adapt the design and production process accordingly. We divided the bird house into glueable parts in order to save a lot of printing time.
With slicer settings, we optimized the design. For example, we were able to reduce the printing time by working with a layer thickness of.8 mm on the body of the birdhouse. This allowed us to maintain the thickness with half the distance to travel.
Printing at such a large layer thickness also makes the walls stronger which is ideal for an outdoor item. Because the model is built with minimalistic shapes, the layer height could be set to .28 mm resulting in a faster printing process.
Finally, we also had to add branding. We don't use a 2 color printer so we had to solve this creatively by printing off bondable components in alternating colors. The challenge was to make these components fit. The logo had a lot of lowercase without rounding.
In FMD printing, this quickly creates problems because the hot PLA accumulates in sharp edges of the model. As a result, we worked with a tolerance of .25 mm and an additional margin of -.1 mm with horizontal expansion added in the Cura slicer.
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