[3D Printing News] Final Part: 3D Printed Decorative Lighting Fixture Mounting Device
With the development of 3D printing technology, we can directly see an increase in the number of final models produced directly from 3D printers , not only producing prototypes, but also opening up new possibilities for designers.
This is partly due to the improved quality of 3D printers. However, it's also because some interesting technologies are being applied to the product design process, helping to enhance the ability to print complex shapes and rigid models.
I designed an example to demonstrate how I use the best techniques every day to create complex models that are just as good as the parts I manufacture.
The design of this model was done in SolidWorks, but the techniques used can be adapted to any design software. 
Lighting accessories with all 3D printed parts
This decorative pulley lamp accessory I designed showcases the different techniques I use to create objects that are difficult to print, and enhances the joy of displaying them in my living room.
In this blog, I will introduce each section and show you which areas I reinforced, where I created custom supports for areas that are difficult to print.
And I used Ultimaker 's features to achieve the standard I was looking for. So let's begin.
Make the model stronger
The main body of the light fixture is an area that can be subjected to severe stress, and everything depends on what is suspended from the pulley. This part will have to bear the weight of the pulley.
Light bulbs and any lampshades you want to add. 
During the design phase, I added two 4.5mm holes to the main support.
This hole allowed me to slide two 4mm threaded rods there. Before sliding them, I glued some super glue to the tire tread.
This secures the threaded rod in place. This increases the weight the support can withstand, but hides the threaded rod inside the model. 
Apply glue before sliding the threaded rod in.
Change your fill rate
You can also increase the strength of a specific part of the model by increasing the fill rate of Cura. I increased the fill rate of the main body to 40%. This means that the internal main body has...
40% plastic and 60% air. The remainder is reduced to 20% because it doesn't withstand much pressure.
However, increasing the fill rate does have two main drawbacks. It increases your printing time and the amount of material used, so it's important to find a fill rate that best suits your items. 
40% filler 20% filler
direction
The forked parts of the wheel can be printed in two directions: option A or option B, as shown in the image below.
I chose option B because it makes the layer run along the length of the U-shape, rather than through it.
The reason is that I know I have to pull apart the forked insert shaft to install this wheel. If I select print option A, where the layers run along the area that needs to be curved, it might bite together due to the fragile areas between the layers.
When designing, consider the orientation of the objects you are printing. Thinking about this early can prevent problems later. 
Option A Option B
Add the shaft to the fork part
Material selection
Material selection can also be an important factor in designing a robust model. Each material has its own properties that can greatly benefit your project.
Since this is a broad topic, let's now look at the four most commonly used materials: PLA, ABS, nylon, and CPE.
Ultimaker PLA : PLA is your standard 3D printing material. It is the most common and easy to print on, but it is fragile and easily broken when bent.
Furthermore, these chemical elements are not ideal and have a low melting point. Immersing it in boiling water allows you to bend and shape it. Therefore, if your design will be exposed to direct sunlight or in hot environments, PLA might not be the right choice.
Ultimaker ABS : ABS is another popular material option, but like PLA, it has some drawbacks. While it is more flexible than PLA and can withstand higher temperatures and elements, it is more difficult to print.
It's more prone to warping if the printing environment isn't properly sealed and controlled, and it must be printed on a heated platform. It also releases unpleasant fumes that can irritate some people, so you should print any material in a well-ventilated room and avoid sitting directly next to the 3D printer.
Ultimaker Nylon : Nylon is a more advanced material. Its chemical composition makes it susceptible to moisture. So, if you work in a damp place...
You need to store it in a dry container or dry it in the oven. A high moisture content in the material will significantly reduce its quality.
However, once you happily use nylon for printing, it becomes a great material. With high impact resistance and low abrasion sensitivity, it's perfect for mechanical parts or components that rub against each other. But like ABS, it can be twisted and retain ambient temperature!
Ultimaker CPE : CPE is an excellent industrial material with superior dimensional stability. This means it does not shrink like other plastics.
The dimensions will be as precise as the original 3D design. This is important for tolerances. CPE also recommends using a heated platform for printing.
Therefore, choosing the right materials based on the object you are making is very important and should be considered in the early design stages.
support
Support material can be your best friend when 3D printing, but it can also cause some problems. It's great for helping you achieve complex shapes that can't be made any other way, but its downside is that it can be difficult to remove sometimes (unless you're using PVA in Ultimaker 3 ). The trick is to avoid using support material as much as possible, but sometimes you'll need it to achieve your design.
In my design, the main body has a rotating axis that helps support the main rod and makes it look nice.
The curled ends and tops clearly need support, but the support at the top is very thin. This is a concern because the higher it goes, the more unstable it becomes, and this thin support needs to maintain its own weight and curl until it touches another support. This is risky and could very well fail. 
You can see how thin the supporting structure is.
So I'll go back to SolidWorks and design my own custom support structure. This could also be done in any other design software.
This takes up a large area on the platform and makes the support provided by Cura more stable.
The support structure I designed is offset by 0.3mm from the top, so they can be easily separated.
This technical approach is very appealing and makes very difficult suspension designs feasible.
Add support using SolidWorks 
Before removing support After removing support
Insert screw
Sometimes you may need to use more glue to join your parts. Screws can be helpful, but you probably don't want them to be easily visible.
You can hide them in several ways. You can hide screws and bolts so that they are only visible from a certain angle, or you can create an insert to completely conceal them.
Alternatively, you can stop printing at a certain point, insert the bolt, and then continue, allowing the printer to seal the holes in the model.
There are two ways to do this. The first is to manually pause the print job and insert the bolt, but this is not very precise.
Cura has an option that does this precisely. This feature is called "pause at height".
It's a bit hidden, but you can find it if you go to the options at the top of the screen. Open "Extensions > Post Processing >"
Modify G-Code >>. Here, select "Add a Script" and then select "Pause at Height".
Here, you can set the exact height you want to pause, the desired position the print nozzles should move to when paused, and the landing point of the platform. Make sure that telling the nozzles where to stop doesn't restrict your printing.
My suggestion is to test this feature by creating a small, insertable square, especially if this is your first time trying it.
Please remember to turn off the pause height option for the next print job. 
These are some basic techniques you can use to help you create more complex custom supports and to provide additional support to areas you might need to focus on.
Make your design more robust.
This is not an absolute "do or don't do" teaching method, but rather a springboard to help inspire your own design and creativity.
Use this knowledge to help you create outstanding projects and develop technologies that enhance yourself.
I'm thrilled to see this community pushing the limits of 3D printing even further than ever before, even for something as simple as inserting a print job.
Some people will learn from it and appreciate it. Happy printing! 
Completed 3D printed lighting fixtures
3D printed light fixture fixing file source: https://www.youmagine.com/designs/decorative-light-fixture
Kirby Downey is a South African designer living in London who enjoys teaching people how to use 3D printing technology and how to overcome its limitations.
With over eight years of knowledge and experience in FDM and SLS technologies, Kirby has helped himself and others provide everything they need on their journey in 3D printing.
Article source: https://ultimaker.com/en/blog/51343-end-use-parts-3d-printing-a-decorative-light-fixture