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RAPID PROTOTYPING AND DDM - ON DEMAND

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"We are very happy with the products we received from RedEye. In fact, we are planning on ordering more trays in a different material and in different colors to ensure that we are using an application that meets our needs."

Dr. Javier B.

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Get Quality Parts Every Time

If you've ever ordered a prototype or production part online, your part may have looked different than you expected. Why? Because sometimes data is lost when you convert your file from CAD to STL.

Since nearly every rapid prototyping and digital manufacturing (end-use parts) organization uses STL files to build parts, it is important to understand what STL is and what settings you can adjust to get the part you really want. Download Your Guide to Quality STL Files >

How to Save CAD Files for Rapid Prototyping

The .STL file format has turned into the Rapid Prototyping industry's standard data transmission format. This format approximates the surfaces of a solid model with triangles. For a simple model, such as the box shown in figure 1, its surfaces can be approximated with twelve triangles, two on each side, as shown in figure 2. The more complex the surface, the more triangles produced as shown in figure 3.

Rapid prototype CAD file

Almost all of today's CAD systems are capable of producing an STL file. For the user, the process is often as simple as selecting File, Save As and STL. Below are steps for producing high quality STL files from a number of today's leading CAD systems.

General Steps

Most CAD packages will have a couple of options that affect the quality of the STL.
- Changing a "Deviation" type of value will alter the overall output or tessellation.
- Changing an "Angle Tolerance" type of value will alter smaller details in your file.
The tighter these parameters, the more triangles placed on the surface of the model.
- Simple geometries tend to be a few hundred kilobytes in size.
- Complex models will range from 1-5MB in size and still produce good parts.
- For many models, files larger then 5MB may be unnecessary and often result in more time to get your quote and models back.
In all cases, export your STL file as a binary file. This saves on time and file size.

Please note, these are general guidelines and may not work or in some cases, produce the best possible STL file. Please consult your user's guide or the software developer's for more information or technical support. Should we determine that your STL file is not adequate for production, we will contact you for an updated file.

| Alibre | AutoCAD | Autodesk Inventor |

Alibre

File
Export
Save As > STL
Enter File Name
Save

STL settings: How to change STL settings and Redeye's recommendation.

Tools > Options
File Types tab
Configure File Types: STL
Normal Deviation: 5

(Smaller deviations will produce a smoother file, but the file size will get larger)

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AutoCAD

Click Output > Send panel > Export. At the Command prompt, enter export.
In the Export Data dialog box, enter a file name.
Under Files of Type, select Lithography (*.stl). Click Save.
Select one or more solid objects. All objects must be entirely within the positive XYZ octant of the world coordinate systems (WCS). That is, their X, Y, and Z coordinates must be greater than zero.

The file extension .stl is automatically appended to the file name

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Autodesk Inventor

Save Copy As
Select STL
Choose Options > Set to High (for highest quality surface)
Enter File Name
Save

Note: The "High" setting will also produce the largest file size. From Low, Medium to High, the Hairdryer sample file in Inventor went from about 6.7MB to 17.6MB to 50MB. Below are images from this sample file with the various settings:


Low	Medium	High

Verify Export Units

Even though you're designing in inches, the STL export might be setup for different units.
RedEye accepts Inch and Millimeter only.

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ProE

File > Export > Model (or File > Save a Copy)
Set type to STL
Set chord height to 0. The field will be replaced by minimum acceptable value.
Set Angle Control to 1
Choose File Name

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ProE Wildfire

File > Save a Copy > Model
Change type to STL (*.stl)
Set Chord Height to 0. The field will be replaced by minimum acceptable value.
Set Angle Control to 1
OK

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Rhino

Open the model design in Rhino.
From the File menu, select Save As. The Save dialog box opens.
In the File name box, enter a name for the new STL file.
In the Save as type box, select Stereolithography [*.stl].
Click Save.
In the STL Mesh Export Options dialog box (Simple Controls), set the STL tolerance – the maximum distance allowed between the surface of the design and the polygon mesh of the STL file.
In the Polygon Mesh Detailed Options dialog box, set the STL tolerance in the field labeled Maximum distance, edge to surface, as shown in the figure. (please refer to the STL help in Rhino for setting definitions)
Click OK.
In the STL Export Options dialog box, set the file type as Binary and click OK.

NOTE: In order to build on additive manufacturing technologies, STL files must contain completely closed (watertight) polygon mesh objects. Refer to Rhino’s STL help for more information.

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SolidEdge

File > Save As
Set Save As Type to STL
Options
Set Conversion Tolerance to 0.001in or 0.0254mm
Set Surface Plan Angle to 45.00
Save

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SolidWorks

File > Save As
Set Save As Type to STL
Options > Resolution > Fine > OK
Save

STL settings: How to change STL settings and Redeye's recommendation.

File > Save As
STL > Options
For a smoother STL file, change the Resolution to Custom
Change the deviation to 0.0005in (0.004 mm)
Change the angle to 5

(Smaller deviations and angles will produce a smoother file, but the file size will get larger)

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UGS NX 6

File > Export > STL
Set Output type to Binary
Set Triangle Tolerance to 0.001
Set Auto Normal Gens to On
Set Normal Display to Off
Set Triangle Display to Off

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3D Studio Max

First check for errors
An STL object must define a complete and closed surface. Use STL-Check modifier to test your geometry before export your object to STL.
Select an object.
Click <Modify>
Click <More...>
Select "STL-Check" under Object-Space Modifiers
Select <Check>
If there are no errors, continue to export the STL file by:
<File> <Export>
Select "StereoLitho [*.STL]" in <Save as type>
Select location in <Save in>
Enter a name in <File name>
<Save>
<OK>
Export To STL dialog:
Object Name: Enter a name for the object you want to save in STL format.
Binary/ASCII: Choose whether the STL output file will be binary or ASCII (character) data. ASCII STL files are much larger than binary STL files.
Selected Only: Exports only objects that you selected in the 3D Studio scene.

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ADT

Select AEC object . Go to 3D SOLID menu & select convert to 3D SOLID (ENTER)
After that you will have an option: Erase selected object [Yes/No] <Yes>: Enter Y
All the objects are converted into 3D Solid using the same procedure for each AEC objects
Select a single solid for STL output... (Must be ONE solid to export to STL)
Command entry: stlout
Select objects: Use an object selection method and press ENTER when you finish
Create a binary STL file? [Yes/No] <Yes>: Enter Y

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Revit

Revit doesn't allow direct export to STL files. We have to first save in dwg file and open in AutoCAD to create STL files.

Go to 3D view
Go to File menu , select Export CAD format
A dialog box opens
Select option
Scroll down the drop down menu (3D view only) & select 3D polymesh
Select “ AutoCAD 2004 DWG “ in <Save as type>
Next open the saved file AUTO CAD
Enter < Explode > on the command menu
Select the object and press <enter>
All the objects are converted into 3D solid
Select a single solid for STL output... (Must be ONE solid to export to STL)
Enter < stlout> or <export > on the command menu
Select objects: Use an object selection method and press < ENTER > when you finish
Create a binary STL file? [Yes/No] <Yes>: Enter y

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Verify Export Units

Even though you're designing in inches, the STL export might be setup for different units.
Check STL Export options in your CAD application.
RedEye accepts Inch and Millimeter only.