{"id":40936,"date":"2021-02-16T21:05:14","date_gmt":"2021-02-17T02:05:14","guid":{"rendered":"https:\/\/www.shapeways.com\/blog\/?p=40936"},"modified":"2021-02-16T21:05:15","modified_gmt":"2021-02-17T02:05:15","slug":"visualizing-wall-thickness-in-a-3d-model","status":"publish","type":"post","link":"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model","title":{"rendered":"Visualizing Wall Thickness In A 3D Model"},"content":{"rendered":"\n

\u201cYour model Shaft_Support_1.stl from order #15251 was\ntaken out of production by one of our 3D printing engineers due to design\nissues: Wall Thickness. See attached image\u2026\u201d<\/em><\/em><\/p>\n\n\n\n

\"Mechanical<\/figure><\/div>\n\n\n\n

Sound familiar? If you\u2019ve ever had a model rejected by 3D printing engineers because of wall thickness issues, you\u2019re not alone. While this is a very common issue, many 3D modelers may not be aware of how wall thickness is inspected.<\/p>\n\n\n\n

Shapeways prints\nthousands of parts on a daily basis, with a comprehensive system for inspecting\nwall thickness based on design and materials. <\/p>\n\n\n\n

What is wall thickness and why is it\nso important in 3D printing?<\/h3>\n\n\n\n

In taking a closer look behind the\nscenes to understand the calculations, it\u2019s clear that many 3D models look nice\non the computer screen but become troublesome during the actual process of 3D\nprinting.<\/p>\n\n\n\n

Difficulties arise when models are\ntoo thin, and the scenario worsens in the face of less advanced materials and technology.\nAttempting to 3D print models with thin aspects will likely result in a failed\nbuild, along with fragile models breaking in post-processing, in shipping, or\nin end use. <\/p>\n\n\n\n

Although a complete analysis of\nstructural strength would be ideal, that also presents a complex calculational problem, leading 3D printing\nengineers to employ more simplified empirical measures with wall thickness\nanalysis. If the model has regions which are\nthinner than some experimental threshold called minimal wall thickness,<\/strong> we assume that the model has high probability to break; therefore, engineers need tools to see where the model is\ntoo thin.<\/p>\n\n\n\n

Wall thickness visualization in 3D\nprinting requires a straightforward approach<\/h3>\n\n\n\n

Consider the example of a small vase\n(shown below as a cross section). The vase has a very small opening, and when\nwe examine it from the outside we have no idea that it has two offending spots\nwith very thin walls.<\/p>\n\n\n\n

\"cross-section
Cross-section of a vase highlights wall thickness problems<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Theoretically speaking, it is relatively easy to find the model thickness at any particular point, by walking inside the model along the internal normal until we hit the opposite surface and exit the model. The distance between entry and exit points is a good approximation to the thickness of the model at that spot. <\/p>\n\n\n\n

\"Naive
 Naive and tedious wall thickness measurement and visualization<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Manual examination can be extremely time\nconsuming. If you have unlimited patience and time that strategy could work\nthough. All the points on the exterior surface of the vase in the example would\neventually be examined and the thin regions would be found and identified. Or\nwould they?<\/p>\n\n\n\n

Such approximation to the objects\u2019\nthickness may sometimes fail spectacularly. In the example, the 20mm<\/em> thickness at the bottom right\ncorner of our vase poses a problem. In that spot the internal normal\npoints in the \u201cwrong\u201d direction. There is a much shorter distance to the exit\npoint shown in the green arrow. It is unclear how to select the\nright<\/em> direction\nfrom the starting point. It looks like we would need to analyze all <\/strong>directions from the starting point\nand select the direction with the shortest distance. This would be very time\nconsuming. <\/p>\n\n\n\n

Rather than this manual approach, a\nbetter solution is needed. We developed an algorithm that gives all the\ntedious work to the computer and provides users with visualization\nof the problematic regions.<\/p>\n\n\n\n

Defining distance function and skeleton calculation in 3D models<\/h3>\n\n\n\n

First, the definition of wall thickness needs to be defined at a particular point. We start from the definition of signed distance function<\/a> of an object. Signed distance function<\/em><\/strong> (SDF<\/em>) value at any point in the space is the distance from that point to the closest point at the surface of the object taken with negative sign inside of the object and with positive sign outside of the object. One of the advantages of working with signed<\/strong> distance is the ability to work with both\u2014interior and exterior regions of the object. The SDF value on the surface of the object is zero, and it is approximately linear near the surface.<\/p>\n\n\n\n

Let’s look at SDF near a region with\na thin wall. The SDF is a function of three spatial variables (x,y,z\ncoordinates of a point) and one needs four dimensions to display such a plot.\nIt is simpler and more instructive to look at a plot of SDF along a\none-dimensional line (a segment). Only two dimensions are needed to display\nsuch a plot, as shown below.<\/p>\n\n\n\n

\"Plot
Plot of the signed distance function (SDF) along the segment AB<\/strong> <\/em><\/figcaption><\/figure><\/div>\n\n\n\n

     The behavior of SDF along the\nsegment AB<\/em><\/strong> is simple to describe. For points inside of the interval AS<\/em><\/strong>\nthe closest point on the surface of the object is point A’<\/em><\/strong> and the plot is a\nsimple linear function – the distance to the point A’<\/em><\/strong> with corresponding\nsign. For points inside of the interval SB<\/em><\/strong> the closest point on the object\nsurface is B’<\/em><\/strong> and the plot is another linear function. The special point S<\/em><\/strong>\nis the point in the interior of the object which has equal distances to\nopposite surfaces of the object (points A’<\/em><\/strong> and B’<\/em><\/strong>). The set of such interior<\/strong> points which have equal\ndistance to more than one point on the object surface is called objects’\nskeleton. The plot of SDF near skeleton points has a sharp minimum and switches\nfrom one linear branch to another linear branch. It is clear that SDF(S)<\/em> – the value of signed distance\nfunction at the skeleton point S<\/em><\/strong> is half of the distance between A’<\/em><\/strong>\nand B’<\/em><\/strong>\nwhich is the natural definition of thickness of the objects at that spot. So,\nwe can define the thickness of object as twice of the absolute value of\nobject\u2019s signed distance function at the object skeleton: Thickness = 2|SDF(S)|<\/em><\/strong>.[3]<\/a> <\/p>\n\n\n\n

Below is a drawing of the skeleton<\/strong> points in color.<\/p>\n\n\n\n

\"Dirty"
“Dirty” skeleton<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Surprisingly, this skeleton has a\nlot of unexpected small branches (shown in magenta<\/strong>). Those are the\npoints near the object\u2019s edges. They all satisfy the definition of skeleton (with\nmore than one nearest point on the surface of the object), but they are\nobviously irrelevant to the object\u2019s thickness. If the initial skeleton were\nfollowed, the conclusion would be that all the\nregions along sharp edges have very small (zero) thickness. This conclusion is\nclearly unsatisfactory and therefore the skeleton is termed a “dirty”\nskeleton. <\/p>\n\n\n\n

Below are details of the dirty\nskeleton near the edges.<\/p>\n\n\n\n

\"\u201cDirty\u201d
\u201cDirty\u201d skeleton detail <\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Few skeleton points are marked\ntogether with corresponding (closest to them) points on the object’s surface.\nPoints U<\/em><\/strong> and V<\/em><\/strong> are intuitively good points and\nare in the middle of the object\u2019s wall. Points E<\/em><\/strong> and D<\/em><\/strong>\nare intuitively “bad” points. They correspond to edges and they have\nto be ignored. The quantitative difference between edge (E and D) and wall (U\nand V) cases is that those directions to the nearest points are almost opposite\nin the case of walls, and form an angle close to 90 degrees in the case of\nedge. This angle can be used as a threshold criterion to remove the edge\u2019s\nskeleton points and leave only the “clean” skeleton consisting of\npoints corresponding to the object\u2019s walls.<\/p>\n\n\n\n

To evaluate more precisely, a\n\u201cclean\u201d skeleton is needed. Below is an example of the clean skeleton for our\nexample.<\/p>\n\n\n\n

\""Clean"
“Clean” skeleton<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Visualizing\nthe skeleton and wall thickness<\/h3>\n\n\n\n

With the clean skeleton, the\ncalculations of walls and thickness at every point have been determined\naccording to the 2|SDF(S)| <\/em>formula; however, the skeleton itself\nmay look rather unattractive, and the relation to the original model may not be\nobvious to the untrained eye. To make the skeleton data accessible, we need to\ntransfer that information to the surface of the original model. <\/p>\n\n\n\n

One way to do this is to create a \u201cthick\u201d skeleton, visualizing all the regions with wall thickness below given wall thickness W<\/em><\/strong>. Build a shell around the clean skeleton with uniform thickness W<\/em> – the thick skeleton, <\/strong>knowing that the thickness of the shell is minimal thickness W<\/em><\/strong>\u2014everywhere the shell is thicker than the model we can easily see a printability problem. Below any wall thickness thinner than W<\/em><\/strong> poses a problem which we highlighted by painting the surface of those spots in red<\/strong>. <\/p>\n\n\n\n

\""Thick"
“Thick” skeleton and problem regions<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

The skeleton can be used in an even more powerful way, employing the distance function to skeleton, mapping distance to skeleton value to color range\u2014using red as an example<\/strong> for distances below minimal thickness, orange<\/strong> for distances slightly larger (say 1.2x minimal wall thickness), and green<\/strong> for everything above 1.5x minimal wall thickness. We can paint the surface of the original model with values of skeleton distance in those colors.<\/p>\n\n\n\n

\"Skeleton
Skeleton distance function painted on the original model<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

The visualization of\nthickness of the original model is complete, but simultaneously exact value of\nmodel thickness at a specific spot arises from this simple formula: Thickness\n= 2*DistanceToSkeleton.<\/em><\/strong> <\/p>\n\n\n\n

That complete procedure is used to create the visualization of the model wall thickness in 3D Tools. It is available only<\/strong> if the algorithm has detected wall thickness problems in your model. <\/p>\n\n\n\n

Visualizing in 3D tools<\/h3>\n\n\n\n
\"3D
3D tools wall thickness visualization<\/em><\/figcaption><\/figure><\/div>\n\n\n\n

Above is an example\nof such visualization of a problematic model. This is a small mechanical part,\nmade of stainless steel. That model printed in that material has to have a\nminimal wall thickness of at least 1mm, but there are few spots where the\nthickness is only 0.8mm. Those spots are colored mostly in red<\/strong> with some yellow<\/strong> stripes along the\nboundaries. Those thin spots are in the load-bearing locations of the part\nand are most definitely the weak spots of the model, requiring the model\nmodification. There are few other places where the algorithm detected the thin\nwalls and highlighted them as well. <\/p>\n\n\n\n

\"mechanical<\/figure><\/div>\n\n\n\n
\"mechanical<\/figure><\/div>\n\n\n\n

Red spots on these two\nviews above are along the holes going under the surface parallel to the part\u2019s\ntop. Those places are not load-bearing and probably<\/em>\nmay be ignored, but this decision has yet to be made by a human. <\/p>\n\n\n\n

Using what you have learned in this blog, you would probably realize immediately that this model has a printability issue. With the visualization, it is easier to analyze and resolve the wall thickness problem before placing an order. The ultimate goal is success in 3D printing, but if you are still having problems with getting the file to a printable state, 3D printing experts <\/a>at Shapeways are available to help with questions.<\/p>\n\n\n\n

\n\n\n\n

Vladimir Bulatov is a 3D graphics\nresearcher at Shapeways, where he has been focusing on 3D printing algorithms\nsince 2012. Beside computer graphics and 3D modeling, his interests include\nphysics, mathematics, and visual arts. <\/em><\/p>\n","protected":false},"excerpt":{"rendered":"

\u201cYour model Shaft_Support_1.stl from order #15251 was taken out of production by one of our 3D printing engineers due to…<\/p>\n","protected":false},"author":183,"featured_media":41385,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[510],"tags":[673,557,555,766,1086],"class_list":["post-40936","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-3d-printing-industry","tag-3d-design","tag-3d-modeling","tag-3d-printing","tag-visualization","tag-wall-thickness"],"thumbnail":"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2021\/02\/wall-thickness-sample-part.png","yoast_head":"\nVisualizing Wall Thickness In A 3D Model - Shapeways Blog<\/title>\n<meta name=\"description\" content=\"\u201cYour model Shaft_Support_1.stl from order #15251 was taken out of production by one of our 3D printing engineers due to design issues: Wall Thickness.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Vladimir Bulatov\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"9 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model#article\",\"isPartOf\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model\"},\"author\":{\"name\":\"Vladimir Bulatov\",\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#\/schema\/person\/8b6e7f0c25d5b8547336151907259f79\"},\"headline\":\"Visualizing Wall Thickness In A 3D Model\",\"datePublished\":\"2021-02-17T02:05:14+00:00\",\"dateModified\":\"2021-02-17T02:05:15+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model\"},\"wordCount\":1808,\"commentCount\":0,\"publisher\":{\"@id\":\"https:\/\/prodshapeblog.wpenginepowered.com\/#organization\"},\"image\":{\"@id\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model#primaryimage\"},\"thumbnailUrl\":\"https:\/\/www.shapeways.com\/blog\/wp-content\/uploads\/2021\/02\/wall-thickness-sample-part.png\",\"keywords\":[\"3D design\",\"3d modeling\",\"3D printing\",\"visualization\",\"wall thickness\"],\"articleSection\":[\"3D Printing Industry\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model\",\"url\":\"https:\/\/www.shapeways.com\/blog\/visualizing-wall-thickness-in-a-3d-model\",\"name\":\"Visualizing Wall Thickness In A 3D Model - 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