How to Convert 3D Models into STL Files
Exporting from Rhino to .stl
- Select Object(s)
- Begin by selecting the object(s) you wish to export.
- Export Selected
- Navigate to File > Export Selected. Alternatively, use the Export command.
- Choose File Type
- In the Save as type dropdown menu, select .stl as the file type.
- In the Save as type dropdown menu, select .stl as the file type.
Meshing NURBS Poly Surfaces
- Meshing Tolerance Input
- If your objects are NURBS poly surfaces, a dialog box will appear asking for tolerance input for meshing. The tolerance input will determine the mesh’s detail level.
- Detailed Controls (Optional)
- For detailed control of meshing options, click the Detailed Controls button. In the Polygon Mesh Detailed Options dialog box, you can set:
- Mesh density
- Maximum angle
- Maximum aspect ratio
- Minimum edge length
- Maximum edge length
- Maximum distance edge to surface
- Minimum initial grid quads
- A good practice is to leave all options blank except for maximum distance edge to surface. This should be set to less than half of the 3D printer’s resolution. Click OK.
- For detailed control of meshing options, click the Detailed Controls button. In the Polygon Mesh Detailed Options dialog box, you can set:
STL Export Options
- STL Export Options
- The STL Export Options dialog box will appear. Set the file type as Binary.
- Export Open Objects
- Uncheck the Export open objects box to avoid exporting objects with open edges, gaps, or holes. This ensures objects are 3D printable without errors. Click OK.
Handling Mesh Objects
- Mesh Objects
- If your objects are meshes (or if you’ve converted NURBS poly surfaces to meshes using the Mesh command), the STL Export Options dialog box will appear immediately.
Error Handling
- Export Errors
- If a problem with the object(s) arises, a window will pop up indicating they are not suitable for 3D printing. Take this warning seriously.
- If you choose Export Anyway, you risk printing errors and potentially wasting material and money.
- Fix Modeling Errors
- Click Cancel and fix modeling errors in Rhino. Common issues include:
- Surfaces not being joined together
- Double or overlapped surfaces
- Holes in a poly surface
- Rebuilt edges of surfaces that appear coincident but are not identical
- Click Cancel and fix modeling errors in Rhino. Common issues include:
Additional Tips and Considerations
- Scale and Units
- Ensure your model is correctly scaled before exporting. The units in Rhino should match the units your 3D printer uses. Incorrect scaling can result in a model that is too large or too small to print.
- Wall Thickness
- Verify that your model has appropriate wall thickness. Thin walls may not print correctly, or they might be too fragile. Check the specifications of your 3D printer for minimum wall thickness requirements.
- Model Orientation
- Consider the orientation of your model in the 3D printer. The orientation can affect the print quality and the amount of support material needed. Optimize the model orientation to minimize supports and improve surface finish.
- File Size and Complexity
- STL files can become very large with high mesh density. Ensure that your computer can handle the file size and that your 3D printer’s software can process it without issues. Simplify the model where possible to reduce file size without compromising print quality.
- Manifold Geometry
- Ensure your model is manifold (watertight). This means every edge should be connected to exactly two faces. Non-manifold geometry can cause errors in the 3D printing process.
- Software Updates
- Keep your Rhino software and 3D printer’s firmware updated. Updates often include bug fixes and new features that can improve the export process and print quality.
- Test Prints
- Before committing to a full-scale print, consider doing a small test print. This can help identify any potential issues and save material and time.
By following these steps and tips, you can ensure a successful conversion of 3D models into STL files suitable for 3D printing, resulting in high-quality prints and efficient use of resources.