The BritForge3D Technical Knowledge Hub
Technical Knowledge Hub
The BritForge3D Technical Knowledge Hub
Welcome to the BritForge3D Technical Knowledge Hub — a structured, in-depth learning library designed to help you understand 3D printing properly.
Whether you are designing functional components, producing prototypes, or commissioning professional 3D printing in the UK, these guides explain not just what to do, but why it works.
This is not a collection of surface-level tips. It is a complete educational pathway covering strength, tolerances, materials, motion control, efficiency, repeatability, and file preparation.
Each guide builds on the previous one. If you are new, start at the beginning. If you are refining professional workflows, jump to the advanced sections.
Start Here – Core Foundations of 3D Printing
Guide 1 – The Basics of 3D Printing
Understand how 3D printing works from digital model to finished part. Learn how slicing software converts models into layers and why layer-by-layer construction affects strength and reliability.
Recommended starting point for all readers.
Guide 2 – Layer Height, Infill, and Strength
Discover how strength is actually created inside a printed part. Learn why wall thickness often matters more than infill, why thinner layers are not automatically stronger, and how print orientation dramatically affects performance.
Essential reading for functional components.
Guide 3 – Tolerances and Dimensional Accuracy
Understand why printed parts do not always fit first time. Learn about shrinkage, hole sizing, axis accuracy, and how to design with predictable clearances.
Critical for assemblies, enclosures, and precision parts.
Advanced Functional Printing & Material Control
Guide 4 – Material Selection for Functional Parts
Explore how PLA, PETG, ASA, ABS, nylon and composites behave under heat, load, UV exposure and long-term stress. Learn why there is no “best filament” — only the correct material for the application.
Key to durability and reliability.
Guide 5 – Print Speed, Acceleration, and Motion Control
Learn how speed affects bonding, surface quality, and dimensional accuracy. Understand why controlled motion produces stronger and more predictable parts than simply printing faster.
Important for consistency and professional results.
Guide 6 – Surface Finish and Post-Processing
Understand how professional finishes are achieved through proper orientation, sanding, chemical smoothing and coatings. Learn why surface finish should be planned before printing begins.
Ideal for presentation-ready or customer-facing parts.
Design Strategy & Production-Level Thinking
Guide 7 – Designing for Efficiency and Cost Control
Learn how hollow structures, wall optimisation, support-free design and modular components reduce failures and improve scalability.
Essential for repeat projects and controlled production costs.
Guide 8 – Repeatability and Production Printing
Discover what makes 3D printing reliable over time. Learn about calibration discipline, material storage, environmental control and batch consistency.
Foundational knowledge for production printing and repeat orders.
Digital File Preparation & Workflow Control
Guide 9 – Understanding 3D Printing File Types: STL, 3MF, OBJ and G-code
Before printing begins, the correct file format must be chosen.
This guide explains:
- The differences between STL and 3MF
- When OBJ is appropriate
- Why G-code is machine-specific
- How file types affect scaling, colour, materials and collaboration
- Why 3MF is increasingly preferred in modern workflows
Understanding 3D printing file formats improves reliability, reduces scaling errors, and supports better collaboration between designers and professional 3D printing services.
Essential reading before uploading files for printing.
3D Scanning and Digital Capture
Guide 10 – Why Doesn’t My 3D Scanner Capture Detail as Small as 0.02 mm?
Many 3D scanners advertise extremely high resolution values, such as 0.02 mm, but users often find that real scans do not appear to capture detail at that level.
This guide explains why this happens.
It explores the difference between scanner resolution and measurement accuracy, and how real-world factors influence scan quality.
Topics covered include:
- Resolution vs accuracy in scanning
- Surface reflectivity and material effects
- Scanner distance and focus range
- Movement and tracking stability
- Lighting conditions
- Mesh processing and software smoothing
Understanding these factors helps users achieve better scan results and set realistic expectations for scanning technology.
How to Use This Knowledge Hub
You can follow the guides in order for a complete structured learning pathway, or explore individual topics based on your current challenges.
Together, these guides provide a comprehensive understanding of:
- 3D printing strength optimisation
- Dimensional accuracy and tolerances
- Material performance
- Motion control and print quality
- Production reliability
- File preparation and workflow best practice
This structured knowledge allows you to move from trial-and-error printing to predictable, professional results.
Need Professional 3D Printing in the UK?
If you prefer to focus on design while leaving production to calibrated, professionally managed equipment, BritForge3D offers reliable UK-based 3D printing services.
We optimise:
- Material selection
- Print orientation
- Strength settings
- Dimensional accuracy
- Production consistency
Upload your file here and receive a quote.
Continue Learning
We regularly expand this hub with new technical guides covering:
- Advanced mechanical design
- Multi-material printing
- File repair and mesh optimisation
- Engineering applications
- Real-world case studies
You can also join our email education series to receive these guides directly.
Continue Learning
We regularly expand this hub with new guides and updates.
Download printable PDF versions of each guide
Technical Knowledge Hub
A Technical Guide – Part Ten
Why Doesn’t My 3D Scanner Capture Detail as Small as 0.02 mm?
One of the most common questions people ask after purchasing or using a 3D scanner is why the scanner does not capture detail as precisely as the specification suggests. Many scanners advertise resolutions such as 0.02 mm, yet when scanning real-world objects the captured model appears far less detailed.
This can be confusing and sometimes disappointing, especially for users expecting extremely fine detail. However, the answer usually lies not in the scanner being faulty, but in how scanner specifications, resolution, accuracy, and real-world conditions actually work.
Understanding these factors helps you get the best results from your scanner and avoid unrealistic expectations.
Resolution vs Accuracy – The First Source of Confusion
When a scanner advertises a resolution of 0.02 mm, this does not mean it can reliably measure every feature at that size.
In most scanners, resolution refers to the smallest point spacing the scanner can record, not the true measurement accuracy.
These are two very different things.
Resolution describes the density of points in the captured mesh.
Accuracy describes how close those points are to the true dimensions of the object.
For example, a scanner may generate points every 0.02 mm, but the true dimensional accuracy may only be ±0.05 mm or ±0.1 mm depending on the scanning conditions.
This distinction explains why extremely fine features may not appear clearly even though the specification seems capable of capturing them.
Surface Properties of the Object
Another major factor affecting scan detail is the surface of the object being scanned.
3D scanners rely on reflected light or structured light patterns to detect geometry. Certain surface types interfere with this process.
Highly reflective surfaces can scatter the projected light pattern, making it difficult for the scanner to calculate depth accurately. Similarly, very dark or matte surfaces may absorb too much light, reducing contrast.
Transparent or glossy materials are particularly challenging because the scanner may detect reflections rather than the actual surface.
This is why professional scanning workflows often use temporary scanning sprays to create a uniform matte surface that improves data capture.
Distance from the Scanner
3D scanners operate within an optimal working distance. If the object is too close or too far away, the scanner cannot resolve small details properly.
Most scanners have a focus range or optimal capture distance, and fine detail is only captured when the object sits within this range.
If the scanner is held too far away, point density decreases and small features are lost. If it is too close, the scanner may struggle to maintain tracking or capture complete geometry.
Maintaining a consistent scanning distance is therefore critical for achieving the best resolution.
Movement and Tracking Stability
Handheld scanners rely on stable tracking of the object’s surface while scanning. If tracking is lost or unstable, the software may smooth or average data during reconstruction.
This smoothing can remove small details that technically fall within the scanner’s resolution.
Even small hand movements or vibrations can affect point alignment. Professional scanning often uses tripods, turntables, or fixed scanning rigs to minimise movement and maximise accuracy.
Lighting Conditions
Ambient lighting also influences scan quality.
Strong sunlight or bright studio lighting can interfere with structured light patterns used by many scanners. Excessive ambient light reduces contrast between projected patterns and the object’s surface.
Most scanners perform best in controlled indoor lighting where the projected pattern remains clearly visible to the sensors.
Mesh Processing and Software Filtering
After scanning, software converts raw point cloud data into a mesh. During this process the software may apply smoothing, noise reduction, and hole filling.
These algorithms are designed to produce clean models but can unintentionally remove small features.
Many scanning applications include adjustable settings for mesh smoothing or detail preservation. Lower smoothing levels often retain more fine geometry.
Understanding these processing settings can significantly improve the final result.
Object Size vs Feature Size
Resolution specifications are also influenced by the overall size of the object being scanned.
Scanning a large object spreads the available point density across a wider area. This means fewer points represent small features.
In contrast, scanning a smaller object concentrates point density and improves feature capture.
For this reason, some scanners perform better when scanning smaller sections individually rather than attempting to capture a large object in one pass.
Calibration and Scanner Setup
Just like 3D printers, scanners require proper calibration.
Calibration ensures that cameras, sensors, and projection systems align correctly. If calibration drifts over time, accuracy can decrease.
Manufacturers typically provide calibration boards or routines. Running these periodically helps maintain optimal scanning performance.
Understanding Real-World Scanner Performance
In practice, the advertised resolution of a scanner represents the best-case scenario under ideal conditions.
Real-world scanning involves variables such as lighting, object surface properties, movement, and software processing. Each of these factors can reduce the amount of detail captured.
This does not mean the scanner is performing poorly. It simply reflects the difference between laboratory specifications and practical operation.
Improving Your Scan Results
While scanners cannot always achieve their theoretical limits, several techniques can significantly improve results.
Using matte scanning spray, maintaining the correct distance, scanning in stable lighting conditions, and adjusting mesh processing settings can all enhance detail capture.
Additionally, scanning smaller sections and combining them later often yields better results than scanning a large object all at once.
These practical adjustments often make the difference between an average scan and a highly detailed one.
Final Thoughts
The advertised resolution of a 3D scanner represents the maximum point density it can achieve under ideal conditions, not the guaranteed detail level in every scan.
Factors such as surface reflectivity, lighting, distance, motion, calibration, and software processing all influence the final result.
Once you understand these variables, scanning becomes far more predictable and far less frustrating.
With the right setup and expectations, modern 3D scanners are capable of producing highly detailed and accurate models suitable for reverse engineering, product design, and digital archiving.
Next Technical Guide
In the next guide, we will explore how to prepare scanned models for 3D printing, including mesh repair, hole filling, and converting scan data into usable CAD geometry.