3d printers and 3d-printing technologies almanac

Interview with graduating Multimedia 3D Designer who managed to do a visual prototype

2008-05-27T08:29:00.000-07:00

Interview with graduating Multimedia 3D Designer from The Higher Professional Diploma Programme of Multimedia Design and Communication

Ilin Tatabitovski, 23 years old, from Skopje, Macedonia.

Ilin tells about:

The final project
the visual prototype and testings
studying in Denmark
group work and projects
relationship with the teatchers
his plans for the future

"I was working with a real life project - not just something abstract or something for an exam. I was using situations from the real world; companies from the real world, analysing the factors on a larger scale - not just this one-month project, but creating something that will last. And that requires good analysis, good preparation, and good design."

Ilin made his project in collaboration with Eureka Informatika, a Macedonian software company that develops integrated software solutions mainly for forwarding companies and hotel management. He had previous knowledge about the company, as he had worked for them as a part-time technician.

The visual prototype is essentially a 'working picture' of the finished project as it is envisaged at this stage of the process. It is normally built in sketch but could equally be built in printing. Many scientists use visual prototypes to varying degrees and in varying ways. Our employment of this technique is specific to a very specific end. The visual prototype must completely describe not only the look and feel, but also the actual functionality, of the finished product. Any user destined to use the finished system should be able to use and understand the finished system from this point. Clearly, because there is no application at this stage, there is some license in striving for this goal. Actions that will occur upon the submission of a choice, etc are simulated with processing part or simple triggers to illustrate the functionality. Experience shows that this works. The visual prototype is the place where all of the minds involved in this process can meet with an accountable and shared understanding of what is intended. The client is at this point intimately involved in the design process. Note that we show a loop on the diagram that cycles the phototyping and requirements processes. This machine cycle is repeated for as long as required to expose needs and intentions and illustrate them fully in the prototype. Changes and the testing of ideas in this step are comparatively cheap and actively encouraged. Every iteration here adds value to the outcome, reduces risks in the Production Cycle, and generally raises the guarantees on an optimal value outcome.

In pursuing this method, we must have a total buy in from our client. The temptation to 'just start constructing to speed the project up' must be resisted at all costs. At best this is a road to wasted effort, extended delivery times and higher costs. At worst, it leads to disaster.

"I wanted to analyse the factors that influence the decisions made in the conceptualising part for the extranet solutions. I started with a wide range of analysis - from company analysis to organisations analysis; to business, to strategy and market communication going to technology analysis and finally target group analysis. Based on those analyses and the requirements from the company, I created an initial concept of what the extranet should present or represent, and what main features should be included. From this concept I created a concept prototype that I used to test my concept ideas, and based on the feedback ideas that I received from the user testing, I changed it in order to serve better the users."

Visual prototype of a user interface
"I made a visual prototype that was basically an extranet presentation of a web page - just the visual interface, not the whole function or prototype. I thought that was the part where the users could contribute most with their feedback to the concept, because the visual interface is what they actually see and interact with. Of course, I made only one prototype and one testing, but since I'm planning to finish this product all the way, more testing will be done and more prototyping and developing."

Testing on a target group
"The primary target group was the clients of the company that were unreachable for me, as they are in Macedonia, and I have no contact with them. What I did was to test the user interface on the company employees, so basically I did the testing on the secondary target group only. The test was done by sending a questionnaire to the employees and presenting them with the prototype and explaining them the idea. The employees are software/interface-developers as well, so their feedback was very valuable."

Studying in Denmark is a valuable experience
"I was studying in the Electro Technical University in Skopje, the capitol of Macedonia, when I read in a newspaper about this school in Denmark and I just wanted to try, because it would be very different from everything that I had tried before. It would give me a new experience, a new way of looking at things, a new way of adopting values. So I just went for it."

"We have excellent conditions of studying - both as regards computers, books, materials, and supervision. I learned most from "Project Management", "Communication," and "Visualisation". The level of "Programming" and "Interaction Development" is not kept so high, because there are people studying from zero. But as a way of thinking, the way of working in a team, the way of understanding things and projecting it and planning, I learned a lot."

Working in groups and projects
"In Macedonia everything is individual, and there is a lot more theory in it. Here everything is done in groups and is more practical. I think that having knowledge of these two methods gives me an advantage in front of people that work in only one way. I can apply different methods at different times and in different situations. There are definitely a lot of positive things of working in groups and exchanging opinions and learning from each other. All in all it was a really valuable experience studying and working this way."

"Study-wise I would like to have more classes and more theory. I think it's good to know a lot of theories because they ensure better practice. Good practice will get better in time, but if you know the theory, you will probably have a better starting position."

Friendly and relaxed relationship with the teachers
"There is a friendly environment, and the relationships with the teachers and the supervisors are different from the ones in Macedonia; they are more relaxed and on a friendly basis. Although this can be a disadvantage, for sometimes you need an authority in order to study or to absorb some theory. But it's not a bad thing that the relationships are more friendly and relaxed."

An open window of opportunities
"After coming here in Denmark, my window of opportunities opened a lot more than when I was back in Macedonia. I have more choices, and I am a little bit confused of what to choose. There are so many things that I want to try."

Ilin has been accepted at the engineering college in Copenhagen, but he's not sure that he's going to start. "That will require three more years, and now I'm young, so I want to experiment a little bit more." So far Ilin's plan is to travel for at least two months, then work as a trainee in some European company and from September 2005 continue the studies in Scotland at the University in Dundee - probably Multimedia Design. After one year in Scotland, Ilin plans to take a Master's degree in Spain - in the field of open source and Linux operating system.

Second Level Servicing

2008-04-14T00:44:00.000-07:00

"Second Level Servicing"? What's that all about? Well, it goes like this: services like TechShop provide access to high-power fabrication equipment that anyone can use simply by dropping by a TechShop. However, Breakpoint offers another possibility: He'll drop by TechShop and build your project for you, thus creating a service on top of a service. This is a great idea for those who just don't have enough time or skills to do the work themselves, yet still want to take advantage of the terrific services offered by TechShop.

Have something crazy to build? Let me know...
Well folks, in my role as Director of Special Projects for TechShop, I am now looking for anybody who has projects for any of the following:

* Laser cutter/engraver
* CNC plasma cutter
* CNC router/mill, metal/plastic (roughly 12x12x4 inches max; larger may be doable), metal casting
* CNC hot-wire foam cutter (VERY large bay, suitable for architecture, movie sets/props, etc.)
* 3D printer (fused-deposition modeler, ABS plastic, 12x12x12 inches max-- this is the real deal)
* Vinyl cutter (3 feet by any sane length; suitable for banners, signs, etc.; cutting or plotting operations only)
* ...anything else in TechShop is open to discussion, but these are the most straightforward candidates

...and needs parts in quantities from 1 to 500 within the next six months. We are considering launching a BETA short-run production capability-- our prototyping services are already live-- and I need a few test projects! Burning Man projects, props for video shoots that are still months away, etc., are probably ideal. Laser and foam work in particular I think we will have alarmingly quick turn-around on.

As you probably know, YOU can walk right on into TechShop, take a class, get a membership or day pass, and start working on Your Own Cool Stuff. However, if you need a bunch of something, or if you have zero time to do it yourself, you need to call or email Yours Truly, and I will help you evaluate some options!

Obviously, while we're getting the kinks out of this process, we're offering some price breaks-- I'd like to offer these to my friends and Genuinely Cool People who have a little flexibility before we offer them to The World at Large.

So, let me know!

Sources:

NPL system speeds up CMM/machine tool calibration

2008-04-14T00:38:00.000-07:00

The UK's National Physical Laboratory has a measurement system claimed to bring laboratory level measurement and calibration standards to shop floor CMMs and machine tools

The UK's national physical laboratory (NPL) will launch what it describes as a 'revolutionary new measurement system' at the UK's MACH 2008 machine tool exhibition. NPL said that its system will bring laboratory level standards to the shop floor. It enables significantly improved calibration times and thereby, minimises machine downtime for industries across the rapid manufacturing sector, said NPL.

Partnered by ETALON, NPL's Laser Tracer is a high-speed, ultra-precise, mobile system for the calibration and verification of coordinate-measuring machines (CMM), CNC machine tools, and other advanced measurement applications.

Laser Tracer uses a highly stable laser source and an NPL patented internal design that is mechanically and thermally decoupled from the tracking mechanism.

In this way, NPL said that Tracer provides 'the ultimate' in measurement stability and accuracy.

* Laser Tracer operation - like conventional laser techniques, Laser Tracer locks out the machine during tool or CMM probe.

It uses the laser to track a reflector mounted on the machine during tool or CMM probe.

The system automatically drives the tool during the measurement cycle for the machine test and then guides the user in simple steps through the testing process.

NPL said that the internal algorithm ensures self-calibration of the system during the test and enables all machine error contribution with unprecedented precision.

Measurement routines do not need highly skilled technicians, said NPL to manufacturingtalk and are significantly quicker than existing traditional methods.

Uncertainties of measurements are generated in real time with a comprehensive test report or UKAS calibration certificate produced at the point of measurement.

Automatic correction of stored error maps is also available for many machine types.

New machines being supported every month and the measurement procedure is designed to meet the requirements of the emerging standard ISO10360-2.

Laser Tracer product manager, David Lowther, said: 'With the Laser Tracer, NPL is bringing cutting edge measurement standards only ever seen before in national standards Laboratories direct to the customer in their place of work.

Machines can now be calibrated in less than three hours, rather than the current time of up to 2 days, and with greatly improved accuracy that will ultimately save time and increase productivity for businesses.

NPL can also provide complementary consultancy and support, on site, to diagnose and solve production critical measurement problems for companies'.

* About the National Physical Laboratory (NPL) - NPL is the UK's national measurement institute and a world-leading centre of excellence in developing and applying the most accurate measurement standards, science and technology available to man.

For more than a century NPL has developed and maintained the nation's primary measurement standards.

These standards support an infrastructure of traceable measurement through the UK and the world that ensures accuracy and consistency.

Good measurement improves productivity and quality; it underpins consumer confidence and trade, and is vital to innovation.

We undertake research and share our expertise with thousands of organisations and individuals to help enhance economic performance and the quality of life.

NPL services range from free technical advice, joint projects, training, secondments, problem solving, consultancy, contract research to highly accurate UKAS accredited measurement services.

The National Physical Laboratory is operated on behalf of the Department for Innovation, Universities and Skills (DIUS) by NPL Management Limited, a wholly owned subsidiary of Serco Group plc.

* NPL at MACH 2008, NEC, Birmingham, UK April 21-25, Hall 5, Stand 5596.

'Credit crunch' yet to damage manufacturing?

2008-04-14T00:36:00.000-07:00

Maintenance free power and free conveyor chains with low-friction running rollers by Iwis have a built-in lubricant reservoir, which supplies the chain links and running rollers with lubricant

Iwis Antriebssysteme has introduced its Megalife range of maintenance-free power and free conveyor chains. Iwis has developed and patented a special link with specially sintered metal bushes (used along with metal casting and other technologies) and running rollers. In addition, the chains have a built-in lubricant reservoir, which supplies the chain links and running rollers with lubricant during the chain operation: The special sintered material is saturated with oil under vacuum conditions.

External Affairs director of Equifax, Neil Munroe, said: 'Business failures fell slightly by 2.8% in the Manufacturing sector year on year, down 6.8 compared to Quarter 4 2007'.

He said that the Transport and Communication Sector was the worst hit, seeing a substantial 16.3% increase year on year.

The gloomy picture was further supported by the latest CBI (Confederation of British Industry) report, which revealed that business volumes fell to a balance of -30%.

The CBI survey showed firms expect the credit crunch to get worse over the next six months, as they continue to find it difficult to raise funds, restricting business growth.

Munroe added: 'Retail shows a further 9% going bust in this quarter compared to 2007 and Services isn't far behind with an increase of 8.3%.

Construction sector was among the worst hit, with an 11% increase in businesses going 'bust''.

The regional picture revealed a 21.4% increase in failures in the North West, followed by 20.9% in the East Midlands and 20.3% in Yorkshire and Humberside.

Only Scotland continues to see a drop in the number of businesses in the region going bust, down 23.8%.

The South East saw a slight drop of 0.4% compared to the same period in 2007 and a 4.8% drop compared to Quarter 4 2007.

Munroe said: 'This is not a good start to the year for most business sectors across the country, with the credit crunch showing no signs of abating.

Banks are going to look at businesses just as closely as they are looking at individuals, making it harder for firms to get funding to pay off debts and bolster cash flow.

With this in mind we urge companies to protect themselves from 'not a good' debt by conducting rigorous credit checks, supported by ongoing monitoring of customers' and suppliers' financial status'.

He concluded: 'There are tough times ahead and smaller firms are the most vulnerable to the threat of business failure.

It only takes one customer going bust to jeopardise a business, but careful monitoring today, can reduce the threat of bad debt tomorrow.'

Magics 12.1 - A New Version Of Rapid Prototyping Software

2008-04-03T04:04:00.001-07:00

Leuven (BELGIUM), March 20, 2008. Materialise NV launches Magics 12.1, the new version of its software for the Rapid Prototyping and Manufacturing (RP&M) industry. Several new features in Magics 12.1 further increase Magics’ added value for RP&M professionals. Efficiency, quality and user-friendliness are the key words of this release.

Below you can find an overview of the main highlights of Magics 12.1. All of these new features streamline the RP&M process and aim to increase the productivity of RP&M professionals.

With Magics 12.1 you can perforate a hole through a wall instead of through the entire part. This way you can easily make drain holes for hollow parts or trapped volumes;

In addition to the existing advanced teeth cut, you can now also perform a more user-friendly teeth cut. This teeth cut assures a perfect fit of parts that had to be cut because they were too big to fit on the platform;

A thumbnail preview of .magics files in Windows Explorer will help you to easily recognize files;

Magics 12.1 allows you to automatically scale down parts that are too large to fit in the Magics workspace;

You can edit textured parts with increased flexibility;

Magics 12.1 interfaces with e-Stage, the new and fully automated technology for support generation. e-Stage automates the work preparation process when supporting SLA parts by eliminating manual editing. The software also optimizes the build process and significantly cuts finishing time by generating its unique support structure. With e-Stage, Materialise takes a major leap forward in realizing its ambition to automate the entire RP&M process.

Rapid Manufacturing Spearheading Growth of the World Rapid Prototyping Equipment Markets

2008-03-18T04:22:00.000-07:00

The evolution of 3D printers driven by severe pricing pressures has made concept modeling and rapid prototyping affordable to most end users. Undoubtedly, the growing trend toward rapid manufacturing has taken the industry to the next level.

New analysis from Frost & Sullivan (www.testandmeasurement.frost.com), World Rapid Prototyping Equipment Markets, reveals that the market earned revenues of $300.0 million in 2006 and estimates this to reach $859.4 million in 2013.

With prices of 3D printers ranging from $15,000 to $60,000, small companies find them extremely affordable to use for concept modeling and design optimization. In addition, the use of additive fabrication technology to directly manufacture the product has become increasingly popular, especially for low volume applications.

Rapid manufacturing is particularly useful when the part complexity is difficult to conceive in traditional manufacturing processes. Hearing-aid application in the medical industry is an example that is worth mentioning. Rapid manufacturing is expected to become mainstream in the future, and eventually drive the growth of the rapid prototyping equipment market.

"Even though rapid prototyping has been adopted early on by the automotive and aerospace markets, research indicates that only a handful of companies, about 15 to 20 percent of the end users worldwide, have taken advantage of the various rapid prototyping technologies," notes Frost & Sullivan Senior Research Analyst S.Vidyasankar. "This clearly demonstrates that the technology's potential has not reached the end users over the years, and thus highlights the need to elevate their awareness levels."

End-user education should focus on the acquisition and cost of new equipment as well as the capabilities of various technologies such as stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), jetted polymer techniques and their applications.

With rapid manufacturing gaining interest among end users, it is imperative for equipment manufacturers to educate the users to ensure sustenance for the market and accelerate the growth of the rapid prototyping equipment market in the future.

Furthermore, market participants may overcome this challenge by increasing their marketing efforts, participating in major industry events, and utilizing the Internet as a tool to keep end users as well as the industry abreast of the latest technological advancements within the rapid prototyping equipment market.

"There is also an increasing interest and growing trend toward services within the rapid prototyping market," notes Vidyasankar. "Even though many participants work closely with service bureaus, customers have forced rapid prototyping equipment manufacturers to provide services, thereby creating key opportunities for rapid prototyping vendors to develop their own service departments that meet customer requests for short-run rapid manufacturing and rapid prototyping needs and thereby grow in business."

Source: thebusinessedition.com

3d Printed Robots Games

2008-03-05T00:11:00.000-08:00

At the Sandusky Robot Games students entered a competition in which they must construct a robot capable of tossing a 40" inflatable ball over a set height. While they had many challenges in constructing such a device, they did make use of a 3D printer to manufacture certain necessary unique parts. The video shows the robot in action, successfully throwing the ball.

This event demonstrates a likely scenario of the near future: While we cannot print whole functioning objects, we can 3D print parts. And those parts can be combined with others that were made using other techniques to form complete objects. So, it seems that it's going to be a lot of "assembly" for now, and we'll have to leave the "Star Trek" for later.

* * *

Throwing an inflatable ball over a 6-foot-6-inch overpass has taken on a new meaning for EHOVE students.

For the second year in a row, students enrolled in EHOVE's College Tech Prep Engineering program entered the "For Inspiration and Recognition of Science and Technology Overdrive" robotics competition.

The nationwide contest requires the teams to build a robot that grabs and throws a 40-inch inflatable ball over a specific height while circling a track.

The College Engineering Tech Prep class, a partnership between EHOVE Career Center and BGSU Firelands, has been working with local engineers and Plum Brook Operational Support Group to apply their knowledge of mechanical design, robotics and physics to the project.

The timeline to build the fastest, most efficient ball launching robot?

Six short weeks.

"Students have had nothing else on the brain but this robot," instructor Jim McIntyre said. "They come into school with ideas about how to fix a problem we've encountered, and they are relentless in their pursuit of improvement. It's exciting to see their enthusiasm, and it's contagious. This contest has a lot of appeal in making engineering cool."

Register photo/ABIGAIL BOBROW EHOVE college tech prep engineering students Tony Renwand, senior, left, and Jonathan Dangelo adjust parts on the robot that they, along with 19 other students, created to compete in a nationwide contest.

McIntyre, his fellow instructor Steve Spriggs and the 21-member Mavericks team are up against 37,500 high school students.

EHOVE team members are:

Bellevue -- Brad Feuerstein, Adam Rectanus, Paul Renwand, Eric Smith
Edison -- Paul Bansek, Zachary Leber, Brett Thayer;
Huron -- Anthony Miller, John Reuter
New London -- Dustin Asmus, Jordan Bracken, Justin Jackson
Norwalk -- Christopher Dahm, Jessica Heydinger, Tyler Miller, Kyle Mowry
Perkins -- Justin Myers
South Central -- Jonathan Dangelo, Cory Williams
Western Reserve -- Steve Ortman
Vermilion -- Rachel Smith

Costs can be up to $6,000 for an entry fee, which provides the team with a kit of parts including 12-volt motors, a controller, various electronic parts, a pneumatic system, a frame, wheels and mechanical components; $3,500 for additional parts; and a $5,000 entry fee for the FIRST Championship.

"It is expensive, but I believe in its educational value," McIntyre said. "I see it as a chance for business and industry to give back and foster our workforce of the future."

He said Sierra Lobo and representative Alex Yeckley have been generous to the group, as have several other local small businesses that donated between $25 and $1,000.

The team faces its first championship event in March at Cleveland State University's Wolstein Center Arena.

"Your robot has to score the most points to win," senior Paul Bansek said. "The best part of this is the communication. Everyone has to talk and be able to communicate with no problems."

Standard machine shop equipment, along with CNC (computer numerical controlled) machines, engineering software and a 3D printer were used to build the robot.

"Everyone has the same task," Bellevue junior Adam Rectanus said. "The game's the same, but teams can take whatever approach they want to."

Students joked around about naming the robot, but McIntyre would take no part of it.

"It's not my job to name it," he said. "You guys have worked on it; the student should do it."

Minor complications included trying to get the robot to release the ball and trying to get the ball not to roll off of the robot's arms.

"We could duct tape it if we wanted," McIntyre said. "But I don't think that would be very professional."

Following weeks of hard work, students fired the robot up to see what it could do. After a few attempts to get the ball over, the group let out delighted laughs and congratulated each other as the ball glided over its mark.

"It's all about teamwork. It's not a one-person thing," South Central junior Cory Williams said. "It takes everyone to get it."

http://www.sanduskyregister.com/articles/2008/02/25/front/620346.txt http://www.fabbaloo.com/2008/03/robots-constructed-with-3d-printer.html

John Kawola Named CEO of Z Corporation

2008-03-04T23:58:00.000-08:00

Longtime Senior Executive Succeeds Tom Clay, Who Drove Remarkable Growth in 3D Printing and Scanning Business

Z Corporation, the leading provider of 3D color printers and 3D scanning solutions, today named John M. Kawola as CEO. Previously executive vice president of sales, marketing and business development, Kawola has served as a vital member of the senior management team since the company’s first commercial launch 10 years ago. He succeeds Tom Clay, CEO since 2005, who is leaving the company to pursue new opportunities.

Kawola has been integral to Z Corporation’s success in virtually every operations area during his decade-long tenure. The company’s first salesperson, Kawola led the globalization of the company’s sales, marketing and support organization, which includes 180 dealers in 40 countries. He has led all new product definition efforts, covering eight new hardware platforms and multiple material sets. He built and led business development, establishing new markets for 3D printing and 3D scanning in education, architecture, geographic information systems and entertainment. Due in large part to Kawola’s marketing vision, Z Corporation has become a market-leading brand signifying speed, color, and affordability.

About Z Corporation

Z Corporation makes products that enable users to capture, edit, and print 3D data with unprecedented speed, ease, versatility and affordability. These products include the world’s fastest high-definition 3D printers — machines that produce physical 3D models from digital data in full color – and uniquely portable 3D scanners – handheld machines that digitize 3D surfaces in real time. Z Corp. technology is enabling a wide range of applications in manufacturing, architecture, civil engineering, reverse engineering, geographic information systems (GIS), medicine and entertainment.

“I am grateful for our success to date and honored to pick up where Tom left off,” Kawola said. “The company is in a remarkably strong position in a growing number of industries, and our team is determined to bring Z Corporation to new heights in the years to come.”

The transition marks a decade of Z Corporation success and increasing industry momentum. In the last year alone, for example, Z Corporation:

Released the ZPrinter® 450, the first automated color 3D printer, named a “revolutionary invention” by Entrepreneur.com and “Best New 3D Printer” by Design News magazine;
Shipped the ZScanner™ 800 for demanding 3D scanning applications, with five times the resolution and twice the accuracy of the previous products; and
Released zp®140, the world’s easiest, safest and greenest material for inkjet-printing 3D models.

Kawola will report to Svenn Poulsen, CEO of the Contex Group, which is Z Corporation’s parent company. “John Kawola has been an integral part of the management team during Z Corporation’s remarkable growth,” Poulsen said. “His leadership, talent and results make him the obvious choice to lead the company going forward.”

Prior to joining Z Corporation, Kawola held technical and sales positions with General Electric and Albany International Corporation.

NASA Seeks For High Resolution 3D Printer

2008-02-28T02:35:00.000-08:00

NASA's Langley Research Center has posted an invitation for solicitations for a "high resolution 3D printer". At first it may seem that this device might be headed to outer space, ready to rapidly produce any missing spacecraft parts during deep space missions. However, looking deeply to the specs specifies: 110 VAC power requirement. Of course, we all know that AC power extension cords simply aren't long enough to reach Outer Space. The competition closes on March 3rd 2008.

Synopsis/Solicitation Combo - Feb 19, 2008 On-Line RFQ - Posted on Feb 19, 2008 New!

General Information

Solicitation Number: NNL08235968Q Posted Date: Feb 19, 2008 FedBizOpps Posted Date: Feb 19, 2008 Original Response Date: Mar 03, 2008 Current Response Date: Mar 03, 2008 Classification Code: 70 -- General purpose information technology equipment NAICS Code: 334119 - Other Computer Peripheral Equipment Manufacturing Set-Aside Code: Total Small Business

Contracting Office Address

NASA/Langley Research Center, Mail Stop 144, Industry Assistance Office, Hampton, VA 23681-0001

Description

NASA/LaRC has a requirement for 1 each high resolution 3D printer for creating functional prototype modules and electronic packaging applications as follows: Capable of producing high-quality ABS models. Model material resolution must have thickness of 0.178 mm (.007 in.) or less with print width of 0.7 mm (0.028 in.) or less. Build size: at least 8 x 8 x 12 in. 110 VAC power requirement. Support material must be water soluble for easy removal. Must be network compatible (TCP/IP 100/10 base T) and Windows XP compatible. Must produce durable working models from ABS with the click of a button. Must run unattended and operate quietly with no noxious fumes or toxic materials that require venting and/or special handling. Must be useable in an office environment. Capable of packing multiple models within the build envelope to maximize efficiency. Fabrication should be a two step process: build cycle and water soluble support removal (no after-processing steps for increasing durability). Lab floor space dimensions should be about 3 ft by 3 ft or less.

This notice is a combined synopsis/solicitation for commercial items prepared in accordance with the format in FAR Subpart 12.6, as supplemented with additional information included in this notice. This announcement constitutes the only solicitation, which is issued as a Request for Quotation (RFQ); quotes are being requested and a written solicitation will not be issued. Offerors are required to use the On-Line RFQ system to submit their quote. The On-line RFQ system is linked above or it may be accessed at prod.nais.nasa.gov/cgi-bin/eps/bizops.cgi?gr=C&pin= . The information required by FAR Subpart 12.6 is included in the on-line RFQ.

The Government intends to acquire a commercial item using FAR Part 12 and the Simplified Acquisition Procedures set forth in FAR Part 13.

Questions regarding this acquisition must be submitted in writing (e-mail is preferred) no later than 2/26/2008. It is the quoter's responsibility to monitor this site for the release of amendments (if any). Potential quoters will be responsible for downloading their own copy of this notice, the on-line RFQ and amendments (if any). An ombudsman has been appointed - See NASA Specific Note "B" for large prototypes and visual prototype.

Any referenced notes may be viewed at the following URLs link below.

Point of Contact

Name: Sandra S Ray Title: Contract Specialist Phone: 757-864-2413 Fax: 757-864-7709 Email: sandra.s.ray@nasa.gov

Name: Deborah L. Ford Title: Contract Specialist Phone: 757-864-6755 Fax: 757-864-9097 Email: Deborah.L.Ford@nasa.gov

www.spaceref.com/news/viewsr.html?pid=27101

3D printing exhibits fotos

2008-02-27T01:41:00.001-08:00

I came across a large and truly amazing collection of photos taken from the recent Generator.X 2.0 event. The collection consists of 270 photos. While not all exhibits were created with 3D printing, all used modern fabbing techniques.

See rest at http://flickr.com/groups/gx20/pool/

Courses and training on 3d printing technology

2008-02-21T22:58:00.001-08:00

The Southeast Region Career & Technology Center (SRCTC) will be offering its annual junior high summer academy in the areas of math, science, engineering and technology from June 9-13. Following a national initiative by the Science, Technology, Engineering and Mathematics (STEM) Education Institute, the classes will be more focused on engineering activities for kids than in the past. The classes will be held in Wahpeton and Oakes and run from 9 a.m. to 3 p.m. each day.

"There's actually a significant national movement in terms of engineering and technical careers," said SRCTC Director Dan Rood Jr. "We're trying to give some students exposure to it."

Mechanical design courses offered will use computer numerical control equipment, which helps manufacture a variety of different parts, and a Dimension 3D printer. Using a cell phone as an example, Rood said the printer will print an exact replica of the cell phone in its full dimension via AutoCAD, a design and drafting computer program. The 3D printer is newer technology used to make samples of items before they go into mass production.With more and more programs being done in three dimensions, Rood said this printer should aid in visualization for the students. Usually used for smaller design projects, the printer can handle a maximum of 8 inch by 8 inch by 12 inch objects.

"It's a changing world," said Rood. "In the old days, you would have to do an injection mold process and now you can just process it. That's a huge difference in time."

During the five day session, students will do some design work and printing. They will also get a shot at using different probes, censors and recording devices the center ordered for the physiology and anatomy portion of the class. After attending a trade show for the National Career and Technical Association in December, Rood discovered the new equipment and wanted to bring the technology back home.

"I think the kids will have some great experiences with that," said Rood. "It's hands-on career exploration, really."

3D Systems to launch dental lab system

2008-02-15T06:53:00.001-08:00

As we've been recently announcing, 3D Systems Corp. has lauched a three-dimensional printer based on the company's multijet modeling technology. The product is dubbed the ProJet HD3000 3-D Production System. According to the Rock Hill-based company, the printer can be used in concept development, design validation, production of molding and casting patterns and other applications. This announcement was reviewd in "Projet hd3000 - high-definition 3d printer" post, and today we are ready to meet some more news from this company.

3D Systems Corp. plans to launch a three-dimensional printer for use in dental labs.

About 3D Systems Corporation 3D Systems fleshes out a flat business. Founded in 1986 and headquartered in Valencia, CA, 3D Systems Corporation (NASDAQ: TDSC) designs, develops, manufactures, markets, and services systems for 3D printing and prototyping. The company makes products that take data from CAD or 3D scanning software and it fabricates prototypes (visual prototype) from plastics, metals, and composites. Applications range from toys to engineered components. It operates in the US, Europe, and Asia. The company had 2005 revenue of about $139.7 million and employs about 350 people. In May 2006, it introduced a new software suite comprised of 3DView, 3DManage, and 3DPrint.

The printer will produce wax-ups -- three-dimensional representations of the patient's teeth after dental work is completed. Users of the ProJet DP Production System can design a virtual wax-up using 3-D software and send the data to a system to print wax-ups in layers. Applications include crowns, bridges and partial frameworks. "We are delivering to dental labs a solution that gives them the ability to increase their productivity and improve the quality, consistency and delivery of their product," says Abe Reichental, chief executive. The system will be available to customers in the United States in March. 3D Systems makes machines that produce three-dimensional functional prototypes (and also large prototypes) and working parts for a range of industries, from plastics to auto racing. The company moved its headquarters to Rock Hill in 2005. It cited the city's proximity to its customers and suppliers as well as the area's favorable business climate, tax benefits and lower cost of doing business. 3D Systems (NASDAQ:TDSC) had been based in Valencia, Calif.

Collected at bizjournals.com, 3dsystems.com, news.google.com.

RepRap 3D print project updates

2008-02-10T03:06:00.001-08:00

PTFE slippage

It was reported that some people were experiencing troubles with PTFE tube which slipped out of the extruder. There was a modification done in order this issue to be fixed: a couple of 3 millimeter hole sideways were put through the clamp. The PTFE should be put in and clamped gently, then 3 mm drilles should be run down those holes. A couple of 3mm pins (or screws) placed in the holes then prevent the PTFE moving downwards under the force from the screw drive. The original post is here

Melbourne impressions

by Vik Olliver:

Being allowed to present RepRap at LinuxConf 2008 was wonderful, and thanks to all for the encouragement I got that really belongs with the RepRap team. So many new ideas, and very little time spent on repairs all considering. One that stood out was the idea of using RepRap to print braille, and to make relief maps with textured surfaces to assist the blind. I contacted the OLPC project to see if they would cooperate on ensuring an OLPC can drive the RepRap. Currently our software won't fit, and the OLPC is essentially python-driven so a re-write or novel way of printing the CAD files might well be necessary as things stand.
Finally, I've been porting Toby Borland's plywood RepRap files to Ponoko's upload format and I think I've got something that should print. Whether one can actually assemble what comes out remains to be seen. The parts cost for RP'd parts, gears & base is in the region of USD$350 and you can download the source. I say again, it's not quite perfected yet. My Darwin has been chugging along while I work, having a little difficulty with the Z axis after its return from Oz. Perhaps I was just lucky before, but now the Z axis rubs on parts of the base. Being me, I've bashed holes to allow clearance for the nuts. Here are three Y bearing housings, recently printed. One is marked with a break and is dud, the other two were printed after Adrian's recent accidental sqrt() bugfix. I now have 3 of them, and have manufactured bearings. Bearings look a little short on infill - OK, very short - but seem functional. I've just done another corner bracket (3 to go) and the next part is: Replacement Y axis flag.

Half-Way to Replication!

And the last, and the most sugnificant message at the moment about the RepRap project is that it has reached the half of the long way to replication! With announcing this event the authors are surely worth receiving conratulations. That is a notable milesotne for us, RepRap project watchers. Ed and Vik have now fabricated half the V1.0 RepRap's parts, if counting them by type. For instance, now there are 8 corner brackets but that only counts as one "part" even if only one is made. The original post is here

Fused Deposition Modeling

2008-02-08T00:28:00.001-08:00

During the past years the demand for functional models and small series of production parts was constantly growing and Fused Deposition Modeling technology exceedingly matches all the present-day requirements. It is a tremendously successful technology.

History

FDM was developed by Scott Crump, and the machines are being sold since 1991

The concept

The concept is that material is heated and then in controlled quantities deposited directly on previous layers. Eventually layers are built up to complete the entire part.

Preparation Process

Fused Deposition Modeling materials

The materials are available on spools of 1/2 mile in length, at costs from $175(US) to $260(US). The filaments are 0.05"

ABS - this is the standard modeling material and produces parts which are both stable and durable. It is the white material most associated with a FDM model. Realize that hand finishing will likely be required for many parts depending on intended use. For many, however, a part straight from the machine is entirely suitable. Please see Craig or a TA for finishing instructions.

Among aditional materials that are available on the FDM machines there are investment casting wax, elastomer, polyester and others.

The Fused Deposition Modeling process starts with importing the part model for FDM which is usually stored in STL file into a specialized FDM software. The software should mathematically slice the model contained in .stl file into horizontal layers. However, much more actions are taken at this step. The FDM application generates the needed supports (special pedestals for holding the part) . Then the requires tool paths for the extrusion head are being created. Here is these steps, one by one:

STL file of a model is imported into a pre-processing software.
This model is being oriented and slices mathematically into horizontal layers varying from 0.1 - 0.2 millimeters thickness.
A support structure is created where needed, based on the part's position and geometry.
After reviewing the path data and generating the toolpaths, the data is downloaded to the FDM machine.

The X, Y and Z axes are operated when drawing the model in FDM Software one layer at a time.

Fused Deposition Modeling (FDM)

In brevi, ABS (FDM material) feeds into the temperature-controlled FDM extrusion head, where it is heated to a semi-liquid state. The head extrudes and deposits the material in thin layers onto a fixtureless base. The head directs the material into place with precision, as each layer is extruded, it bonds to the previous layer and solidifies. The designed object emerges as a solid three-dimensional part without the need for tooling.

Fused Deposition Modeling technology advantages and disadvantages

During the Fused Deposition Modeling process three-dimensional objects are constructed directly from 3D CAD data. A thermoplastic material is extruded by temperature-controlled head layer by layer.

FDM Advantages	FDM Disadvantages
1. A good variety of materials available	1. Seam line between layers
2. Easy material change	2. The extrusion head must continue moving, or else material bumps up
3. Low maintenance costs	3. Supports may be required
4. Thin parts produced fast	4. Part strength is weak perpendicular to build axis
5. Tolerance of +/- 0.005" overall	5. More area in slices requires longer build times
6. No supervision required	6. More area in slices requires longer build times
7. No toxic materials	7. Temperature fluctuations during production could lead to delamination
8. Very compact size
9. Low temperature operation

FDM Flow

The system operates in X, Y and Z axes, drawing the model one layer at a time. This process is similar to how a hot glue gun extrudes melted beads of glue. The temperature-controlled extrusion head is fed with thermoplastic modeling material that is heated to a semi-liquid state. The head extrudes and directs the material with precision in ultrathin layers onto a fixtureless base. The result of the solidified material laminating to the preceding layer is a plastic 3D model built up one strand at a time.

Concluding, the key of FDM is an extrusion head:

the material is fed into the head
the material is heated until melting
the material is then extruded from the tip in controlled quantities
the material is wiped on the previous layer

Finishing

Material changeover requires a few minutes of "flushing-out". Once the part is completed the support columns are removed and the surface is finished.

Fused Deposition Modeling Video

^{Fused Deposition Modeling Video}

Printing 3D Toys with Fabr, home-made 3d-printer

2008-02-06T02:05:00.001-08:00

It is great to discover that more and more people people are inventing unique applications of 3D printing technology. For example, a certain Lou Amadio writes in his blog that he wishes and deserves to print toys for his son who is four years old, or at least recreate replacement components for those toys inevitably broken or eaten by kid. But his approach promises to become much more extreme then you might consider: he's not only going to print the toys, he's creating his own specialized 3D printer to do it with! By following the RepRap project he has designed the Fabr. instead According to Lou's blog post.

Just before my son’s 4th birthday, my wife and I purged some of his toys. We looked for things he didn’t play with any more, stuff our younger son wasn’t interested in, broken toys, and toys with missing parts. The amount of stuff we found was staggering. What we could - we donated; what we couldn’t donate we removed non-recyclable parts and recycled the rest - but we still ended up with lots of stuff that went right into the landfill. There has got to be a better way. With the recent spat of recalls related to lead or dangerous products, I wanted to be more aware of the life cycle of the toys my kids play with.
What if you could make your own toys?
And have the ability to directly recycle them into new toys when the children get bored or break them?
What if you could share your toy designs with a community?
These thoughts have driven me to start designing and building my own 3D printer. I’ve been following the RepRap dev team with enthusiasm, but wanted to take a slightly different approach to the problem. The RepRap’s goal is to achieve self replication - but in order to build your own RepRap, at the moment you need access to a real 3d printer.I designed Fabr as a 3D printer which uses commonly available parts, requires minimal part fabrication, is highly accurate, and has enough power to not only extrude plastic, but can be used to mill metal (metal casting), wood or plastic.Here are some of Fabr’s key components:
80/20 extruded aluminum
Bars and Fasteners (purchased from the 80/20 Garage Sale on eBay)
Anti-backlash nuts and drive
Couplers from Dumpster CNC
from Jameco
Screws, bearings, and aluminum bars from McMaster-Carr
Timing belts, and Pulleys from SmallParts
A custom stepper motor controller board based on EasyDriver3
Interfaces with Sketchup
Here’s a Sketchup of the latest design:
I’ve been developing an arduino shield based on the EasyDriver which uses an Allegro 3967 Microstepping stepper motor controller. Essentially the board has 3 drivers, and connectors for end stops. The first board is currently being made at Batch PCB - an offshoot of SparkFun; I expect it any day now. Once complete, I’ll solder it up, and run it through its paces. I’m looking into using the 3977 which would allow a 2.5 amp motor - a project for another time.

The next part of the project is the extruder. I’m currently determining if I want to route a cord, or have a granule hopper directly on the extruder head. Stay tuned. And yes, it has a funky Web 2.0 name - domains are hard to come by…. Fabr.org currently redirects to ooeygui.com.

Taken from www.ooeygui.com/?p=56

Links

2008-02-06T01:53:00.000-08:00

The Link Subsection is a quick way to list web page links which I recommend. All the links will redirect to different sites.

This is often used in the broader context of a topic, i.e. a page about a class project on Mars, might contain a with several links to NASA web resources on Mars, a link to several space observatories, etc.

Recommended sites:

http://3dreplicators.com - Tommelise is a bootstrap 3D replicator that you can make with a very few hand tools for about $100-150. Once you've built it you can use it to make ... more or less anything, including another Tommelise
http://blog.reprap.org/ - Blog for the RepRap project at www.reprap.org - a project to create an open-source self-copying 3D printer.
The MIT Fab Lab project.
Making a hot air, surface-mount soldering iron from a desoldering tool.
Making negative resistance simply - a possible way for RepRap to make electronics.
How to drive inkjet printheads
OScar the open-source car.
The Open Prosthetics Project - these folk are designing new and useful prosthetics and giving the desgin plans away for free!
Wiring - Wiring is an open source programming environment and electronics i/o board for exploring the electronic arts, tangible media, teaching and learning computer programming and prototyping with electronics.
Arduino is an open-source physical computing platform based on a simple i/o board, and a development environment for writing Arduino software. The Arduino programming language is an implementation of Wiring, itself built on Processing
Processing - Processing is an open source programming language and environment for people who want to program images, animation, and sound.
Printing electronics.
Tux Droid - A wireless robotic penguin intended as a toy and a way of interacting with your computer.
MechMate - A set of plans to build a large-scale (~2 meter x 3 meter) cnc router, to cut plywood sheet. The router frame is made from welded steel components. The plans are free to download for noncommercial use. Mechmate apparently started as a set of modifications to the commercial Shopbot CNC router system.
The MultiMachine: a humanitarian, open source machine tool project for developing countries.
DAVID Laserscanner A free laserscanner software package. See also here.
Moshe Sipper's Artificial Self-replication page.
The Worldwide Rapid Prototyping Directory.
Article on microfactories
fabbers.com - Digital Fabrication Portal.
Matt Moses' Kinematic Self-Replicating Machines pages.
The AdCiv site, which is dedicated to the study of the post-scarcity age.
A Universal Constructor made from cellular automata by Renato Nobili and Umberto Pesavento.
Ralph Merkle's work on Self replicating systems and low cost manufacturing.
NASA and the Universal Constructor: Advanced Automation for Space Missions edited by Robert Freitas and William Gilbreath.
Brock Hinzmann's paper: The Personal Factory.
Josh Storrs Hall's systems-level analysis of self-replicating systems.
The Kinematic Self-Replicating Machines pages and book by Robert Freitas and Ralph Merkle.
The Norwegian Metal Casting Printing Process project.
The Cornell self-reproducing robot.
Simon McAuliffe's Repstrap project: booting RepRap without an initial RP machine.
The Clanking Replicator Project Site: bootstrapping yourself into very low-cost 3D protopyping technology
Turbosquid: a big library of 3D designs for download, some free, some for money.

Please feel free to contact me if you would like to suggest a site to be added. The contact email is noted at the bottom.

Predictions: 3D printers will be affordable in 2008

2008-02-05T06:03:00.001-08:00

Every year in December american magazine The Economist publishes the collection of predictions about what could be possible in the upcoming year in the sphere of science and technologies. The predictions are gathered among famous poiticians, economists and scientists.

The predictions about 3d-printers are also in the list. It seems that this year 3d-printer is really going to become an affordable thing for everyone who needs it's accomplishment.

People can prepare themself to be ready to impress friends with high-tech wizardry in 2008. Consider shopping for a three-dimensional printer will become an outstanding example of such an advance. As far as 3d-printers were well-established in sophisticated design studios and industrial duties, the price of basic 3D printers is likely to go under $5,000 in 2008. This opens them to home use. Wizardry is the right word, for a 3D printer can really create any three-dimensional object, no matter how complicated, that you can design in a computer. Chain-mail, the coats of interlinking rings that were worn by knights of old, provides a beautiful example. You might think that to make chain-mail you would need a lot of rings, which you then join painstakingly to neighbouring rings, up and down, left and right. That’s how medieval armourers made them. A 3D printer can just print chain-mail, already all linked up; it emerges from the printer almost ready to wear.

The underlying process is quite simple. Objects are built up inside the printer (commercial models are about the size of a domestic fridge), thin layer upon thin layer as a printer makes repeated passes, following a sliced-up blueprint provided by the computer. The 3D form grows upwards, at a rate of about 5cm (2 inches) an hour, until it is done.

Different manufacturers have different approaches. Two leading companies, Z Corp and 3D Systems, offer a choice between powder and polymer as the material from which the object emerges. In either case, an inkjet printer creates the shape of the object, either by adding a glue to the powder, or by pumping out fine drops of polymer that are then cured by an ultra-violet lamp.

Add a 3D scanner and you can reproduce real objects, including your own head. The scan takes a few seconds. Then just wait as a copy of your head gradually grows inside the printer.

More serious uses for high-end machines include making models of buildings for architects, drug molecules for pharmaceutical companies and shoes for fashion companies. Extremely specialised machines can even print in titanium, using powdered titanium and an electron beam, making it possible to create usable one-off parts for aeroplanes and F1 racing cars. There is talk of machines that will print from powdered gold and shake up the jewellery-design business. But the real fun will come as ordinary folk at home feel free to let their creativity run wild. If you can imagine it, you can make it.

Projet hd3000 - high-definition 3d printer

2008-02-01T04:04:00.001-08:00

The "High-Definition" phrase that comes from television is now becoming popular in other spheres. With this new term The 3D Systems corporations chracterizes it's new device for rapid prototypes manufacturing (3D-printer) ProJet HD 3000 3-D Production System. This device has become a part of company's expositions on the SolidWorks World 2008 Exhibition, where it was presented to public at the last week. In these days the ProJet HD 3000 3-D printing system can be reviewed by the participants and guests of Pacific Design & Manufacturing Show, which finishes up in California.

“We are absolutely delighted with the Publish Postoverwhelming and positive responses we received from the CAD and engineering community for our new 3-D Production System,” said Abe Reichental, 3D Systems’ president and chief executive officer. “Just like SolidWorks users, many CAD software communities are benefiting daily from transforming their designs and ideas into physical, accurate and functional three-dimensional parts by utilizing 3D Systems’ Rapid Prototyping and Manufacturing technologies. The positive feedback from SolidWorks World attendees validates our continued R&D efforts to deliver more high-performance 3-D Printing solutions to the marketplace.”

Among the unique possibilities of ProJet HD 3000 the developers claim the ability to create parts (3-dimentional models to print) of intricate and complex form which had to be formed earlier from several separate parts and the existence of a few work regimes. The company promises to begin the commercial delivery of ProJet 3-D Production System in March 2008. The facility will base upon the patented technology of Multi-Jet Modeling (MJM) which is considered among the new generation technologies by it's creators. It can be considered as a 3d printer for architects, 3d architectural printing tools, or 3d architectural modeling "printer".

The ProJet™ 3-D Production System, available for customers worldwide beginning in March 2008, is a next generation 3-D Printer based on 3D Systems’ patented and proprietary Multi-Jet Modeling (MJM) technology. This high-throughput 3-D Printer produces best-in-class part quality and accuracy while providing the choice of both high-definition and ultra high-definition build modes. Compatible with 3D Systems’ VisiJet® Materials, it is ideal for a wide range of uses, including concept development, design validation, form and fit analysis, production of molding and casting patterns, direct investment casting of jewelry and other fine feature applications.

The presented 3d printer grants the numerous 3d printing advantages that include high preformance, the highest accuracy of creating functional parts from 3d printers, samples and surfaces quality in it's printing class. The mode of "high-definition" is foreseen and even "ultra high-definition" is there. The new three dimensional printer is compatible with the 3D Systems VisiJet materials series which allow to produce large prototypes with the high specters of 3d properties. In the last year the company promised to low the price of 3D-printers to 2000 dollars and below. The products that were told about were those that are targeted towards the broad range of users, including visual prototype collectors, modelers and decorators. Source: 3D Systems Corporation

The human organs printing becomes reality

2007-12-18T05:11:00.001-08:00

A group of researchers led by Professor Gabor Forgaksa from the American University of Missouri has made important strides in the development of printing technology of "human organs".

"Printing" organs is a promising method of creating the necessary organs by printing them on special printers where the natural cells and sustances (growth factors) are used instead of ink. A study of american scientists clarified some important issues that had prevented earlier this technology to become mass, and implement it in clinical and laboratory practices.

Biologists used the "ink" from the microspheres (ball), each of which contained between 10 and 40 thousand cells of a body.

Three-dimensional printing done in a special substrate containing collagen. Once on the substrate, smashing microspheres, releasing cells that soon multiplied and formed intercell contacts and then substrate was removed.

It was found that cells of different types in the correct ratio themselves are distributed as needed in the body. The authors note in the work that this process is entirely similar to those that occurs during embryonic body development. Thus, "Colored" printing of different types of cells (entering the exact location) is not required. It is sufficiently to print in "black and white", using a mixture of all types. Moreover, the typical periodic processes of the body launched self in printed organ alone after reaching the necessary development stage.

Thus, the artificial heart, printed from chicken's kardiocytes, gradually began beating like natural. The study showed that printed organs recied by the process are very similar in structure and functional properties to natural.

All this promises that printed organs will soon take a significant place in the arsenal of techniques and laboratory medicine.

Objet Geometries set to unveil multi-material 3D printer

2007-12-07T00:30:00.001-08:00

CAD fans, prepare to get stoked. Objet Geometries -- a "world leader" in photopolymer jetting - has announced that it will debut a system capable of producing 3D parts and assemblies made from different materials in a single build. The device, known as the Connex500, utilizes the company's "PolyJet Matrix," which can create 21 composite materials and seven separate model materials. "The Connex500 opens a new chapter for the 3-D printing and rapid prototyping industry," said Adina Shorr, CEO of Objet.

The machine is capable of producing both rigid and flexible material, and can create polypropylene-like surfaces. Honestly, the process the Connex500 uses is pretty complicated stuff, but you really only need to understand one basic fact: you will never again be missing a piece from your chess set. Hit the functional prototype and get all the technical details on your next pricey purchase.

3-D Printers Redefine Industrial Design

2007-11-28T02:05:00.000-08:00

When it came time for Joe Hebenstreit to buy a wedding ring for his wife-to-be, he stuck with what he knew. That didn't involve going to the neighborhood jewelry store or venturing into a Tiffany's. Instead, Hebenstreit simply designed the ring in CAD by himself and then printed out a three-dimensional prototype using a 3-D printer.

"I designed it in 3-D, printed it out in wax, and then cast it in platinum at a high temperature casting place," Hebenstreit explains nonchalantly. "You can do a lot of cool things with 3-D printers," he continues. "They come up with new uses for them all the time."

Granted, as the principal engineer for Palo Alto-based industrial design shop Frog Design, Hebenstreit has access to gadgets that most geek grooms can only dream of. But 3-D printers aren't just handy for making wedding rings. Armed with new capabilities, they're taking a central role in the rapid prototyping and even production of consumer products.

The technology behind 3-D printers isn't new. Rapid prototyping machines have existed in myriad forms since the early 1980s, but the pace at which new capabilities and printing materials are being added to the machines is astonishing, says Scott Summit, the co-founder of San Francisco-based industrial design firm Summit ID. These printers typically work by spewing out successive layers of a given material to build a three-dimensional object, slice by horizontal slice.

These end results aren't just prototypes (large prototypes, visual prototype, functional prototype) or proof-of-concepts any more. As the technology has evolved, 3-D printers are now capable of printing out fully functional finished products. For example, according to Summit, battleships and aircraft carriers now make extensive use of selective laser sintering (SLS) printers, which can "print out" materials like titanium, cobalt chromium and polyamide, to fabricate spare parts on the spot instead of carrying huge warehouses full of replacements. And some manufacturers of 3-D printers even use their own products to create parts for the next generation of printers. "It's like the Terminator self-replicator machine or something," Summit says. "Machines are making the next-generation machines."

The printer at Frog Design, which is used for more traditional modeling purposes, uses two materials: ABS (acrylonitrile butadiene styrene) plastic and industrial-strength glue. The glue is what enables the machine to build hollow or concave objects without letting them collapse in on themselves.

These rapid prototyping printers are bringing an entirely very new mentality to design, where the user becomes a key participant in the creation of the product. Summit and Hebenstreit both cite hearing aids as one example of this new approach.

"They stick some clay in your ear, it takes the shape of your ear, then they 3-D laser scan that and it gets fabricated by a 3-D printer," Summit explains. "It's kind of co-designed by your ear -- by your personal geometry."

This personalized approach to design can also be a godsend for new designers trying to break into the business. Teaming up with those who own and operate 3-D printers, designers open a web store with little more than a handful of designs. A customer simply chooses the design he or she wants, a rented printer fabricates the product, a traditional 2-D printer creates a mailing label, and Fed Ex picks up the box and ships it to the customer.

Companies like Freedom of Creation, which sells home furnishings, are already starting to experiment with this approach to doing business without relying on inventory or big capital investments.

"(3-D printers) are basically like the new car that landed in everybody's driveway," Summit concludes. "(Every designer) wants to try them out and see what they can do."

MeadWestvaco Expands Specialty Print Capabilities with Azuna 3D Technology

2007-11-26T02:54:00.000-08:00

Richmond

Richmond - MeadWestvaco Corporation today announced it is expanding its portfolio of specialty print technologies by licensing a patented three-dimensional (3D) design and printing technology from Azuna LLC, based in Jenkintown, Pennsylvania.

Azuna 3D technology produces high-quality, four-color imagery with uniquely deep dimensional effects on recycled polypropylene (PP) plastic substrate. MeadWestvaco will offer Azuna state-of-the-art specialty print technology through innovative consumer product packaging produced at its facility in Warrington, Pennsylvania for customers in the North American media and entertainment, beauty and personal care, healthcare and beverage markets.

For more information about MeadWestvaco’s specialty printing services and Azuna 3D technology, contact Zane Peterson, director, Special Packaging, at (919)334-4105 or zane.peterson@meadwestvaco.com.

About MeadWestvaco

MeadWestvaco Corporation (NYSE: MWV) provides packaging solutions to many of the world’s most-admired brands in the food and beverage, media and entertainment, personal care, home and garden, cosmetics, and healthcare industries. The company has market-leading positions in its Consumer & Office Products and Specialty Chemicals businesses, and operates in more than 30 countries. MeadWestvaco manages all of its forestlands in accordance with internationally recognized forest certification standards, and has been named to the Dow Jones Sustainability World Index for the fourth consecutive year. For more information, please visit us at meadwestvaco.com.

About Azuna

Azuna LLC, headquartered in Jenkintown, Pa., is a new media company providing patented 3D design and printing technology for high-end packaging, point of purchase, ad inserts, direct marketing, printing and promotional applications. For more information, please visit azuna.net.

Selective Laser Sintering (SLS)

2007-11-12T03:17:00.000-08:00

What is SLS?

Rapid Prototyping refers to the creation of quick representations of final products from an initial idea and taking it through successive iterations until the final form is developed without tooling or molds. Selective Laser Sintering (SLS) is one of the most popular Rapid Prototyping mechanisms in which a laser beam selectively fuses or sinters powder materials, nylon, elastomer etc. Selective Laser Sintering (SLS) can provide your manufacturing business with a leading edge by producing rapid plastic or metal prototypes that closely match their molded counterparts.

SLA vs SLS

The primary advantage of Selective Laser Sintering (SLS) over Stereolithography is that it builds prototypes in nylon material. It is possible to make structurally functional parts such as living hinges, functioning springs, snap fit components with nylon material using Selective Laser Sintering. The process in itself is very simple and there is no molds or tooling involved. The nylon material used in SLS can be easily machined, drilled and tapped unlike those used in SLA, which are brittle as they are built with liquid photopolymers and cured with UV light. They continue to cure once complete and as a result become more brittle as time goes on.

Since being patented by Dr. Carl Deckard in 1989, the Selective Laser Sintering (SLS) technology has become one of the most popularly utilized processes for rapid prototyping and product development in manufacturing industries. Selective Laser Sintering has become a very reliable and trusted form of rapid prototyping due to its structural properties. Selective Laser Sintering (SLS) is particularly useful when the design is complex, customized, needs to be functional or requires short run production.

Process

In the Selective Laser Sintering (SLS) process, 3D parts are created when an infrared laser beam sinters and fuses powdered materials. The final object is created by repeatedly fusing thin layers using the laser beam. This process also known as additive manufacturing producing parts that gradually increase in size until they reach the prescribed size. These prototypes are created directly from the STL file obtained from 3D CAD models.

The most beneficial characteristic of Selective Laser Sintering (SLS) is how durable and functional the materials are. These materials include versions of the original DuraForm and DuraForm glass-filled (GF), which are nylon-based materials that create highly durable and functional plastic prototypes. Other Selective Laser Sintering (SLS) materials available are Flex Plastic for elastomeric, rubber-like parts, and LaserForm, which makes metal prototypes.

Advantages

Research and development has been progressing to bring newer selective laser sintering (SLS) materials to the market. These materials are such that they require no post processing steps whatsoever after building and this offers a distinct advantage over stereolithography (SLA). This however does not mean that these materials cannot be processed. All of the selective laser sintering (SLS) materials can be finished in multiple ways. They can be painted, plated, drilled, tapped, or even machined. This allows for a higher grade of appearance to these parts thus giving users an unlimited potential to use them.

Nano-ink for three-dimensional printing

2007-10-25T00:25:00.000-07:00

According to the statement by Defense Tech, the University of Illinois has developed inks to create nano-scaled three-dimensional structures. The characteristic size of the elements produced by the printing has already reached 225 nm. It is planed to bring the size up to 100 nm. New technology will have applications like fuel microelements and gas sensors.

3d printing introduction

2007-10-11T02:18:00.000-07:00

For those wo are not familiar to the technology that this blog will cover upon here is a short introduction.

3D printing is a technology that uses special printers for solid object creation. How they work: The printers build each model layer by layer, starting at the base. For each iteration, a thin layer of powder is spread over the entire building area. Then, a print head similar to that of an inkjet printer prints a layer of binder onto the powder plane. The colorful binder bonds with the powder to create a solid layer of your object. You can think of the complete model as a stack of 2D images that were printed onto the powder. When the process is finally finished with the top layer, the model will be completely enclosed in a matrix of powder that will be removed during the excavation process.

The printing process: First there must be acquired a 3D model. You can create one using Mayo, Rhino, Inventor, AutoCAD, ProE, and other 3D modeling software. The model file must be converted to a suitable format. These include .zbd, .stl, .bld, .ply, .zcp, .sfx, .zec, and .wrl and others. Next, there should ber reserved time on the printer, where the model is going to be printed. Sometimes it is needed to arrive at the lab in order to review the model with specialists and to make sure that printing the model is feasible (for example, you can't print something with paper-thin walls). If the model looks good, they will open the model using the specialized software where it can be resized and positioned before it is sent to the printer. Next, the printer prints the model. Printing can take less than an hour for very small parts up to many hours for large ones. After the print completion, a staff member scoops and vaccuums away the powder matrix to reveal the model. After the model is removed from the printer, it is blasted with a fine stream of air in the depowdering station. This process removes more loose powder, especially powder in holes or crevices. Finally, the model needs to be infiltrated with wax, cyanoacrylate, epoxy, or an elastomer. The neccessary structural integrity for the model is provides by ths; without infiltration the model can be very easily scratched, chipped, and cracked.

Features:

Models may be printed with a clear binder or in full color.
Models may have interlocking parts such as chains.
Thin models can be infiltrated with an elastomer to make flexible parts

Examples (Click for large size):