On the whole, this is a good development.  Tinkercad as a large following and it’s nice to know that that those users will be supported.

Here’s Backman’s announcement:

“I am happy to announce that we have just signed a deal where Autodesk will purchase the Tinkercad site and core technologies. This is a great day for all Tinkercad users, Autodesk is a very enthusiastic and capable steward. There are two main impacts of this deal: the site is fully operational and Autodesk has some very exciting plans for Tinkercad.

The shutdown plan has been rolled back and effective immediately new users are again able to sign up for the site. Even better, at the request of Autodesk, we have supercharged the free plan. You can now create unlimited designs, all import and export functionality is enabled and ShapeScripts are turned on for free accounts. We have automatically upgraded all existing free accounts to this new powerful plan. This account will be offered for a limited time only so make sure you sign up as soon as possible.

Before signing the deal the we spent a lot of time talking to Autodesk engineers and product people about their vision for Tinkercad. We were impressed by the deep insight the Autodesk team had into the Tinkercad interface and the underlying technology. There is also a strong alignment on topics like furthering education and the vision of making design more accessible. But most of all we are very excited about the roadmap Autodesk has drafted for Tinkercad.

As our team continues working on Airstone I’m pleased to see Tinkercad find a safe and welcoming home. I can speak for everyone when I say that we are looking forward to using Tinkercad for a long time to come.

Yours sincerely,

Kai Backman, Founder & CEO

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We’ll be interested in seeing what users do with it as well!

Formlabs
www.formlabs.com

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At the recent AMUG conference, we had a chance to see the possibilities of this technology up close. Optomec (Albuquerque, NM) offers a 3D printing process, Aerosol Jet printing, which uses 3DP, additive manufacturing technology to incorporate electronics into a 3D printed part. Nanomaterials are used to produce fine feature circuitry and embedded components without the use of masks or patterns, as well as reduce the overall size of electronic systems. The resulting functional electronics can “have line widths and pattern features ranging from 10′s of microns to centimeters.”

According to Optomec, common electronic materials including conductor, dielectric, resistor, and semiconductor inks can be processed by its Aerosol Jet system to print conformal sensors, antennae, shielding and other active and passive components. The ability to print these electronic components on or in a physical device eliminates the need for separate printed circuit boards, cabling and wiring, simplifying assembly.

One example of the use of this technology was a 3D printing UAV wing. The Aerosol Jet system was used to print a conformal sensor, antenna, and power and signal circuitry directly onto the wing of a UAV model. The wing itself was 3D printed with Stratasys FDM 3D printer. The electrical and sensor designs were provided by Aurora Flight Sciences, a supplier of UAVs.

Optomec developed the Aerosol Jet process for a DARPA project. Initially, the print material is atomized to produce droplets of one to two microns in diameter. According to Optomec, materials with viscosities ranging for 1 cP to 1,000 cP have been successfully atomized and deposited.

The atomized femtoliter size droplets are then entrained in a gas stream and delivered to the material deposition print head. Here a second gas is introduced around the aerosol stream to focus the droplets into a tightly collimated beam and also to eliminate clogging of the nozzle. The combined gas streams exit the print head through a converging nozzle that compresses the aerosol stream to a diameter as small as 10 microns. The jet stream of droplets exits the print head at high velocity onto the substrate, which enables a relatively large separation (about 2 to 5 mm) between the print head and the substrate. The aerosol stream stays tightly focused over this distance, resulting in the ability to print conformal patterns on three-dimensional substrates. Despite the high velocity, the printing process is gentle; substrate damage does not occur and there is generally no splatter or over-spray from the droplets.

The print head is scalable supporting 2, 3, 5, or more nozzles at a time. It is pitch dependent, enabling throughputs as high as 25,000 or more interconnects per hour. The print head comes with a mechanical shutter for rapid on/off of the print stream and can extend print runtimes of twelve hours or more before ink refill is required.

Aerosol Jet systems can also print fine line conformal circuitry on non planar surfaces, a capability seen as a key enabler for fully printed electronics on 3D surfaces. The relatively large stand-off, up to 5 mm from the nozzle tip to the substrate, and high velocity particle stream enable the Aerosol Jet material deposition head to print on surfaces with inclines of up to 60 degrees without tilting the head.

Optomec
www.optomec.com

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Autodesk and MakerBot previously announced that the companies would jointly market a combination of 3D design software and 3D printing hardware to engineers, designers, architects, makers, creators and artists. A new 123D Premium bundle that includes the MakerBot® Replicator® 2 Desktop 3D Printer and a new 3D Print Utility accessible from the 123D apps is the result of that partnership, and optimizes the design-to-print process for the 123D community. Users can choose from three different membership options including a free membership, a premium membership and a premium bundle.

The Free Membership offerings include:

• Access to the Autodesk 123D family of apps, free 3D models for download through the 123D web gallery, the option to save creations to the cloud, and the ability to share projects and designs with the 123D community.

The 123D Premium Membership options include:

• A one-year Premium Membership is available for $99.99 and includes a $40 promo code toward the purchase of a MakerBot Replicator 2 Desktop 3D Printer through 123Dapp.com, one free 3D print from the 123D 3D print service, an Instructables Pro account, 10 premium model downloads per month from the 123D Gallery, and the ability to create 2D layouts (.dwg) from 123D Design models.

• A two-year Premium Membership is available for $189.99 includes a $90 promo code toward the purchase of a MakerBot Replicator 2 Desktop 3D Printer through 123Dapp.com, as well as the other benefits of the one year membership.

The 123D Premium Membership Bundle is offered in the following packages:

• A 1-year Premium Bundle with MakerBot Replicator 2 is available for $2,249.99 and includes a 123D exclusive MakerBot Replicator 2 Desktop 3D Printer with a custom faceplate, plus an additional 1kg spool of White PLA Filament (ships in approximately 2 weeks). It also includes all the benefits of a Premium Membership.

A 2-year Premium Bundle with MakerBot Replicator 2 is available for $2,299.99 and includes a 123D exclusive MakerBot Replicator 2 Desktop 3D Printer with a custom faceplate plus three additional 1kg spools of PLA Filament – White, Natural and Red (ships in approximately 2 weeks) and the same benefits of a Premium Membership.

The new Autodesk 3D Print Utility will be available within the Autodesk 123D Catch, 123D Design and 123D Make Windows desktop apps, as well as from models posted to the 123D website Gallery. With the 3D Print Utility, users have the option to optimize their model to help reduce material use and print time, before printing the model on the MakerBot Replicator 2 Desktop 3D Printer. The 3D Print Utility will be appearing within additional 123D apps in the immediate future.

The Autodesk 123D family of apps—which includes 123D Catch, 123D Creature, 123D Design, 123D Make, and 123D Sculpt—provides users with the ability to capture, design and make their ideas, and connect with other makers for support or inspiration. According to MakerBot, the MakerBot Replicator 2 Desktop 3D Printer is its easiest, fastest, and most affordable tool for creating 3D prints, setting a new standard in resolution and accuracy for creating high quality models.

Autodesk
www.autodesk.com

MakerBot
www,makerbot.com

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Attendees were scanned with the FaceScanner and their face scans were turned into custom USB memory stick holders which were then printed on the 3D Systems ProJet 460Plus in the booth. Also shown were face scans and x-ray scans taken simultaneously that can be used to show before and after treatment options from treatment planning software. 3D Systems new cloud based medical modeling software, Bespoke Modeling, was shown that can take a DICOM data set and turn it into a 3D color model with just a few mouse clicks which can then be printed on the ProJet x60 series color 3D printers.

This will enable dental professionals to educate and communicate with patients and medical coworkers with actual physical models representing the patients actual anatomy.

3D Systems
www.3dsystems.com

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“We are thrilled to re-shape the engineers’ desktop with game changing design-to-manufacturing tools that deliver enhanced productivity and embedded manufacturability,” said Calvin Hur, Vice President and General Manager, 3D Systems Geomagic Solutions. “We are committed to provide optimum support for our new and existing products, ensuring our customers’ continuity and best overall experience.” Learn more about 3D Systems entire portfolio of Geomagic Solutions at Geomagic.com and Rapidform.com. New products will be released in July 2013.

3D Systems
www.3DSystems.com

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Renishaw, a global company operating in the fields of metrology, healthcare and additive manufacturing is acquiring, as part of an asset deal, the business and employees of LBC Laser Bearbeitungs Center GmbH, a pioneer in the field of additive manufacturing for tool and mould making. Already a leader in the supply of laser melting systems, the deal will also allow Renishaw to offer additional additive manufacturing services, including design and simulation, and the contract manufacture of metal prototypes and production parts.

The deal will create a new business, LBC Engineering, comprised of former employees of LBC Laser Bearbeitungs Center GmbH, which will continue to offer services to its existing customers. The new business will be fully integrated within Renishaw GmbH at its offices in Pliezhausen.

Rainer Lotz, Managing Director of Renishaw GmbH, said: “Through this acquisition the Renishaw Group has gained excellent additional skills and experience, which will allow us to further develop our additive manufacturing business for a range of applications. The customers for our laser melting machines will benefit from this additional expertise, allowing them to quickly integrate this exciting new technology, with its many benefits, into their everyday processes.”

LBC Laser Bearbeitungs Center GmbH was established in 2002 as a service provider for laser inscription and 3D laser engraving, and is a recognized pioneer in the field of metal-based additive manufacturing. The company has mainly focused on the additive manufacture of conformally cooled mold tools and tool inserts for injection molding and die-casting applications. An important part of the service offered includes component design and simulation to maximize the economic benefits of the laser-melted inserts.

Laser melting is an additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD using a high-powered laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere layer-by-layer. The process gives designers more freedom, resulting in structures and shapes, such as conformal cooling channels, that would otherwise be constrained by conventional ‘subtractive’ processes, or the tooling requirements of volume production.

Ralph Mayer and Marc Dimter, executive shareholders of LBC Laser Bearbeitungs Center GmbH, see important synergies for additive manufacturing: “Through the new relationship with Renishaw, we can drive this new technology forward together and specifically focus on meeting increased customer demands for stable processes and industrial use of additive manufacturing machines. Renishaw offers extensive technological knowledge and highly effective research and development from which our existing customers will also benefit.“

Renishaw
www.renishaw.com

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Built upon the philosophy of “Libre Hardware,” LulzBot gives you the freedom to continually learn from, share and improve hardware and software. You can swap out or modify tool heads and print with a range of materials, including ABS and PLA in a variety of colors as well as HIPS, nylon and wood filament.

Additionally, an updated Budaschnozzle hot end provides fine resolution prints with a smooth surface finish. Robust and reliable, TAZ is engineered for ease of use and low maintenance.

With distribution centers in the U.S., Canada and the U.K., the TAZ ships next day already calibrated with tool-free assembly, toolkit, unpacking guide and a 3D printing resource manual. LulzBot has also extended its support of Libre Hardware-inspired innovation by launching a new forum for the TAZ: forum.lulzbot.com.

Aleph Objects, Inc.
lulzbot.com

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VeroDentPlus MED690 enables the 3D printing of dental models that are highly accurate, economical to produce, and offer the appearance of dental stone with fine details and resolution. 

The material can be used in conjunction with all open intra-oral impression and plaster scanners and is optimized for printing models for crowns, bridges, orthodontic appliances, and implants.

“Appearance and accuracy are everything in our business and we’re delighted with the details and resolution on the models being produced on our Objet Eden260V 3D Printer with the new VeroDentPlus,” said Chris Brown, manager of Apex Dental Milling in Ann Arbor, Michigan.

VeroDentPlus MED690 expands Stratasys growing family of materials for digital dentistry. Designed especially for use in dental and orthodontic solutions, these materials combine accurate detail visualization with high dimensional stability. They are used by the Objet EdenV line of 3D Printers which print ultrafine 16 micron layers for exceptional detail.

Stratasys Ltd.
www.stratasys.com
www.StratasysDental.com

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1. Let’s start with smaller size, big build envelope. Even at desktop size, many 3D printers take up a lot of space when not in use. The Japicain Revolution (J-Rev) 3D printer, however, handles this issue in a unique way—it’s collapsible.

Based on fused filament fabrication (FFF) technology, this printer’s extruder is attached to the top frame of the unit. The top frame starts at near the build plate, increasing the Z axis at it builds the part. It prints in layers 20 microns thick, delivering fairly smooth parts.

This is currently on Kickstarter for funding.

2. Part of the issue with materials and 3D printers is that most printers are built to work with a specific material or specific range of material, whether that range is a type of plastic or resin or metal. All manufacturers are working to expand their material offerings, but this area is still a frustration point for many users; not only the availability, but the cost of materials too.

Medical applications have specific requirements, but what if a 3D printer used water as the build medium? This custom 3D printer uses water as the build medium. It uses lipid coated water to build the scaffolds that will then hold tissue cells, which could eventually be used to “print” organs or tissue.

According to the research, “When the machine prints lipid-coated water droplets onto a platform submerged in an oil bath, the 50-µm-diameter droplets adhere to one another. Oil-water repulsion partly drives the interaction. The researchers have been able to produce 3-D patterned networks of tens of thousands of connected caviar-like droplets. And they’ve printed more than one kind of droplet with their multinozzle printer.”

Source: C&EN

3. Today, there are two methods to printing parts in color. One uses inks that are deposited onto a powder as a part is built. The other method uses paper that is colored, then bound together and then cut to build a part. Color is one of those capabilities highly desired by the hobby/maker community. And it is useful to engineers as well.

According to some in this industry, the next development you’ll see in 3D printing is color. Botobjects has developed what it claims is a full color 3D desktop printer—the ProDesk3D. With a dual head extruder, it includes a reusable but proprietary 5-color PLA material cartridge system. You can take these 5 colors and mix them as needed to create a greater range of colors. According to the company, this printer prints to a 25-micron accuracy.

BotObjects
www.botobjects.com

4. RepRap and MakerBot were among the first FFF-based desktop 3D printers. It has taken a while for stereolithography technology to be downsized to fit the desktop. One of the first ones to emerge was the Form 1 from Formlabs, a spinoff from the MIT Media Lab. Now, several other stereolithography based printers have emerged.

One is the B9Creator.

This 3D printer uses a home movie projector to build objects as large as belt buckles or as detailed as a tiny filigree ring. The build volume varies, depending on resolution. However, a few details are given:

Resolutions in the x/y plane (horizontal) of 50, 75 or 100 microns are possible by adjustment of the projector’s position and focus.

Resolutions in the z (vertical) build axis from 101.6 to 6.35 microns are possible via software selection. (The minimum z axis “step” size is 6.35 microns.)

The build material is a photopolymer resin that is directly castable when cured properly. The B9Creator™ will be initially offered in two versions, as a kit, which will require user assembly for US $2,990, and as an assembled machine including some consumables and extra parts for US $4,995. These prices may be subject to change at any time.

B9Creator
b9creator.com

5. Another stereolithography system is the mUVe1. According to its developers, its design addresses the issue of build speed. Available as a modular, expandable kit, it uses 8 mm hardened steel linear rods and bearings for smooth motion. The laser is 20 mW.

The build space is 145 mm x 145 mm x 185 mm. It uses standard RepRap electronics and a standard Cartesian control system. Resolution is currently 0.01 mm.

Some of the key features are its print speed; 300-600 mm/s. And there are no extruder heater cores to burn out or extruder insulators that melt and are irreparable. Components include a $15 laser diode, a $4 laser driver, or an $18 reservoir heater. It is seeking funding now.

6. One of the more buzzed about desktop stereolithography 3d printers is the Unirapid III from a company in Japan. This printer delivers a minimum layer resolution of 50 microns. It uses a solid state 355 nm laser, and can build walls as thin as 0.1 mm. This printer is close to being a microprinter.

Source: 3Dprinting.com

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Digital orthodontics is rapidly becoming the industry standard because of its many business advantages including the ability to significantly shorten delivery times, increase production capacity and eliminate bulky model storage. The collaboration with Scheu Dental GmbH is expected to expand digital orthodontic sales globally.

“We are very pleased to offer our orthodontic lab customers access to complementary solutions from Stratasys. This represents yet another leap towards the age of the full digital orthodontic lab,” commented Mr. Christian Scheu, CEO of Scheu Dental GmbH. “The knowledge learned through the successful cooperation of both companies in the orthodontic market has certainly allowed a faster and a more successful collaboration of the digital orthodontics highway for all orthodontic labs worldwide, bringing mass customization to small and mid-sized labs alike.”

“Scheu Dental has worked closely with Stratasys to qualify the complete process required to produce orthodontic appliances using the Scheu Dental equipment,” says Avi Cohen, Director of Global Dental at Stratasys Ltd. “Stratasys’ goal is to provide productive and complete digital solutions to the market by teaming up with the leading orthodontic equipment and materials provider. This collaboration will provide dental labs with a full digital lab solution that sets new productivity standards.”

Stratasys Ltd
www.StratasysDental.com
www.stratasys.com

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Richard Van As, one of the Robohand creators, with his MakerBot Replicator 2 Desktop 3D Printer in South Africa.

Robohand is a mechanical 3D printed hand that you can make on a MakerBot Replicator 2 Desktop 3D Printer. It is a set of fingers that open and close to grasp things based on the motion of the wrist. When the wrist folds and contracts, the cables attaching the fingers to the base structure cause the fingers to curl. Nearly all the parts of a Robohand are made on MakerBot Replicator 2 Desktop 3D printers.

The idea was originally conceived by Richard Van As to replace four severed fingers that he lost in a woodworking accident in 2011. Van As struggled with finding a cost-effective means of creating substitute fingers for those that were gone. He frustratingly discovered that prosthetic fingers, made specifically for him, could cost upward of $10,000 per finger. When Van As found Ivan Owen, a Seattle-based theatrical prop designer who specialized in hands, the two collaborated to create a design for working fingers that could be inexpensively built. After trying numerous types of materials, the pair hit upon the idea of using a 3D printer.

“The process of designing and crafting fingers for Rich was taking weeks and months per cycle,” noted Bre Pettis, CEO of MakerBot. “For us here at MakerBot, that was too much wasted time. We knew our 3D printer, the MakerBot Replicator 2 Desktop 3D Printer, could take this important work to new heights. We saw their collaboration and the work they were doing as ground-breaking, and we asked them to accept a donation from us: one MakerBot Replicator 2 Desktop 3D Printer for each of them – one in Washington state, and the other in South Africa.”

“The donation of the MakerBot Replicator 2 Desktop 3D Printers transformed our process,” noted Richard Van As. “It turns out the MakerBots were incredibly useful. Just hours after receiving our MakerBots from Brooklyn, N.Y., we were sharing files back and forth, testing the design on one side of the world, and doing another iteration on the other side. Each of us having a MakerBot Replicator 2 Desktop 3D Printer took the prototyping process down from weeks to just 20 minutes.”

“The impact that utilizing the MakerBot Replicator 2 Desktop 3D Printer had was incredible,” said Ivan Owen. “It dramatically increased the speed at which we could prototype and try out ideas. It gave us the ability to both hold physical copies of the exact same thing, even though we were separated by 10,000 miles.”

And that’s only half the story…

With Robohand, Richard began to realize how quickly he could refine the design for other people that have lost their fingers, or who were born without fingers. After posting his own story, he received emails and Facebook messages from parents whose children were perfect candidates for a Robohand of their own. One of these children was five-year-old Liam.

Liam suffers from a birth defect called Amniotic Band Syndrome. Amniotic Band Syndrome is poorly understood, but the effects of it are pretty clear. Children are often born without extremities, especially fingers and toes, when fibrous bands in the womb prevent these parts from developing normally. It’s this condition that caused Liam to be born with no fingers on his right hand.

The cost of purchasing a traditional prosthesis was far too much for the family, especially since Liam is a fast-growing little boy who would outgrow prosthesis in a few months. 

Liam was given a Robohand in January 2013; just days after Richard and Ivan received their MakerBots. He has grown so much in the past several months that he has already been fitted for his second Robohand.

The word spread, and other children with ABS in the Johannesburg area like Liam, wanted their own Robohands, sized just for them. The files, including the assembly instructions, have been posted online on Thingiverse, and people around the globe have downloaded the design more than 3,500 times in just three short months.

 It is the Robohand Project’s hope that by posting the Robohand plans on Thingiverse, it will empower others around the world to download the design and 3D print Robohands for those who need it.

Ivan  studied the anatomy of crab legs and human fingers to get the basic muscle and tendon structure. The result is a simple assembly that Richard believes anyone can make themselves. While a full set of prosthetic fingers may cost thousands of dollars, all of the Robohand parts that are made on the MakerBot Replicator 2 Desktop 3D Printer add up to roughly several dollars ($2.50 USD) in material costs and the total cost is around $150 USD.

 Finger amputations are the most common amputation in the United States, accounting for more than 90%  of all amputations. Amniotic Band Syndrome (ABS) affects 1 in 1,200 live births, and of those, about 80% of ABS cases involve the loss or malformation of fingers and hands. For these people, Robohand is a great alternative to traditional routes of treatment.

While Robohand has been gaining in popularity these last couple months, there is still a lot to be done. Richard Van As has given hands-on help to a few of the people within his reach, but Robohand was made to be shared. For a full set of parts, 3D printed designs, and assembly instructions, see Robohand on Thingiverse.

To support the Robohand project, see www.indiegogo.com/projects/robohand and support this worthy cause.

MakerBot
www.makerbot.com

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Leslie Langnau
llangnau@wtwhmedia.com

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Ben Bowlby and his team of designers and engineers have a vision of racing that is a revolutionary peek into the future of competitive Motorsports. Instead of relying on higher horsepower to propel the increase in performance they created the DeltaWing with a “less is more” approach. The result is a dramatic increase in the efficiency the modern racecar.

Bowlbys’ challenge was to create a racing car that would perform at the same level as other Le Mans Prototype cars, but with only half the available horsepower! The math is easy: this means the car can only have half the mass and half the drag.

The unique design and construction of the DeltaWing car relies heavily on a cleaner aerodynamic shape that achieves a low drag coefficient while still creating enough down force to turn competitive lap times. This improvement requires less power to push the air at higher speeds, improving the efficiency of the vehicle operation.

Aerodynamic advantage was not the only goal of the DeltaWing team, though. Accelerating the car from low speed corners with only half the available power means the car can only weigh half as much, so an extreme weight loss program was key to making the car work.

To compound the challenge, the timing was a short 7 months from design to the first track test. So the team decided to use 3D printing technology together with Windform materials where applicable to shortcut the manufacturing time and save every bit of weight they could. In September 2011 they started to build the car at All American Racers (AAR) in Santa Ana, CA. In March 2012 Alex Gurney, test driver and son of DeltaWing constructor Dan Gurney became the first man to test the car at Buttonwillow Raceway in California.

During this process, Laser Sintered Windform XT 2.0 was used not only in prototyping and testing, but in mission critical applications on the car during the 24 hours of the Le Mans race, and continue to race at the Petit Le Mans, in the US. The DeltaWing team was able to move the bar for both racing and Additive Manufacturing applications forward.

Windform parts on the car included:

• Bespoke electronics enclosures

• Electrical breakout boxes

• Transmission seal covers with integrated pressurized oil feed passages

• Tow hook plinth

Windform parts used in prototyping, tooling & testing

• Brake inlets and ducting

• Air inlet ducting and filter enclosure

• BLAT – Underbody extension flange (5 foot long bonded assembly)

The carbon fiber reinforced Windform XT 2.0 was used to construct the gearbox side covers: The DeltaWing used a non- “stressed member” engine and gearbox to reduce the structural requirements of the assembly as well as reducing the vibration loads introduced into the lightweight car.

The gearbox with integral bell housing came in at a svelte 33 kg, a fraction of the other transmissions. Zack Eakin was the DeltaWing engineer responsible for the design of the gearbox: “Once we realized that we could use Windform XT 2.0 as a race-able part at the elevated temperatures and pressures we run the gearbox oil at, it opened up a big possibility for us that would have been cost and time prohibitive otherwise. We went for a design that put the output seal on the half shaft rather than around the outside of the Tripod joint which represents a big reduction in parasitic losses. But this design means that you have a seal that moves with suspension travel, a non-rotating CV Boot that will react to the seal drag, and that you need to somehow get oil into the tripod cavity. Creating a metallic part that would orient the CV boot perpendicular to the average half shaft angle, with integral oil drillings was a 5-axis machining job that still would be heavier than what Windform gave us. With rapid prototyping technology we were able to make a very complicated geometry, keep gentle radius’s in the oil passages, and get rid of all unnecessary material without introducing great cost or lead time in the parts. We were able to bond the CV boots directly to the Windform, seal directly to them with an O-Ring, and run the part at temperatures as high as 135oC, and pressures over 1 bar gauge without any issues. Windform was a real homerun for us on these parts”

Zack also believes the electrical enclosures were another very good fit for 3D printing technology “We designed a number of our own electrical controllers for things like the DRS and differential that we needed enclosures for. All an electrical enclosure needs to be is waterproof, durable, and have sufficient heat dissipation for the circuit it houses. We found that we couldn’t make an aluminum housing that was as light as a Windform one, let alone cost or time competitive. Often we would make a simple aluminum lid that the PCB would mount and heat sink to, which screwed into a Windform box via some tiny threaded inserts.”

Windform XT 2.0 was the material mostly used for the manufacturing of parts because of its mechanical and thermal characteristics. The use of 3d printing and Windform materials was fundamental to shorten the timing of car construction. In this case CRP Technology and CRP USA worked to support step by step the technical staff of the DeltaWing team in order to help them finding the best solution.

CRP Technology
www.crptechnology.com

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The ATOS ScanBox 6130 is the newest addition to GOM’s product line of advanced automated solutions with the capability of scanning parts larger than 6.5 ft and/or up to 4,400 lbs in weight. The ATOS ScanBox series is a turnkey solution for automating 3D scanning and inspection applications. It is designed to industrial standards and engineered with high quality components to ensure process optimization, increased throughput, and automation success. Delivery time is short and setup is plug-and-play. The ATOS ScanBox is integrated with an ATOS Triple Scan sensor which is recognized by the industry for its precise accuracy, high resolution and speed. When coupled with automation, it becomes a metrology power house increasing productivity, repeatability, and accelerating ROI.

Capture 3D
www.capture3d.com

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PolyJet technology involves multiple print nozzles jetting one or more liquid photopolymers onto a build tray, which are cured with UV light. With some of the model materials, the 3D printer also jets a gel-like support material for overhangs and complex geometries. This support material is easily removed by hand and with water.

In 2007, Objet introduced its Connex multi-material 3D printing capability. It jetted two materials at the same time and even mixed and composed them to produce up to 14 different and unique material characteristics in one 3D-printed part.

Today these printers can deliver more than 100 materials and digital material combinations, including rigid to rubber-like, opaque to transparent and ABS-simulating performance.

Compared to other processes, the PolyJet process delivers precise, accurate parts with a smooth finish. Layers can be thin to print fine details and deliver smooth surface finishes. However, some of the materials may not handle heat well, as they are not a true plastic. Other materials will handle heat and deliver high strength too.

FDM materials are known for their strength and they handle high temperatures well. However, objects made through this process tend to show stair-stepping “ridges.”

Stereolithography
 materials are popular, precise, water resistant, and range in cost from low to high. But these materials are not true plastic.

And laser sintering
 materials are durable; handle chemicals and high temperatures but they typically have a rough finish.

The PolyJet materials are available with a variety of characteristics. Some are rigid and opaque and come in blue, black, white, and gray colors. Some are rigid and transparent. Some are rubber-like and range from translucent to gray and black with varying Shore A values. Polypropylene-like materials, and various dental and medical materials, including a transparent bio-compatible material suitable for prolonged skin contact and mucosal membrane contact of up to 24 hours are also available.

To achieve this impressive range of materials, these 3D printers mix and compose two base materials together to create a range of composite materials, known as Digital Materials. The printers use two cartridges. Depending on the material you wish to work with, you select a material from a computer menu, such as VeroBlack, TangoPlus, and so on. The 3D printer software determines which material from the cartridges goes into each of the 798 nozzles of the print head. The print head then deposits the materials, a drop at a time, fabricating a digital material on the fly to create the part. So, for example, by jetting both a rigid and rubber-like material together you can produce a range of different materials with variable Shore A values, or varying color shades.

With this ability to both mix and compose materials and of course, print separate different material elements within the same model, you can accurately simulate complex assembled products. For example, it’s possible to print a pair of transparent eyeglasses with rubber over-molded nose and ear supports—all in a single print job—or a car wheel with a rigid hub and rubber-like tire, or a hair brush with a rigid white body and black rubber-like bristles—all seamlessly grown together within a Connex 3D printer.

Until now, all of these material developments have occurred within the realms of standard plastics simulation. Digital Materials allow you to also create hybrid composites that feature the best properties of two base materials so you can create engineered plastics. This means that you are no longer limited to prototypes that look and feel like the end product, these prototypes can function like the end product.

Leslie Langnau
llangnau@wtwhmedia.com

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ProJet® 860 Professional 3D Printer

There are 6 new ProJet printer models:

•ProJet 160 – compact size, most affordable monochrome printing
•ProJet 260C– compact size, most affordable full color 3D printer available
•ProJet 360 – medium size, monochrome printing affordability
•ProJet 460Plus – medium size, high-quality full color printing
•ProJet 660Pro – large format, premium-quality full color printing
•ProJet 860Pro – super-large format, premium-quality full color printing

“These exciting, next generation color printers embody 3D Systems’ commitment to democratize access to powerful and affordable 3D printing solutions for professionals, educators and consumers, alike,” said Michele Marchesan, Vice President and General Manager, Personal and Professional Printers for 3D Systems. “The new ProJet x60 series builds on our innovation heritage, leverages our expanded line of 3D content-to-print solutions and enables users to create more, faster.”

3D Systems, Inc.
www.3dsystems.com

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The 2013-2014 AMUG board members are:
-          President: Bret Bordner, Laser Reproductions
-          Vice President: Mark Barfoot, Christie Digital Systems
-          Secretary: Kim Killoran, Stratasys
-          Past President: Gary Rabinovitz, Reebok International
-          Event Manager: Tom Sorovetz, Chrysler Group

(back row, left to right) Vince Anewenter, Mark Abshire, Mark Barfoot, Tom Sorovetz, Todd Grimm. (front row, left to right) Gary Rabinovitz, Bret Bordner, and Kim Killoran (front right)

The board will plan and organize the 2014 AMUG Conference, which will be held in the western United States. AMUG expects to select the location and announce the conference dates by mid-May.

Gary Rabinovitz, outgoing president said, “We are coming to the close of a very successful and well received 2013 conference. Attendees have commented that this is the best event they’ve ever attended. This success is a reflection of the hard work and dedication of the best group of volunteer leaders that I have ever had the pleasure of working with.”

Bret Bordner, incoming president, said, “I have no doubt that next year’s conference will be even better and significantly larger. Considering both the elected and appointed board positions, I have the advantage of leading a team that is predominantly the same as the one that supported Gary.”

The newly formed board announced three appointments: Vince Anewenter, Milwaukee School of Engineering, was named as treasurer; Todd Grimm, T. A. Grimm & Associates, was named as additive manufacturing industry advisor; and Mark Abshire, DSM Somos, was named as advisor to the board, a newly created position.

At the conclusion of the meeting, the board also announced that Graham Tromans, G. P. Tromans Associates, and Stefan Ritt, SLM Solutions, will stay on as European liaisons. Ulf Linde, netfabb, was also named as a European liaison.

Additive Manufacturing Users Group (AMUG)
www.am-ug.com

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During the annual Awards Banquet, the association named the winners of the 2013 Technical Competition. This competition recognizes excellence in additive manufacturing applications and skill in finishing additive manufacturing parts. A panel of industry veterans selected  Carl Dekker, president of Met-L-Flo, as the winner for both categories. Carl’s entry was a prototype shifter assembly that used multiple additive manufacturing technologies. Runner ups included Danice Chou, Biomedical Modeling Inc., Joe Holland, Christie Digital Systems/Hyphen, and Steve Kossett, Northern Lights Technology Center.

Gary Rabinovitz (right), AMUG president, presents Carl Dekker of Met-L-Flo with the Technical Competition award.

Another event highlight was the presentations of five DINO (Distinguished INnovator Operator) Awards, which recognize industry veterans with exceptional skills that in turn contribute back to the additive manufacturing industry. The newly named dinosaurs are:

•             Terry Hoppe, Stratasys
•             Paul Bordner, Laser Reproductions
•             Chuck Alexander, Solid Concepts
•             Brian Bauman, Linked In 3d
•             Todd Grimm, T. A. Grimm & Associates

DINO awards presented to Terry Hoppe, Paul Bordner, Chuck Alexander, Brian Bauman and Todd Grimm.

Gary Rabinovitz, outgoing president, said, “Without question, this is one of the most prestigious awards in the additive manufacturing industry. While there were many deserving candidates among the hundreds of highly skilled, seasoned veterans that attended the conference, these five men best represent what the DINO Award is all about: excellence and service.”

Additive Manufacturing Users Group (AMUG)
www.am-ug.com

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1. Designing confidence

Scott Summit has a brilliant vision—to help amputees feel more whole.  I first saw his work on TED talks.  In 2012, his company, Bespoke Innovations was acquired by 3D Systems.  In this video, he shares how it all began and how it helps others.  An engineer, he demonstrates the very best kind of engineering—helping a segment of the population in more than just technical ways.

2. 3D Printed Steampunk Themed 28-Geared Cube

I love out-of-the-box thinking.  And the more convoluted the better.  This simple video is a nice example of out-of-the-box design and a 3D printer’s ability to print complex objects without assembly.  Who needs a cube with 28 gears?  Does anyone care? This design is just plain cool.  I want one. On each side of the cube are 7 gears: 2 large outer ones that move in opposite directions. The outermost gear has handles on it so it can be easily rotated, the motion between the 2 large cogs is reversed due to 5 smaller gears set within the cube in a similar layout to a planetary gearbox to reverse the gear’s direction on each of these 4 faces. Each of these sets of gears on the  faces are all linked through the big gear on each of the  faces meshing at 90 degrees with the big gear on each of the 2 neighboring sides. This means that if any one gear is spun, they all spin. It’s available for $90 from Shapeways.

3. The World’s First Fully Articulated 3-D Printed Gown
Yes, the result is “hot.” But aside from that, this is just another amazing example of what 3D printing can do. The “first articulated 3D printed gown” is 3D printed “material” that is jointed to move and flex with wearer. The gown was designed by Michael Schmidt with architect Francis Bitonti and printed by Shapeways for burlesque icon Dita Von Teese.

4. 3D Printed Flute
This is a classic video, one of the earlier ones to showcase the ability to print in multiple materials. And, on top of that, the flute actually makes pretty good music. The video has a nice display of a printer in action too.

5. 3D printed magic arms
For many engineers, this touching story shows why they went into engineering in the first place–to help solve a problem. This video went viral last year. The engineers were able to use 3D printing to develop a prosthesis that helps a young girl with a medical condition use her arms.
As the engineer involved noted, the needs of the prosthetic industry match so well with the abilities of 3D printing because everything must be custom.

What are some of your favorites?

Leslie Langnau
llangnau@wtwhmedia.com

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An older article, but still a good one is this one from Todd Grimm, “3D Printer Benchmark Profiles Seven Systems.” Some of these systems are no longer offered, and others have gone through several changes. But this article still offers good, basic information on how to evaluate a printer for your particular use.

The next article, “How to evaluate a 3D printer, additive manufacturing system” also contained a lot of information from Todd Grimm. It was based on a presentation he gave at the 2012 AMUG conference, and it offers excellent advise about how to select the right 3D printer for your particular needs.

I thought this next article, “How to Justify the Cost of a Rapid Prototyping System,” also offered good tips for making the case for purchasing a 3DP/AM machine. Speaking the language of accounting can be a challenge, and this article explains what is needed for best the communication.

“The Third Industrial Revolution,” published in the economist is one of the more balanced articles on 3D printing. I like the history at the beginning, but there are a couple of points I disagree with. For example, when was the last time the author toured a factory? It’s not future factories that will be “squeaky clean,” most of today’s factories already are! I’ve toured a number of factories in my career, and not once have I encountered a dirty factory. It’s past time we let that image from the 1960s go.

And again, I’m not convinced that this technology will be disruptive. I still think it will literally be additive, in that it will another tool we can use; it will expand manufacturing by making custom parts really affordable.

This technology has a way to go, however. If you’ve checked some of the objects available on sites like Shapeways and others, you will find custom parts in the hundreds of dollars. If they were mass produced, the price would certainly drop.

“Fabricated: The New World of 3D Printing,” is interesting because it discusses each of the major application markets for 3D printing. It also gives a nice review of the book, Fabricated, by Hod Lipson and Melba Kurman.

And finally, one of the better articles on just “What is 3D printing?” Thorough, balanced, and informative, it discusses the major technologies of additive manufacturing. And there’s a decent infographic included.

Happy reading!

Leslie Langnau
llangnau@wtwhmedia.com

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Leveraging 3D Systems’ combined Alibre and Geomagic platform, Geomagic Design is now also available as part of a series of software packages that include Geomagic Freeform products. These powerful packages combine organic, touch-based 3D sculpting with robust B-Rep CAD and detail design tools from Geomagic Design.

An assembly model created using Alibre of an extruding machine, with full history shown

Geomagic Design is available in three versions: Personal, Professional and Expert, each tailored to the needs and budgets of our growing user base. Geomagic Design comes with over 35 new tools and more than 100 enhancements, built on a robust platform that is sure to deliver a rock-solid design-to-manufacture experience.

Top features of Geomagic Design include:

Using the Geomagic Freeform + Geomagic Design Expert software bundles, prismatic CAD data can be imported into Geomagic Freeform for organic design using voxel, NURBs, and SUBD surfacing tools, and then exported out to Geomagic Design for production and detail drawing creation.

Geomagic Design solutions also include comprehensive rendering tools, built-in motion simulation tools and a wide range of 3D CAD and neutral 3D format support to enable interoperability of design data.

An online tour and Free Trial of Geomagic Design is available here.

3D Systems
www.3DSystems.com

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Ed Morris from NAMII gave a presentation on this initiative. This public-private partnership will focus on innovation in every aspect involving additive manufacturing (AM). Noted Morris, NAMII exists because the U.S. is in an economic war. The U.S. needs manufacturing to be re-energized to create more economic value, and 3D printing is a key technology in this effort. NAMII efforts will be directed at accelerating the use of this technology. There are many barriers to knock down, but AM changes the rules. The idea of a factory is changing.

Soon you will be able to access your knowledge of this industry and receive certification for what you know.  Efforts are underway to design tests for certification. Eight areas of knowledge have been identified so far: the basics of AM, called AM overview; AM Technology which will cover knowledge about processes and materials; AM secondary processes; AM inputs; Designing for AM, which will cover information engineers need to know to take the best advantage of what it can offer; Quality assurance in AM; Business and economics of AM; and emerging issues.

Industry Consultant Graham Tromans gave an overview of what is going on in Europe.  One key development is how much China is taking to and investing in 3D printing.  China is investing nearly 3 times the amount the U.S. is in the NAMII initiative. This country will have it’s first world conference on 3D printing later this year.

Leslie Langnau
llangnau@wtwhmedia.com

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One of the entrants in the AMUG 2013 competition.

3D printing has the potential to help engineers deliver better designs, while reducing costs and still get to market ahead of the competition—if management doesn’t mess it up. A keynote address at today’s AMUG conference, “Aligning Cultures, The Ironic Art of Successfully Managing Product Development Products, by Randy Iliff, Vice President of InSight Services, presented the audience with some interesting thoughts about how we could use 3D printing. But this promise may go unfulfilled if we continue to apply the variation elimination processes and methods used for manufacturing a part to that of designing a part. The process of designing is exactly the opposite of that of manufacturing. Prototyping and designing are inherently unpredictable processes. Variance is critical to discovering, which then leads to better design. But trying to remove variability and turn design into a predictable, repetitive process is what results in dull, uninteresting designs that don’t appeal to customers.

Prototyping is still one of the best uses for 3D printing. But, given Iliff’s comments, I can see why artists, hobbyists, and makers have taken to 3D printing so strongly—the ability to create anything you can imagine. What has happened to industrial engineering, in that design engineers don’t gravitate to 3D printers in the tens of thousands like the makers do? Perhaps its because the current business thinking is to apply strategies that succeed with manufacturing to design.

You cannot always apply manufacturing’s repetitive methods to everything, noted Iliff. Using repetitive methodology, (the goal of which is to eliminate all variables), “out of context is profoundly harmful,” especially to design creativity. “Manufacturing is a special case and benefits from the removal of variance.”

Design, on the other hand, needs variance, variation, chaos, serendipity, experimentation, and so on—processes anathema to manufacturing. As Iliff noted, “Understanding is a necessity in the creative space. It is not needed in manufacturing,” where everything is automated.

3D printing can return these characteristics to the design engineer. And project management should get out of the way and let this happen.

A couple of other interesting notes from today’s conference;

It looks like the merger between Stratasys and Objet is going very well. The sessions on their materials emphasized the use of FDM as more for applications requiring performance, and those of polyjet for applications requiring fine detail. The goals of the materials department at Stratasys LTD are to develop cartridges with more material for even longer build times, improve material toughness and elongation at breaks, increase tensile strength and modulus, and develop materials that are easier to remove hands free support.

In the third quarter of this year, Stratasys LTD expects to release a 2nd generation Digital ABS material. This material will suit applications for objects with dimensional variations, such as thin walls, 1.2 mm or less. Another material the company expects to announce then will be a digital ABS in the color ivory (instead of the current green).

I met with Dr. Conor MacCormack at the show today. Mcor Technologies is renaming its process Selective Deposition Lamination (SDL).

The Mcor printers can deposit pico liters of adhesives exactly where it is needed, making the removal of excess material from the printer part much easier.

The color process of the Mcor systems is impressive. In addition, other applications for printing in a paper medium include medical, packaging, living hinges, and others.

Stay tuned. The conference continues tomorrow with some interesting presentations scheduled!

Leslie Langnau
llangnau@wtwhmedia.com

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Somos®NeXt LV Grey produces durable, grey parts with high resolution detail.  The ABS-like parts have a high modulus while maintaining a low viscosity for easier cleaning and reduced part processing times.

This third-generation, high-impact Somos material is designed for creating tough, high-quality, complex parts that are more resistant to fracture and cracking than standard SL resins. Somos NeXt LV Grey also offers superior water resistance and thermal properties. It is ideal for use in functional testing and low-volume manufacturing applications, as well as functional end-use performance parts; especially snap-fit designs, impellers, connectors, and sporting goods.

For more information about Somos stereolithography materials, visit www.dsm.com/somos

DSM
www.dsm.com

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Stratasys Ltd. announced the winners of its ninth annual Extreme Redesign 3D Printing Challenge. The global contest encourages students to submit an innovative product design, a redesign of an existing product, or an original work of art or architecture.

Stratasys is awarding the top three student winners $2,500 or $1,000 scholarships in each of the categories of Middle and High School Engineering, College Engineering, and Art and Architecture. Instructors of each of the three first-place student winners will receive a tablet PC for use in the classroom.

This year’s finalists in the College Engineering category also had their designs examined to see if they had potential for a licensing agreement and commercialization by a manufacturer. This process was done in partnership with online inventor community, Edison Nation, which operates the hit TV show, Everyday Edisons. After considering finalist designs, Edison Nation identified one design submission as having strong potential for submission to the licensing search process and a potential future licensing agreement.  The company will recommend steps the entrant should take to pursue this possibility.

Designs are awarded based on creativity, usefulness, part integrity and aesthetics. Each submission is required to be a sound mechanical design, be realistic and achievable and include a clear written description of the design. This year’s contest also featured the award category, “Engineering a Difference,” in which students competed for a bonus prize. Students whose designs were aimed at solving a great societal challenge had a chance to win a $250 gift card.

Winners were selected by a distinguished panel of independent judges from industry. This year’s judges were Patrick Gannon, RP+M division of Thogus, Todd Grimm, TAGrimm & Associates, and Ian Kovacevich, Enventys.

For video, photos, and descriptions of this year’s winning designs, visit Extreme Redesign 3D Printing Challenge.

WINNING DESIGNS:

College Engineering Category

1st  Crawler 2.0; Andrew Roderick/Brian Booth, Andrews Univ., Berrien Springs, Michigan
2nd  Multi-Rack; Sandra Wojtecki/Helena Skonieczna, Ryerson Univ., Toronto, Ontario
3rd  Snack Cup; Sivan Arbel/Julia Mozheyko, Ryerson Univ., Toronto, Ontario

Art & Architecture Category

1st  Emergent Automated Mfg; Connor Nicholas, Savannah College of Art & Design, Savannah, Georgia
2nd  Virtual Organic Glasses; Hichang Ki; IDAS, Seoul, South Korea
3rd  Running Charger; Max Meaker, Kentridge H.S. Kent, Washington

Middle/High School Engineering Category

1st  Magnesium Fire Starter; Josh Ryan, Grand Haven H.S., Michigan
2nd Math Over All Boundaries; Ethan Koeppe/Ethan McMillan, Grand Haven H.S., Michigan
3rd  Easy Open Bottle Cap; Zachary Sia, Pittsford Mendon H.S., Pittsford, New York

Edison Nation Pick

Crawler 2.0; Andrew Roderick, Brian Booth; Andrews Univ; Berrien Springs, Michigan

Edison Nation will advise the team of Roderick and Booth on steps they should take to pursue a possible licensing agreement and commercialization of their invention.

Stratasys
www.stratasys.com

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The Health Care Partner 3D scanner is a great alternative to traditional, tiresome and messy measurement methods like plaster casts. Scanning sessions are extremely short. Consultation times are drastically shortened, which leads to more patients being treated. The 3D scanner is quick, 3D surface is generated as you scan, which makes for minimal waiting time. Data files can be sent rapidly and securely over the internet to a remote fabrication center to optimize machining process.

Accuracy of scanned data is up to 0.5mm, whatever the technician’s level of expertise, or the surrounding environment (vs manual measuring). The Health Care Partner 3D scanner is durable and lightweight, only weighing in at about 2 lbs. it fits in a suitcase smaller than a carry-on.

Creaform
www.creaform3d.com

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3D Systems offers the largest number of 3D printers and additive manufacturing systems. At the top of the homepage, 3D Systems breaks your choices to personal printers, professional printers, and production printers.

Let’s say you select professional printers. When you click on that link, the next page on the website has a menu at the top plus other general or news information throughout the page. The Products choice on the menu bar will take you to 3D printers, materials, software, and training and education.

Unless you scroll down this entire page, you will most likely click on 3D printers, where you will find a list of about 19 systems. If you are not familiar with each of these systems and where they best apply, this list can be daunting and may mean going through each one, one at a time. The text on each one gives you a broad idea of printer capabilities, but you will likely have to download a brochure from each one to determine it’s specifications.

If you did scroll down the page a bit, you find a question—“Which 3D printer is best for me?” Clicking on that takes you to a general configurator, which asks you to check a couple of choices and then returns with 2 machine suggestions. Parts of this tool are incomplete. When we made a couple of choices, we found the message “page not found,” so this tool might not be as helpful as you would want.

For the production printers, you select the Printers choice on the top menu, and then you must determine whether you want laser sintering, stereolithography, direct metal sintering or a voxeljet system. The Stereolithography choice has the most printers listed under it. Here, however, you get a broad idea of what each system can do to help narrow your choice a bit. For detailed information, you will need to download a brochure.

For the most part, you can find specification data within 3 to 4 site clicks.

For the personal choices, the first click will list 3 choices. Clicking on RapMan and 3D Touch takes you to the Cubify portion of 3D Systems website. These systems are no longer being sold, but you can obtain parts and service.

The Project 1500 choice takes you a page that briefly describes this printer, but that also lists a number of 3D Systems printers on the left. Some of these are desktop, personal versions, some are professional units, so there’s room for confusion here. For detailed specs, you will have to download a brochure about the systems you are interested in.

Clicking on the Cube takes you to the Cubify website, which is similar to the MakerBot website. It will take you 2 clicks to get to the order page. Between the Cube and CubeX, they have a nice chart of features and capabilities to help you choose.

Stratasys

Since the merger with Objet, the Stratays website has been reorganized. You can begin your search by clicking on a menu bar that lists 3D printers, materials, applications, industries, or resources depending on whether the material, the application, the industry or the printer is your key selection criteria. If you click on any of these, you will be guided to the 3D printing/additive manufacturing system(s) that best suit your criteria.

Clicking on the 3D printers tab will take you to a break out of systems grouped as the Ideas series, the Design series and the Production series. The Idea series is where you will find the smaller desktop units, Mojo and the uPrint line. The Design series includes the Objet line as well as Dimension line. Plus, it is further separated into another choice—do you need precision or performance? And the Production series has the Fortus line.

When you click on the material choice of the menu bar, you will find a list of materials Stratasys offers. Clicking on a specific material will give you some info about that material’s properties, and then a list of which machines work best with that material.

In the application, the site gives a brief description and offers video and other content. It would be nice if this section had a cross-reference indicating with systems suited which applications. This section lists materials appropriate to specific applications, but one more step would be helpful too.

In the industries section, some selections will suggest a specific printer, others will go into materials, and from there you can narrow your choices.

With this website, it will take you about 2 clicks to get to a printer where you can download a specification sheet for more information.

EOS

EOS makes it fairly easy to find a 3D printing/additive manufacturing system, but you do have to do a little interpreting. It might seem obvious to click on the Additive manufacturing choice on its menu bar, but that will take you to more of a marketing page on innovative EOS technology. If you go to Systems and Solutions instead, you can make a material choice, which will lead you to Systems and Equipment. Selection any one of the systems displayed will take you to its page, which will list all the specifications. Depending on the system, you can still download a data sheet, but not all systems have a data sheet available.

SLM Solutions

SLM Solutions makes it easy to find info on its products. Click on products, pick one and read about it as well as examine the specs. You can download other information, like brochures, easily as well.

MakerBot

Makerbot has an easy to use site as well. In two clicks you get to specification information. Plus you can buy online, adding material and parts to your shopping cart. Definitely geared to hobby/makers, but it is easy to use.

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Better Efficiency in 3D Modeling Design

3D printing allows designers and developers to progress quickly from virtual images in software to physical objects in reality and make adjustments and changes in a more intuitive way by judging real products rather than conceptual drawings. In addition, manufacturing process will be completed in a more cost-effective manner, instead of mold making and modification. A huge amount of molding fees can be saved for product innovation and development, helping to accelerate the product life circle in 3D modeling industry. With the new Print3D function in ZW3D 2013, designers and engineers can leverage the advantages of 3D printing to improve their working efficiency.

Easily Bring Your Design into Reality

As 3D printing matures, this technology has started to affect almost every aspect of our life, from small items like cells, food and medicine to large objects such as furniture and even buildings. Companies including MakieLab, Kodama Studios and Shapeways have created simplified Web services with which clients can make custom objects based on customization software. These services enable designers to easily print out their works after drawing without a complicated production process. Moreover, the size, shape, painting and material can be customized in their desired way, allowing designers to make unique creations and distinguish from the standardized products.

“With the launch of 3D printing technology, it now allows designers to see their designs in a more intuitive way.” said Colin Lin, Vice Director of ZW3D Overseas Business. “With the evolving technology and the increasing popularity of 3D printing, the seamless integration between design software and 3D printer will become a trend for 3D printing. Therefore, we want to establish a close connection with 3D printing in ZW3D, allowing designers to better leverage the 3D printing technology to improve product quality, boost design efficiency and facilitate prototyping and manufacturing as well.”

ZW3D
www.zwsoft.com/products/zw3d.html

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Said Bob Romanoff, President, Romanoff International, “Romanoff will provide sales, service and training for the LaserCUSING machines to the automotive, dental, jewelry, medical and molding industries in the Americas. With our in-house dedicated service, technical and applications personnel, Romanoff can offer a solid experience to LaserCUSING adopters.”

“We are very excited to partner with Concept Laser and expand the availability of the LaserCUSING technology to the Americas,” said Brian Romanoff, Vice President, Romanoff. “From the MLab to the M1 and M2 LaserCUSING machines, customers will have the ability to produce components with delicate and intricate structures, such as medical device applications, to larger industrial components such as an exhaust manifold. Over the last year, we have been working with customers and the LaserCUSING technology. We have all been impressed with the quality of parts, as well as the reliability and repeatability of the machines.”

Oil pump housing. Photo courtesy of Concept Laser

The LaserCUSING materials that can be used include high-grade and tool steels, stainless steels, aluminum or titanium alloys, nickel-based superalloys, cobalt-chromium alloys, bronze alloys, and precious metals such as gold and silver. Concept Laser powder materials are 100% compatible for re-use in subsequent construction processes.

FineLine Prototyping Installs LaserCUSING MLab for High-Quality, Precision Rapid Prototyping

As the first installation of the LaserCUSING MLab machine by Concept Laser in the United States, FineLine Prototyping is known for their high-quality, precision rapid prototyping.

When it came time to expand their operations, FineLine decided that two MLab machines would aid in meeting the increasing demand for micro-resolution parts made from Stainless Steel.

“The MLab machine is designed solid, simple and small for reliable production of accurate, fine-featured parts,” said Rob Connelly, President, FineLine Prototyping Inc. “Its small footprint and basic facilities requirements make it easy to drop in place and set up for operation quickly. In each of the two installations, we made parts on the machine the same day as the technician arrived.”

Photo Courtesy of FineLine Prototyping.
FineLine uses the MLab to produce MicroFine Metal Direct Stainless Steel 17-4PH

In response to customer demands for larger parts and exotic materials, such as titanium, FineLine Prototyping recently purchased the M2 LaserCUSING machine.

Concept Laser
www.concept-laser.de

Romanoff International Supply Corporation
www.romanoff-rp.com

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Photo source: freedomofcreation

It’s not manufacturing that 3D printing technology should disrupt—it’s habitual thinking. 3D printing can change the habits we get into with design and prototyping, as well as production, and how fast we get to market.

Habitual thinking is what leads engineers to specify 500 prototype parts when 10 or 1 will suffice until the next design iteration. Habitual thinking is what leads us to specify the production of 10,000 parts when perhaps only a couple hundred, or less, are needed. In the past, specifying 10,000 may have been the lowest cost choice. Now, with 3D printing, those numbers can, and should be, different.

Noted Technology Consultant Todd Grim, “Instead of looking for 3D printing to be a replacement for something that’s already working, start with a clean slate. Look at it and say, with no expectations and no requirements, how should we develop this product? How many do we really need in the first year, second year, third year? What is it that we really need? What are the material properties we really need? And then, see if additive manufacturing gives any value or benefits that other processes can’t.”

These comments came from a recent interview I had with Todd. Another interesting point, along the lines of habitual thinking, involves the current idea of using today’s 3D printing technology for manufacturing. It can be done, but the technology was not specifically designed for making thousands of the same part over and over again. The 3D printers available today were originally designed for prototyping, to shrink the time it took to outsource this task. Now some 3d printing systems can be used in manufacturing type applications, the dental industry is an example, but they are not optimized for manufacturing.

For a general manufacturing 3D printer—“we still need time for it to happen,” continued Grimm. To truly suit the needs of manufacturing, as we know it today, designers of 3D printers may need to go back to the drawing board. “For the most part, no one has come out with a new platform that uses their core technology that is built from the ground up to be a manufacturing device. If we want to move into production applications, it probably would behoove the OEMs to start with a fresh sheet of paper and build the thing from the ground up with the eye towards repeatability in terms of quality using topnotch components, but design that whole machine such that they can leverage what those topnotch components can give them.”

Continued Grimm, “Manufacturers’ are looking for something that you turn it on and what was made yesterday is what you’re going to get today.”

To achieve this goal, Grimm notes that designers will need to start fresh, and “start with the idea that everything you put down is with the purposes of improving quality, throughput and repeatability. So a specific manufacturing machine (as in the dental industry) is doable, but a general one, we still need time for it to happen.”

Another point about habitual thinking is how we justify the purchase of a unit, focusing on cost rather than the benefits 3D printing technology can deliver. “If you’re just trying to do the dollar analysis, it’s tough to make the math work,” said Bruce Bradshaw, Stratasys Ltd. “I can say that across the board with our customers, whether it’s the FDM side or the polyjet side, they experience significant improvement in time to market with their products using 3D printing technology.

“We see it help our customers bring products to market faster. Plus, it improves the quality of their design. I hear this all the time. I talk to somebody that uses a service bureau and they get a prototype of their design several weeks into the design process and inevitably they’ll say, ‘Wow, had I had this in my hands a month ago, I would have changed XYZ. But it’s too late and I have a deadline and I can’t change my design now because it’s too late in the design process.’ It’s said that a picture is worth a thousand words; I say a part is worth a thousand pictures.”

Whether it’s design, manufacturing, or justification, let 3D printing disrupt your habitual thinking.

Leslie Langnau
llangnau@wtwhmedia.com

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Stem cells, which have enormous potential in medical research because of their ability to differentiate into specialized cells types, may one day provide a renewable source of replacement cells for people that require organ transplants or are suffering from ailments such as Parkinson’s disease, Type I diabetes, and Cardiovascular disease.

According to Boston University Investigators, understanding and controlling stem cell differentiation in vitro is proving to be a major challenge because cells can interact with each other either through direct contact or by cell-secreted factors, and a more controlled cell micro-environment is needed to systematically elucidate the important factors that influence cell behavior.

Utilizing a high-resolution 3D printer, Potomac Photonics fabricated precision stencils to pattern seeded stem cells such that cells are grown in a defined arrangement relative to each other. By preparing various stencils, the BU researchers hope to determine how the relative position of stem cells affects their differentiation efficiency and differentiated progeny.

This work, which was performed within Potomac Photonics’ Educational Manufacturing Initiative, demonstrated another novel way that 3D printing and advanced micromanufacturing technologies are spearheading the development of innovative new applications and products.  According to V.P. of Operations Mike Davis, “It fills us with great pride that our advanced manufacturing technologies such as lasers, micro-CNC and 3D printers are being used to promote  research and development of new devices that will help improve our quality of life.”

Potomac Photonics
www.potomac-laser.com

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We interviewed Samuel Hamner, design engineer with the project, about how rapid injection molding help move the project forward.

Make Parts Fast

All 3D printing technologies have a common starting point—a CAD program that describes an object. This CAD program is then usually converted into a standard tessellation language (STL) file format. This file format is then fed into the 3D printers control, which takes the STL file and separates it into hundreds or thousands of “slices.” The control feeds the building data on each slice into the 3D printer, which then builds the object, layer by layer, based on this slice information. The thickness of these slices varies by 3D printing technology. Thicknesses average 0.1 mm, but can be thinner or thicker.

According to the ASTM designation F2792, Standard Terminology for Additive Manufacturing Technologies, laser sintering is defined as a “powder bed fusion process used to produce objects from powdered materials using one or more lasers to selectively fuse or melt the particles at the surface, layer by layer, in an enclosed chamber.” The definition goes further to note that the term “sintering” …”is a historical term and a misnomer, as the process typically involves full or partial melting, as opposed to traditional powdered metal sintering using a mold and heat and pressure.”

Laser sintering is often used to develop robust parts, parts that can be tested or have end-use application.

Several 3D printing laser-sintering systems have a central build area with repositories for powder material on each side of the build area. A roller spreads a layer of power from either repository onto the build table. Then one or more lasers moves across the build area in a specific pattern, melting a specific portion of the powder, which then hardens as it cools. The powder not exposed to the laser beam remains loose. The roller spreads another layer of powder over the entire build area, and the laser moves over the area again, melting a specific portion of the powder, which automatically melts and adheres to the previous layer. These steps are repeated sometimes thousands of times until the part is completely built. The powder can be a plastic or metal. EOS and 3D Systems laser sintering systems use this method of powder delivery and melting.

One of the newer laser sintering systems from SLM Solutions, the SLM 500 HL handles powder delivery and melting a bit differently. This machine is an example of one of the largest and most productive systems for a powder-bed based laser beam melting. This machine has a build chamber of 500 x 280 x 325 cm³ and uses double beam technology. Each of the two fiber lasers (400 +1000 W) operates on the powder bed by a 3D scanning unit. Two of these units work simultaneously, which makes a total of 4 lasers in operation. Included in the SLM® 500 HL is the shell-core-imaging process with two different laser beam profiles. These profiles may be used independently, but also parallel and simultaneously in the process, significantly increasing productivity.

This method takes into account not only 2 lasers operating simultaneously and parallel (“dual spot scanning”), but at the same time the lasers are melting several layers of powder in one melting process with a 1000 W-Laser. This technique is why the melting process gets a 10 times higher build rate compared to other additive metal systems.

Metal power is automatically transported by a continuous conveying system to meet the increased volumes and weights.

Advantages of LS

–no support material needed to help build objects. The un-melted, loose powder serves as support for any part of a built object. This approach decreases both raw material usage and the time needed to make the part.

-no post curing needed. Finished parts usually won’t lose their shape with time, although this depends on the powder material.

–good choice for parts with flexible snaps and living hinges since these parts are flexible.

Disadvantages of LS

–parts tend to porous and have a rough texture. Porosity depends on the material used. Coatings can be used to alter the surface, and in some cases enhance the strength or rigidity of the part.

– complex operation with multiple build variables, such as temperature. In some cases, excess fused material can compromise dimensional accuracy.

Other names for laser sintering include powder bed fusion, Direct Laser Metal Sintering (DLMS) and Selective Laser Sintering (SLS). DLMS and SLS both involve laser melting of powder material. However, DLMS uses a metal powder that is fused by the laser, and SLS typically uses a plastic powder that is melted. SLS is also a term coined by 3D Systems for its 3D printing machines.

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BEGO Bremer Goldschlägerei Wilh. Herbst GmbH & Co. KG, is one of the leading international companies in dental prosthodontics and implantology. Based in Bremen, Germany, the company has a long track record of making significant investments in R&D and the development of future technologies. In the growing market of digital CAD/CAM solutions, BEGO is a pioneer in additive manufacturing processes for the dental sector for which it holds various patents.

The new licensing agreement between Renishaw and BEGO will allow the Renishaw Group to strengthen its existing dental business on a global basis.

Christoph Weiss, managing partner of BEGO says, “We are delighted to find in Renishaw an innovative and strong licensee. The dental industry is one of the most competitive industries worldwide and the licensing agreement strengthens the position of Renishaw and BEGO. In particular the license agreement emphasises the BEGO strategy of investing in new technologies and to be a key innovator in the dental industry.”

Geoff McFarland, Renishaw’s Group Engineering Director, adds, “This is an important agreement for Renishaw which allows us to sell and utilise our own additive manufacturing machines for dental market applications, and gives our customers access to important patents from BEGO which is a leader in this field. It also comes at a time when we are introducing a range of innovative processes for the manufacture of dental structures.”

BEGO launched additive manufacturing (AM) technologies into the dental industry in 2001. The AM process allows the production of precision metal parts direct from 3D CAD data in a layer building process that removes many of the design limitations and material waste associated with conventional ‘subtractive’ milling processes.

“The licence agreement with Renishaw underlines BEGO’s approach to create win-win-solutions in the dental sector and therefore merchandise our patent portfolio successfully”, concludes Dr. Thomas Kosin, technical director of BEGO.

Renishaw plc
www.renishaw.com

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Digital orthodontics is rapidly becoming the industry standard because of its many business advantages including the ability to significantly shorten delivery times, increase production capacity and eliminate bulky model storage. Until today, due to cost considerations, 3D printers have only been practical for larger labs.

Affordable and simple-to-use, Objet30 OrthoDesk conveniently fits on a desktop in any lab, With industry-leading precision, it enables orthodontists to create accurate, smooth, orthodontic models more easily than ever before. Now orthodontists can automate the entire workflow from CAD file to model fabrication, significantly accelerating production times and increasing capacity. By transitioning to a fully digital workflow, the process of physical impressions can be eliminated as well, improving patient satisfaction. Models can now be stored digitally, so bulky physical models no longer need to be saved.

“Objet30 OrthoDesk is great for smaller labs. It offers efficiency, quality and accuracy in a convenient desktop size which is just right for us,” said Ana L. Marin, Lab Owner, ARCAD Lab. “It’s enabling us to expand our services to a wider range of customers. I definitely see Objet30 OrthoDesk as a game-changer.”

“Stratasys continues to make digital orthodontics happen, one lab and clinic at a time,” said Avi Cohen, Director of Global Dental at Stratasys. “We are excited to launch the Objet30 OrthoDesk and bring the most accurate 3D printing technology to all the smaller labs and clinics who want to benefit from the future of orthodontics, today.”

The Objet30 OrthoDesk combines accurate, precise 3D printing technology with a small desktop footprint. It comes with specialized dental printing materials in convenient sealed cartridges. Stone models, orthodontic appliances, delivery and positioning trays, clear aligners, retainers and surgical guides can all be produced significantly faster and more accurately. Based on PolyJet® 3D Printing technology, Objet30 OrthoDesk jets ultrafine layers of material for smooth, accurate models. As many as 20 models can be created with every print run.

The Objet line of 3D printers has received various awards in recent years, including the Design World 2013 Leaders in Engineering Award, the Dental Advisor 2013 Top Innovative Equipment Award, and the Dental Labs Products 2011 Readers Choice Award. The same technology is now available with the Objet30 OrthoDesk. It is clean and efficient and delivers the highest quality orthodontic 3D printing. It is available immediately.

About the Objet30 OrthoDesk

• Produces models with smooth surfaces, fine details & moving parts

• Suitable for small spaces, offices and desktop operation

• Tray Size (X×Y×Z) 300 x 200 x 100 mm (11.81 x 7.87 x 3.94 inches)

• Layer Thickness (Z-axis)
Horizontal build layers down to 28 µm (0.0011 in)

• Build Resolution
 X-axis: 600 dpi | Y-axis: 600 dpi | Z-axis: 900 dpi

• Material Cartridges
 Sealed 4×1 kg (2.2 lb) cartridges

• Power Requirements: 
Single Phase:
100-120V~; 50-60Hz; 7A, 200-240V~; 50-60Hz; 3.5A

• Machine Dimensions
 82.5 x 62 x 59 cm (W x D x H) (32.28 x 24.4 x 23.22 in.)

• Machine Weight
: 93 kg (205 lb)

Stratasys Ltd
www.stratasysdental.com

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One step at a time, vendors to the maker market are adding the tools needed to turn these low-cost 3D printers into fully useful devices. Will they compete with the professional 3D printing market? Not yet, at least not for users who must have very high quality printed parts for form, fit, and function. However, these developments in the maker market could lead to more interesting, and lower cost tools for the professional engineer.

The MakerBot and Autodesk announcement may not have much impact on professional users of 3D printers, even though the press release states that this development is for engineers, designers, architects, makers, creators, and artists. Autodesk 123D is really aimed at users unfamiliar with CAD programming.

The agreement between the two companies will entail the resale of MakerBot® Replicator® 2 Desktop 3D Printers in connection with Autodesk’s 123D membership offerings. The two companies will work together to help enable users to 3D print a model to their MakerBot Replicator 2 Desktop 3D Printer after creating designs from within the 123D apps.

The Autodesk 123D family of apps—which includes 123D Catch, 123D Creature, 123D Design, and 123D Sculpt—lets users capture, design and make their ideas, and connect with other makers around the world for support or inspiration.

According to MakerBot, the MakerBot Replicator 2 Desktop 3D Printer is its easiest, fastest, and most affordable tool for creating 3D prints, setting a new standard in resolution and accuracy for creating high quality models.

Bre Pettis, CEO of MakerBot, announced the partnership during his Opening Remarks for SXSW 2013, and the companies showcased creatures designed with Autodesk’s new 123D Creature iPad app, which were printed on a MakerBot Replicator 2 Desktop 3D Printer.

The MakerBot Digitizer Desktop 3D Scanner, apparently still a prototype, adds to MakerBot’s product family, which includes the Replicator 3D Printers, Thingiverse.com, MakerWare, MakerCare, and the apps inside Thingiverse, including the Customizer app.

According to Pettis, “It’s a natural progression for us to create a product that makes 3D printing even easier. With the MakerBot Digitizer, now everyone will be able to scan a physical item, digitize it, and print it in 3D – with little or no design experience.”

The scanner will use lasers and cameras to replicate physical objects into a digital form and file.

While the majority of 3D scanners are high-end, there are a few already out there that do a good job of capturing digital information about an object, and working with the major CAD programs. One that comes to mind is the NextEngine 3D laser scanner that Jay Leno uses.

Leslie Langnau
llangnau@wtwhmedia.com

Make Parts Fast

By Hiroshi Ono, Group Product Manager, Roland DGA Corp.

ABS iPod prototype case milled with SRP.

While many designers outsource their prototyping work, the industry’s most advanced technologies are bringing prototyping right to the designer’s desktop with several important benefits.

Many product designers and engineers who are researching in-house prototyping options are drawn to the hype surrounding new additive technologies, which create prototypes by fusing, binding or solidifying materials such as liquid resin or powders, layer upon layer. While bringing these systems in-house can offer significant benefits over traditional outsourcing models, for many applications, there is an alternative that can deliver a better, less expensive, better-finished prototype. This alternative is known as subtractive rapid prototyping (SRP).

Roland, for example, uses SRP technology as the foundation for its 3-D mills, including the MDX series used for product prototyping and short-run production. To create the prototype or part, this benchtop machine mills away excess material from a solid substrate, a method based on CNC milling. The process is easy, efficient and precise. Prototypes are built with precision and a surface finish that is often better than several comparable 3D printers, and easier than on many CNC mills. The MDX machine is an example of an integrated software/hardware system that is easy to navigate and is effective for intricate applications.

No G-Code required

CNC mills have been around for decades. Initially, these systems required time consuming and often tedious code writing to create the CNC program. Not an easy task–one wrong line of code and a production part is scrap, increasing the overall cost of production. Today, with SRP technology, G-Code programming is largely a thing of the past. Design files can be exported as STL, IGES and 3D DXF from your CAD software and loaded into CAM software for a seamless workflow.

An optional rotary axis produces parts with speed and accuracy. When one side is completed, the part is automatically rotated until all four sides have been milled.

Unlike traditional CNC machines, these 3-D mills are automated to reduce user errors and improve consistency and quality from part to part. There are no complex control panels, and instead the mills come with a user-friendly, easy-to-use computer interface. The wizard-base software walks you through a job to determine the appropriate tool to use. It also automatically programs how fast and deep it will cut, and how fast the tool should turn, depending on the material used. Thus, SRP technology provides full CNC function without the traditional CNC complexity. Even better, today’s SRP mills are affordable and more compact, enabling full rapid prototyping and small lot production right at the desktop.

Flexible material choice

When you are designing a product or part, the end material plays a key role in its function, fit testing, finish and product durability, as well as for structural, thermal and electrical testing. Material choice is another area where subtractive technologies shine. Additive technologies typically require a specific material to be processed, which is often proprietary to the machine. Subtractive methods can process multiple materials. You can choose from ABS, acrylic, aluminum, chemical woods, plaster, styrene, Acetal, Nylon and FDA approved plastics.

Prototyping in one material and then manufacturing in another, as additive systems do, adds an inherent risk that the part will not perform as expected. While additive technologies can handle some thermoplastics, few support materials such as aluminum, which are commonly used in manufacturing molds, products and parts. Also consider that additive systems lay down material in layers, which means the tolerances are limited by the thickness of these layers.

The MDX-540’s handy panel and virtual control panel simplify both setup and operation, allowing you to control the mill directly from the panel or from your PC.

With SRP systems, software and hardware components work for precise, repeatable results. From engineered plastics, resin and wood to non-ferrous metals, an SRP system produces a final product with smooth surface finishes and tight tolerances.

Workflow flexibility and versatility

By bringing SRP technology in-house, you can reduce delays and costs for die manufacturing over outsourcing models, and you are immediately able to implement corrections and adjustments to designs, and have instant visibility and verification of product design. You can explore creative options with full confidence in the accuracy and functional integrity of the prototype

Versatility is also a critical factor. Flexible machines that can handle a variety of jobs are in demand. SRP technology lets you create prototypes, PCB boards and engravings, as well as use the machines for post manufacturing work such as drilling holes or surface milling.

In addition, multiple SRP devices can be used together for Rapid Custom Manufacturing (RCM). For example, a Roland customer in the orthopedic industry relies on an assembly line of MDX milling machines to quickly manufacture custom spinal implants used in spine fusion surgeries. Each part is a custom fit for the patient at hand.

Finally, SRP technology is affordable. The list prices for additive and subtractive devices are roughly equivalent, but operating costs can be lower with SRP systems. The difference is due to the higher material costs and maintenance contracts associated with additive technologies. Our research shows that an SRP system saves an average of more than $20,000 over a 5-year period when compared to the cost basis of a comparable 3-D printer.

Gallery of SRP Applications

The following examples are real-world applications, ranging from visual concept models to prototypes and functional production parts. All were created using Roland SRP technology.

Fan Part:  This functional model is used on Roland machines to blow chips out of the cutting area when milling acrylic, wood or aluminum. Once the model was created it was put to work immediately after being removed from the machine.
Approximate part dimensions: 40 mm x 40 mm x 10 mm | Part build time: 1.1 hour
Return on Investment
Acetal Material $9.50
Labor (1/2 hr) $17.32
Total Cost $26.82
Value $199.00
Savings $172.18

Bearing Block Prototype: This medium density tooling board provides fast concept models that are dimensionally accurate. The material lets you create concept models at a fraction of the time of plastics or non-ferrous metals, giving you a dimensionally accurate, smooth surfaced model that will hold up to design reviews. Approximate part dimensions: 165 mm x 67 mm x 40 mm | Part build time: 3.2 hours
Return on Investment
Tooling Board Material $25.00
Labor (1 hr) $34.00
Total Cost $59.00
Value $950.00
Savings $891.00

Hair Dryer Prototype: When the designers wanted to test the fit and finish of a new travel-sized hair dryer, they used SRP technology to produce a prototype that would go beyond concept. Accurate materials, smooth surface finish and tight tolerances gave them an assembly that could stand up to thermal and impact testing.
Approximate part dimensions: 135 mm x 175 mm x 60 mm | Part build time: 12 hours
Return on Investment
Acetal Material $65.00
Labor (2 hrs) $69.30
Total Cost $134.30
Value $1,768.00
Savings $1,633.70

Rocker Arm Prototype: This aluminum rocker arm prototype was an early design model used to test the overall shape and function of a mountain bike part. This prototype was created in production grade material to match the production part and confirm fit, finish and functionality. Approximate part dimensions: 140 mm x 45 mm x 7.5 mm | Part build time: 2.1 hours
Return on Investment
Tooling Board Material $25.00
Labor (1 hr) $34.00
Total Cost $59.00
Value $950.00
Savings $891.00

Gear Prototype: This gear was used as a prototype to test real-world function. This fully operational gear was cut in the exact material used for the final product, which enabled accurate component testing. Approximate part dimensions: 51 mm x 51 mm x 15 mm | Part build time: 3.7 hours
Return on Investment
Nylon Material $5.00
Labor(1/2 hr) $17.32
Total Cost $22.32
Value $199.00
Savings $176.68

Fixturing Prototype: This assembly is composed of several close tolerance parts. The jig required a special fixture clamp that was not commercially available and was quickly created on a Roland SRP milling machine. The acetyl copolymer material will maintain tolerances over the entire production run. Approximate part dimensions: 28 mm x 98 mm x 48 mm | Part build time:4.2 hours
Return on Investment
Acetal Material $20.00
Labor (1 hr) $34.00
Total Cost $54.00
Value $375.00
Savings $321.00

Roland DGA
www.roland.com

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Inspire brings the power of topology optimization to a new audience by applying algorithms previously only used in engineering simulation departments. By using these algorithms to generate optimal solutions, design cycle time, material consumption, and product weight are all reduced.

Topology optimization and additive manufacturing are two techniques that together have the potential to help you create a new generation of exciting products. While additive manufacturing, also known as 3D printing, is widely used by product development organizations to create prototypes from digital models, topology optimization has been restricted to companies with extensive CAE resources, such as automotive and aerospace manufacturers. Until recently, the tools needed to generate designs with organic-like structures had not been available at a price, or a level of usability, that encouraged broader industry adoption. But that is changing, and topology optimization and additive manufacturing are now poised to accelerate the process of product development.

The promise of marrying these techniques is not just theoretical. A number of organizations have demonstrated the benefits of combining additive layer manufacturing (ALM) with topology optimization design. For example, research at EADS has showed that an Airbus A320 hinge bracket could be significantly reduced in weight by using ALM in tandem with topology optimization. The optimization process enabled the designers to quickly hone in on the most efficient, lightweight structure, while the use of ALM created further weight reductions by minimizing waste in the manufacturing process. Using these techniques together, the EADS design engineers had greater freedom to explore alternatives while cutting overall development time and costs.

Elegant solutions

So what is topology optimization? It is a mathematical method that generates a material layout within a given design space based on a set of loads and other conditions provided by a design engineer. By way of example, let’s look at a simple beam created and optimized using topology optimization software solidThinking Inspire. In this case, the design space is a rectangular block, supported at the lower corners with a single load applied to the top face. Once the design space has been created and the loads applied, you run the optimization and within minutes, the software generates a result that looks like a structure one would find in nature. It is apparent that additive manufacturing technology is a more appropriate process for creating this structure than a traditional subtractive process like machining from a billet. The design freedom of additive manufacturing processes allows a literal interpretation of the design, saving weight while also reducing local stress and maintaining structural stiffness.

The Inspire software lets you sketch surfaces and create solids within an intuitive user interface or import data from your existing CAD tool. The geometry can then be prepared as a design space and materials and loading conditions assigned before being optimized. Although not always required for 3D printing, manufacturing and shape controls can be applied including minimum member size, symmetry, pattern repetition, or cyclic repetition. The results of the optimization can be exported in STL format.

The first step in a topology optimization is to define the “design space,” which represents the maximum volume that a part can occupy. Then the loads that the structure will be subject to are applied. In this simple example, the rectangular design space is supported at either end and must carry a centrally located load.

The optimal result to the problem is not unexpected, but presents geometry that would require interpretation or the use of a manufacturing control on the optimization to be realized with a traditional manufacturing technique. 3D printing techniques are ideally suited to fully exploit this type of concept generation.

Faster concepts

Topology optimization results often have a visual appeal that provokes discussion. These conversations enhance the product development process by inviting early dialog about part loading, the product aesthetic, and manufacturing considerations. The optimization tool then enables you to quickly explore alternative directions, ensuring that you find a mass-efficient proposal. The opportunity to realize these results in a physical form through additive manufacturing increases the impact of the presented design concept.

3D printed versions of the above concept generated with solidThinking Inspire demonstrate the elegance of the results and can stimulate dialog about the design direction. This approach to development helps engage a cross-functional product team in early discussions about functionality, aesthetics, and manufacturing.

The images of the chairs shows the rapid evolution of two of them designed using topology optimization and produced using 3D printing. The design space, shown in brown, represents the maximum volume that a solution can occupy. Typical loads for a chair and symmetry controls have also been applied. The optimized result is shown in orange. This result can be exported in STL format allowing minor updates to be made prior to prototype manufacture.

Efficient parts

Now that additive manufacturing has removed many traditional constraints, the potential benefits of topology optimization are amplified. Saving product weight on a machined part does not necessarily save money. The size of the billet required is usually the same, but more material gets removed in the manufacturing process. With an additive technique, the amount of material used is directly proportional to the part weight: the heavier the part the more expensive it is to make. Now a part designed using topology optimization to achieve minimum mass will save money in raw materials. Our approach to product design should change as a result, especially when manufacturing small quantities of parts.

One historical challenge for engineers when presented with the results of topology optimization is translating organic-looking forms into CAD geometry ready for manufacture. While the manufacturing controls in the Inspire program make it easier to produce models suitable for conventional manufacturing processes, those who use 3D printing have the freedom to produce more complex shapes. The unconstrained topology results are invariably lighter than an interpreted version and save more time in the development process.

Faster, smarter, lighter

solidThinking Inspire is a tool that helps you create and investigate structurally efficient concepts through an intuitive user interface. This is a design space for a chair shown in the product. Loading conditions have been applied and the plane shows that a symmetric result is desired.

The Inspire software is not just suited to parts created using additive manufacturing processes. Stefan Terebesi Sr. Engineer at Key Safety Systems, Inc., a Tier 1 manufacturer of automotive safety equipment, has been using the software to help him and his team generate efficient structures for safety critical components in vehicle restraint systems. He explained, “We were interested in generating design concepts based on optimized performance requirements that would help design better performing parts in less time.”

The use of Inspire allowed the team to study quickly what effect changes to loading conditions or package space might have on their design direction. Said Terebesi, “solidThinking Inspire provides a tool that can quickly suggest ideal part geometries, giving an opportunity to reduce development cycle time and enhancing the knowledge of the engineer regarding structural requirements of the component.”

Additive manufacturing and topology optimization share many common attributes including the speed at which designs can be realized, the opportunity to quickly understand the effect of changes, and the delivery of the lightest weight solution. Using the two technologies together compounds these advantages.

While each has virtues when used independently, there is an enormous opportunity to combine them and multiply their advantages. MPF

solidThinking
www.solidthinking.com

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Material limitations, including:

• The 3D printing process and how fast a previous layer of material cools before you can deposit the next layer.

• Temperature. Many 3D printers experience considerable temperature variation in the build chamber throughout the build process. For some materials, these temperature changes affect the grain structure of the material, affecting the part’s final properties. A number of engineers are calling for better control of the temperature, perhaps through the use of a closed-loop control system.

• The famous “razor blade” business model, where you give away the razor, or in this case the 3D printer, for minimal cost and make your profits through the supplies, which for 3D printers is materials. A number of people are frustrated by the cost of materials, and even more by the fact that they can only purchase the manufacturer’s material offerings. While there are some technical reasons for restricting materials to specific 3D printing machines (better control over part tolerances, resolutions, and accuracies), could it be possible to open this up? Larger industries, such as aerospace and automotive, may help here, as they tend to insist on multiple sources of critical material, components, and so on.

Print speed:

• Which is affected by materials and the temperature of the printer itself. But a number of users would like faster builds.

Material database:

• A data base on mechanical information on parts printed in various materials with various 3D printing processes. Manufacturers will resist full acceptance of this technology for manufacturing without data confirming that parts hold up to their designed function.

Better CAD programs:

Many novice users are finding that you must have a good CAD program to move to the next steps of printing your 3D part. The designed part must be built in the CAD program properly, often referred to as “water tight.” Novices are finding out that downloadable programs are often missing critical data needed for a good printable part. And just scanning data into a CAD program is often not quite enough to deliver a good part. Some tweaking and massaging of the scan data is often necessary, although several companies are developing enhancements to their programs that shorten the time for this.

Post processing:

• The time it takes, and the need for more, easier options to finish a part.

These are just the most popular frustrations. If your favorite frustration is not mentioned here, drop me a note!

Leslie Langnau
llangnau@wtwhmedia.com

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The KOR EcoLogic team will fully design URBEE 2 in CAD files, sending them to RedEye On Demand for building through Stratasys’ Fused Deposition Modeling (FDM) process. This unique process applies thermoplastics in layers from the bottom up, yielding parts that are durable, precise and repeatable. The finished two-passenger vehicle will comprise 40 large, intricate 3D-printed parts compared to hundreds of parts in the average car. The strong, lightweight vehicle will be designed to go 70 mph on the freeway, using a biofuel like 100 percent ethanol. The goal is for URBEE 2 to drive from San Francisco to New York City on only 10 gallons of fuel, setting a new world record.

“As a mechanical engineer, I’ve always believed we could use technology to help us solve some of society’s greatest challenges, like minimizing our dependence on oil and reducing ozone emissions. How cool is it that American manufacturing can evolve to tackle these challenges head-on? Our team is excited to launch URBEE 2, putting a next-generation vehicle on the road that will eventually be sold to the public,” said Jim Kor, president and senior designer for Winnipeg-based KOR EcoLogic.

URBEE 2, which stands for urban electric, follows in the tracks of its conceptual predecessor, Urbee 1. Produced in 2011 as a partnership between KOR EcoLogic, Stratasys and RedEye On Demand, Urbee 1 proved that 3D printing could in fact produce large, strong parts that meet accurate specifications of a car body. URBEE 2 will take the basic concepts of Urbee 1 to a higher level, including features like a fully functioning heater, windshield wipers and mirrors.

“With the Urbee 1 project, I learned that product design is nearly unencumbered by considerations on
how parts can be made with digital manufacturing. That liberation is incredibly powerful and holds a
lot of potential for the future of manufacturing,” said Kor.

RedEye On Demand
www.RedEyeOnDemand.com

Stratasys Ltd.
www.stratasys.com

Make Parts Fast

By Dr. Conor MacCormack, CEO, Mcor Technologies

An Mcor 3D printer produces patterns using standard business letter or office A4 paper. These patterns are suitable for casting low temperature metals, such as gold, silver, zinc and magnesium, to very high temperature metals, such as aluminum and steel.

Traditional methods of producing castings with patterns that are CNC machined, hand sculpted and silicon molded can be expensive, time consuming, labor intensive and sometimes geometry prohibitive. These constraints often inhibit the production of metal prototypes during the product development stage and small-batch or one-off part manufacture.

3D printing molds for casting has been considered an alternative, but foundries haven’t generally gravitated to 3D printers as a popular alternative to conventional casting methods because most 3D printers are limited to just one type of casting approach and, even more importantly, producing castings using 3D printed molds is still often cost prohibitive, due to the large amount of print material needed to produce a mold and the large print size required (since molds are much bigger than the cast part needed). Even 3D printing patterns are usually cost prohibitive due to expensive print material costs and the fact that many 3D print materials don’t successfully burn out from investment cast shells; instead they expand and crack the mold.

Mcor Technologies, based in Ireland, uniquely uses paper as the build medium for the Matrix 300+ and IRIS line of 3D printers. As such, paper 3D printing technology provides a distinctive versatility in the industry to produce both investment and sand casting patterns, and at a fraction of the cost of conventional methods and other 3D printing technologies. Specific cost savings will vary according to the size and complexity of the part geometry, but can be substantial.

The process still maintains the traditional casting method of pouring metals into molds created using patterns normally made from wood, metal, plastics or other materials. Using Mcor technology, the casting pattern is 3D printed out of paper directly from a PC on a Mcor 3D printer and enables you to directly print complex casting patterns affordably and faster than conventional complex methods. The 3D printed parts closely resemble wood, feel very smooth and are surprisingly robust.

Using traditional casting methods, molds would need to be created by first producing a pattern, or pattern set, which would then be used to produce the molds. In the case of sanding casting, a set of patterns is used to create the impressions in the sand, and for investment casting, wax patterns would be used to subsequently create a ceramic or Plaster of Paris mold. Mcor makes the patterns for sand castings and investment castings in the form of 3D printed parts.

The patterns produced on a Mcor 3D printer are made of standard business letter or office A4 paper that can be purchased inexpensively from any office supply store around the world. As such, they are suitable for casting low temperature metals, such as gold, silver, zinc and magnesium, to very high temperature metals, such as aluminum and steel. Any metal traditionally cast can be used because the mold is still a traditional casting mold; it’s the pattern making that is optimized using Mcor 3D printing.

How to produce castings with paper 3D printing

Investment casting: To produce investment castings of low temperature metals using Plaster of Paris, you first create a 3D printed version of the part to be cast. The 3D printed part is then dipped into cyanoacrylate (CA) to seal, and once dried (5 minutes), it is placed into silicon to produce a silicon mold for creating a wax pattern. The wax pattern is then encapsulated in Plaster of Paris. After the Plaster of Paris dries, the wax is melted out of the plaster mold and metal is poured into the mold. The advantage of this method is that the original pattern is 3D printed rather than hand sculpted or CNC machined.

Paper 3D printed molds work for basic, solid industrial geometries, such as an engine block, door hardware, statues and walking stick handles. It is not well suited for complex geometries, such as small, detailed jewelry.

If you need to produce investment castings using ceramic shell casting for high temperature metals, the steps are similar, but no wax is needed. The 3D printed pattern can be sealed with CA or paraffin wax and then repeatedly coated in liquid ceramic slurry, dried and placed in a furnace. This is slowly heated to 1,600-1,950° F. The paper prototype will burn out, leaving a hollow cavity ceramic shell mold, which must be flushed with water and compressed air to remove any ash. Then you pour in the molten metal. Once the casting has cooled, the ceramic will easily break away from the metal cast part. Multiple parts can be investment cast by creating a tree of parts using traditional methods.

Sand casting: To produce basic sand castings using paper 3D printed parts, first 3D print in two pieces a prototype of the part to be cast. Taking each half of the 3D printed part, the two parts of the sand casting flask (cope and drag) can be made using traditional methods which involve compacting the sand around the part and calculating the ideal locations for the sprue and risers. When the cope and drag are separated, the 3D paper part can be easily removed to reveal the negative impression of the shape to be made. The cope and drag are then joined together, allowing the molten metal to be poured. When cooled, the metal part can be removed. With more complex sand castings, many of the complex pattern pieces can be made with an Mcor 3D printer, saving days or weeks of manufacturing time.

Pros and cons

The cast metal parts produced with paper 3D printed molds have identical metallurgical characteristics as metal parts made using conventional casting methods, and can therefore be machined. A leading UK foundry, in addition to Mcor customers, have produced parts using this process and yielded results that mimic traditional sand and investment casting finishes and tolerances.

Mcor’s paper 3D printed molds work for basic, solid industrial geometries, such as an engine block, door hardware, statues and walking stick handles. It is not well suited for complex geometries, such as small, detailed jewelry.

Paper 3D printing is a useful, versatile and low cost addition to your toolbox for many applications, including concept modeling, prototyping, investment casting and sand casting. MPF

Mcor Technologies
www.mcortechnologies.com

Make Parts Fast

by Bob Cramblitt

When Chinese exchange student Jiahone Guo suffered a cranial injury during a club soccer match, he thought “maybe I will go to see God,” according to a report on WFAA-TV in Dallas/Fort Worth, Texas.

Fortunately, due to timely surgery and a custom-made prosthetic skull plate designed by MedCAD (Dallas, Texas), Guo is able to do almost everything he could do before the fateful match.

3D model generated in Geomagic Freeform showing Guo’s skull with the prosthetic plate in place.

WFAA-TV reported that about a quarter of Guo’s skull was removed after the injury, believed to have been sustained when an opponent accidentally kneed him in the head when he was falling. Guo finished the game, then began feeling pain.

Dr. Rob Dickerman, director of neurosurgery at Presbyterian Hospital of Plano, says that Guo was comatose when he initially arrived at the hospital. His brain was swollen and crushing his brain stem. There was no alternative but to remove a portion of Guo’s skull and let the swelling subside.

“At the time of the injury, I told the family it was a 50-50 chance of survival,” said Dickerman in an interview with WFAA-TV.

AccuShape helps create a new skull plate

Two months after being admitted to the hospital, Guo’s swelling was gone and Dickerman implanted the prosthetic skull plate.

The CNC-machined implant made of PEEK material created by MedCAD.

“I didn’t die,” Guo told WFAA-TV. “I can do anything — I can drive, I can walk, I can think.”

The prosthetic plate received by Guo was made possible by a new process developed in recent years by MedCAD, a custom biomedical device company specializing in cranial and cranio-facial/oral surgery prosthetics.

MedCAD’s trademarked AccuShape process — based on 3D technologies from Geomagic — enables the company to digitally design and manufacture cranial implants from CT scans. Major advantages of the process include:

• Faster digital design and manufacturing that eliminates time-consuming and sometimes error-prone manual sculpting.

• Greater accuracy by modeling directly from a patient’s CT scan, saving time and reducing risk in the operating room.

• Better aesthetic result for the surgeon and the patient.

• Ability to create implants in PEEK (poly-ether-ether-ketone), a surgical-quality polymer.

A new standard

“The standard of care has been to make a mold from a patient’s skull defect in plaster and hand-make an implant out of acrylic or some other moldable biomedical material,” said Nancy Hairston, MedCAD’s president and CEO. “Our digital process is much more accurate and PEEK is the closest biomedical material to natural bone. It is very strong, but very light, and not prone to infection.”

Beyond the final product, MedCAD works closely with physicians in surgical planning. The company takes a doctor’s surgical plan — including CT data and detailed paperwork — and transforms it into a detailed 3D model.

The virtual surgery approach makes it possible for surgeons to explore the upcoming procedure from every angle, previewing “what-if” scenarios and assessing potential problem areas. Last year MedCAD made its planning tool, called AccuPlan, available as an iPad app.

Digital modeling with Geomagic

The Guo project was brought to MedCAD by OsteoMed, a MedCAD distributor and provider of patient-specific implants. OsteoMed couriered Guo’s CT scan over to MedCAD, which used its AccuShape digital workflow to create the implant.

3D model generated in Geomagic Freeform showing the cranial opening.

First, an STL file (a standardized format for computer-aided design) is brought into Geomagic Freeform, software that enables designers and engineers to work on digital models as if they are molding in clay, except with all the advantages of speed and accuracy inherent in a digital process.

The input device for the modeling process is Geomagic Sensable Phantom, a haptic device that provides tactile feedback, enabling the design engineer to feel surfaces, edges and topology.

“Geomagic Freeform is the only tool on the market that allows for complex sculptural modeling,” says Hairston. “For any anatomical modeling, it shines compared to traditional CAD software due to its direct and intuitive modeling tools.”

Surface patches created in Geomagic Studio for the Jiahone Guo prosthetic skull plate.

Another key link in the AccuShape chain is Geomagic Studio software, which gives MedCAD the ability to create complex surfaces from STL data. This is especially important for accurate digital manufacturing of the custom-fitted implant.

“Typical CAD software cannot generate accurate surfaces for these types of intricate, organic shapes,” says Hairston.

Tying everything together is proprietary in-house software and procedures developed by MedCAD.

Certain devices created by MedCAD can be manufactured with a 3D printer depending on the material required and how the final piece will be used. But since 3D printing is not approved by the FDA for PEEK material, the Guo implant was manufactured with a CNC machine.

The implant for Jiahone Guo did not present any unusual technical challenges for MedCAD, but the project did come with a special treat: discovering the story behind the delivered product. Because of strict patient confidentiality, MedCAD engineers rarely know what happens after an implant leaves their hands.

“We make these devices on a daily basis, so this case design-wise was not unique until we learned the back story,” says Emily Aberg, MedCAD marketing lead and graphic designer. “But our machining intern, who helped build the implant, saw the story on WFAA, and said ‘that cranial implant looks real familiar.’ We were so excited to hear about Guo’s recovery and we wish him the best.”

Jiahone Guo with protective helmet following surgery, flanked by his parents. At far right is Janet St. James, who reported on the story for WFAA-TV in Dallas/Fort Worth.

Beyond bones

Hairston believes that rapid technologies for creating customized medical devices will be the norm for the future, not only for bone implants but someday for organs such as the heart and liver.

“Rapid technologies built upon 3D software such as Geomagic deliver the best possible outcome for patients and surgeons,” says Hairston. “More accurate implants are delivered faster, leading to less time in the operating room, less risk for the patient, and a better aesthetic result.”

Geomagic
www.geomagic.com

Bob Cramblitt writes about 3D technologies that are radically changing the way we work and live. He can be reached at info@cramco.com.

Make Parts Fast

Proto Labs launched the Cool Idea! Award in 2011 to give product designers the opportunity to bring their innovations to life by presenting up to $250,000 worth of prototyping and short-run production services to award recipients. D-Rev, designer and manufacturer of the ReMotion knee, is 2013’s first Cool Idea! recipient. Proto Labs is providing D-Rev with injection molded parts to fulfill its next round of testing.

The ReMotion Knee project started in 2008 as a project in a graduate bio-medical engineering class. The class collaborated with the JaipurFoot Organization, India’s largest provider of low cost prosthetics, and later teamed up with San Francisco based designer Vinesh Narayan. In 2010, D-Rev, a non-profit organization dedicated to improving the health and income of people living on less than $4 per day, continued the project with Narayan, who was hired on as a product manager.

“About 10 million above-the-knee amputees live in developing countries, and the ReMotion Knee allows them to walk stably on uneven or unpaved terrain typical of the developing world. It also helps them return to work, and remain independent,” said Narayan. “Current low-cost knee joints are mostly single axis joints. They operate similarly to a door hinge, and although they are inexpensive, they are unstable. ReMotion uses a polycentric mechanism, similar to anatomical knees, to provide greater stability.”

Today, more than 4,600 amputees have been fitted with a ReMotion Knee. As part of the Cool Idea! Award, 100 knee joints will be injection molded and used in field testing to ensure performance as manufacturing changes from CNC machining to injection molded parts. The shift is important for maintaining quality while serving large numbers of people.

“We were attracted to the ReMotion Knee largely because of its mission and potential to improve the lives of thousands of people,” said Larry Lukis, founder and chief technology officer of Proto Labs. “The entire design is extremely well done, both aesthetically and functionally. Every aspect of the device has been well thought through, from the use of high quality plastics, instead of metals, to save on cost and maintenance without sacrificing performance; to the rounded edges and spring that create a more natural appearance and gait.”

“With the Cool Idea! Award we are able to test the new knee design with much less risk, by only producing 100 injection molded knee joints. This is not typical for most injection molders who require large production runs. Working with Proto Labs has significantly accelerated the project without adding risk,” said Narayan.

Unlike other product awards that recognize products after they’re in mass production and on store shelves, Proto Labs’ Cool Idea! Award is meant to help cool ideas come to life. Eligibility for the award is during the design and development stage, when innovators are too often stymied by lack of resources or funds to turn their ideas into real products.

Proto Labs
www.protolabs.com

D-Rev
www.d-rev.org

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Make Parts Fast

“Because the Fortus 900mc was designed for the highest accuracy and repeatability using real thermoplastic material in additive manufacturing, the addition of a second machine enables us to keep up with the increased demand of our customers to transform their designs from ideas on paper to working prototypes,” stated Matt Hlavin, CEO of rp+m.

The second Fortus 900 joins a family of seven Stratasys Fused Deposition Modeling (FDM) machines, rapid prototyping equipment that uses thermoplastic materials to build three-dimensional, durable pieces — the Stratasys uPrint, Stratasys Dimension, two Stratasys Fortus 400 machines, two Fortus 900mc machines, and the Objet Connex500, which can print products that feature a soft-touch material, are near water-clear and can to run up to 14 materials in one build to create prototypes that offer very high resolution and accuracy.

The Fortus 900mc has the highest throughput and envelope volume (36 x 24 x 36 in), making it appropriate for fabrication and assembly tools, as well as end-use parts. It has precision ball-screw technology for increased accuracy, repeatability and reliability, and is suitable for high-heat applications.

rp+m is comprised of a core group of engineers (industrial and mechanical), product development specialists and plastic experts who understand that speed to market and quality is critical.

rp+m LLC
www.rpplusm.com

Make Parts Fast

The Additive Manufacturing Users Group (AMUG) announced that its keynote address will spotlight a major barrier to success: corporate cultures that are polarized with a development or production orientation. Randy Iliff, Vice President of InSight Services at Bjorksten | bit 7, will lead conference attendees through the “ironic art” of negotiating with stakeholders for permission to help them to align and balance cultures, objectives and expectations.

Gary Rabinovitz, AMUG president, said, “Education and training for additive manufacturing practitioners must span technologies, processes and business practices. Randy Iliff will tackle the latter, and the balance of our four-day conference agenda will address the hands-on and technical concerns that help our members do more with additive manufacturing.”

With over 80 presentations, training sessions and hands-on workshops, the AMUG Conference covers topics such as machine maintenance, material selection, secondary processes and system justification. “I am especially excited to offer ten hours of Magics software training, at no cost to our attendees, and four hands-on workshops that provide step-by-step instruction on processes such as rubber molding and hydroprinting,” said Rabinovitz.

The users group conference, now in its 25th year, is open to owners and operators of all additive manufacturing/3D printing technologies. The conference will be held in Jacksonville, Florida, from April 14 – 18, 2013. The all-inclusive conference registration fee is $595.00 until March 15th.

AMUG
www.am-ug.com

AMUG is an organization that educates and advances the uses and applications of additive manufacturing technologies. AMUG members include all commercial additive manufacturing/3D printing technologies for companies such as Stratasys, SLM Solutions, Mcor Technologies and Renishaw. AMUG meets annually to provide education and training through technical presentations on processes and new technologies. This information addresses operation of additive manufacturing equipment and the applications that use the parts they make. Online at www.am-ug.com.

Make Parts Fast

You can use this pen, called the 3Doodler, to draw in the air. Using ABS plastic, the 3Doodler draws in the air or on surfaces. No software or computers are needed to create simple three-dimensional objects. According to WobbleWorks, you just plug the pen into a power socket and start drawing anything within minutes.

As this pen draws, it extrudes heated plastic, which quickly cools and solidifies into a strong stable structure. Thus, you can build an infinite variety of shapes and items.

The 3Doodler pen is 180 mm by 24 mm and weighs less than 200 grams (7 ounces), although the exact weight will depend on the final shell specifications once in production. It uses a universal power supply, so provided you have the correct adapter for your country, it will work on 110 Vor 240 V.

It uses 3 mm ABS or PLA plastic as its “ink” – just like a 3D printer. Each 3Doodler backed on Kickstarter comes with at least one bag of plastic; each bag will contain ten 1 ft strands of plastic; and each 1 ft strand produces approximately 11 ft of 3Doodling fun… yes, you read that right, a foot of plastic goes a very long way in the 3Doodler. Here’s the video.

Make Parts Fast

The hobbyist and engineer alike are eager for low-cost, kit style 3D printers that accurately and repeatably deliver 3D printed parts. But as users are discovering, it’s not quite as easy or simple for vendors to deliver such a 3D printer. One of the keys to quality, robust 3D printers is the components used to deliver motion.

The Aluminatus TrinityOne, is an open source design. Not only is Ezra a proponent of open source technology and committed to providing designs for this community, he had interesting insights into the prosumer 3D printing industry and engineering needs.

But first, a bit about the Aluminatus. This printer uses the SIMO Series lead screw driven rails on the X and Y axes and Constant Force Technology (CFT) lead screw and nut to drive the carriage, from PBC Linear. The 3D printer delivers linear motion with a repeatability of ± 0.02 mm/m and a layer height of 50 microns. The parts produced on this printer show a very small stair-step effect. The CFT lead screw allows the drive mechanism to accelerate, brake, and corner fast and precisely.

Many 3D printers in this price range use belt drive technology. Depending on the printer, belts will hold repeatability to ±0.1 mm/m and layer height to about 100 microns. Belt technology, though, can result in “springy” motion, which can create parts with moray patterns and a loss of sharpness in holes, cavities, or other object features. So the use of machined components delivers better quality 3D printed parts.

Use of rails and lead screws in the Aluminatus also means this printer is made of fewer components than many 3D printers in this class—35 parts versus several hundred in other units. It takes about 2 hours to assemble. Another benefit is the lead screws let users use the entire 300 X 300 X 350 mm workspace.

In his design, Ezra wanted a simple, easy to build printer, so he chose to work with a company experienced with motion and motion control. Noted Ezra, PBC Linear offers a range of axes, actuators, lead screws and other components, at an affordable price, that fit together in the kit style he wanted, and that take the work out of assuring his printer delivers good resolution and accuracy.

Ezra and I spoke about a number of things, but one of the more interesting comments he made involved materials. While he believes the prosumer market is the way to go, he noted that for engineers to unhesitatingly use any model of 3D printer, the material cost of prototyping a part must be about $0.30 per part. Today’s 3D printers, of any class, don’t quite deliver that price point. But this is what he sees as necessary. He went on to note that engineers won’t readily spend $50 to print a part. (Some material cassettes cost $50, and if you build one part with that much material, a definite possibility, it becomes an expensive prototype.) Ezra sees little reason for the price of materials to be high, and is developing his own materials for the Aluminatus. This printer currently works with PLA and ABS in multiple colors. As Ezra noted, all the Pantone colors.

PBC Linear
www.PBCLinear.com

TrinityLabs
www.trinitylabs.com

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