By Zehavit B. Reisin, Head of Consumables Line of Business, Objet and Sam Green, author, Objet blog

After selecting the material you want from a computer menu, the software commands material from the two cartridges mounted in a Connex 3D printer to dispense from the 798 nozzles of the print head. The print head deposits the materials, a drop at a time, fabricating on the fly a digital material, 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.

When Objet introduced its first inkjet-based 3D printing system in early 2000, it made it practical for medium and small-size companies to quickly and efficiently produce complex, high quality 3D models and prototypes. But that of course, was just the beginning.

Back in 2000, Objet’s original Quadra Tempo delivered just one material, known in its time as M510. Fast forward to December 2007 when Objet introduced its Connex multi-material 3D printing capability. Unlike other 3D printers, and unique to inkjet-based technology, the Objet Connex jets two materials at the same time and even mixes and composes them to produce up to 14 different and unique material characteristics in one 3D printed part.

Alongside the technological developments in 3D printers are the major improvements in the variety and function of the materials that go into producing the actual 3D models and prototypes: Whereas in 2000 Objet offered the single M510 material, today it has nearly 70 different 3D printing materials.

Some of these materials are new in their own right. These include a family of rigid opaque materials in blue, black, white and gray; two rigid transparent materials, a family of rubber-like materials ranging from translucent to gray and black with varying Shore A values, a polypropylene-like material, 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.

So how do you reach nearly 70 materials? The Connex multi-material system is able to mix and compose two base materials together to create a range of composite materials, known as Digital Materials.

3D printed skateboard deck

It begins with the two cartridges you mount into the Connex. There are 17 modeling material base cartridges, from which you install two into the 3D printer. Then, you select from a computer menu the material you want to use for your prototype, such as VeroBlack, TangoPlus, and so on. The Objet 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 on the fly, a digital material 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.

Some combinations of two cartridges can develop up to 14 specific Digital Materials in a single part. So far, Objet has developed the chemistry for 70 materials. This process provides a unique level of prototyping flexibility enabling designers and engineers to precisely match their prototypes to suit the look, feel and in some cases function of their intended end products.

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 the 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.

The Objet260 Connex is the third multi-material 3D printer.

In 2011 for example, Objet introduced an ABS-like Digital Material—its first composite material able to simulate strength, toughness, and temperature resistance. The ability to use acrylic-based photopolymer materials to 3D print functional prototypes combining high toughness and temperature resistance has traditionally been a challenge. However, with the Connex multi-material 3D printer, you can combine two different cartridges, one for toughness and one for temperature resistance, to create an ABS like material that is both tough and temperature resistant for a functional prototype.

This means that designers and engineers are no longer limited to prototypes that look and feel like the end product—now they can even function like the end product. The ABS-like Digital Material can be used to create a range of functioning parts such as a skateboard deck that can support a full-grown man, or a foldable stool able to support more than 100 kg.

The ABS-like Digital Material is also suitable to simulate snap-fit parts such as clips and buckles or springs that undergo repeated flex during usage.

This year Objet also introduced a clear transparent material and a high-temperature resistant material, important additions for inkjet-based 3D printing and functional prototyping. And of course, like almost every other Objet material, any new addition to their range becomes another component for a whole range of new Digital Materials. Each Digital material is tested and examined by Objet according to ASTM standards. Data sheets detailing a material’s characteristics are available on the company’s website.

In effect then, Objet’s range of materials is exponentially increasing with every new material they develop. Twelve years ago there was one. Today there are nearly 70. And in a few years’ time? Probably hundreds.

The rapid advance in 3D printing capabilities opened up by the multi-material Connex technology and Digital Materials means that the future for product design and development is bright. Objet is at the first generation of inkjet-based engineering plastics simulation. Now that the threshold has been crossed, expect materials with even higher toughness and temperature resistance in the coming years.

This means that designers will be able to simulate nearly any 3D design they imagine—and do so to the last detail, whether it’s how they appear to the eye, how they feel in the hand and how they perform in real functional tests. It also means that 3D printing will continue to become an even more important component to design companies and offices in every industry and application.

3D printed architectural model in Objet Rigid White Material. Courtesy of Rietveld Architects.

In an economic environment where the loss of manufacturing efficiency is increasingly felt, 3D printing is now being recognized as a primary tool for reducing costs, time-to-market and stimulating the production of more effective end-products—which is, of course, the goal of every designer, manufacturer and entrepreneur. MPF

Objet Ltd.
www.Objet.com

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Todd Grimm was one of the speakers there, and according to his research, there’s a 90/10 ratio in the use of 3DP/AM technology, which  states that 90% of engineers are using just the basic capabilities (10%) this technology has to offer.

At the AMUG conference, I met a number of 10% users, primarily engineers who worked at service bureaus. But if you want to become one of the “10%,” plan on coming to AMUG next year.

When you can, take advantage of all conference opportunities available to you. The next one is the RAPID 2012 conference in Atlanta, May 22 through 24. See you there!

Leslie Langnau
llangnau@wtwhmedia.com

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The compound annual growth rate (CAGR) of additive manufacturing was 29.4% in 2011%

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The expansion is scheduled to be completed by the Fall of 2012, and will provide the modern plant with an overall footprint of 150,000 square feet. According to Mark Rathbone, CEO, “Our continued commitment to be in the forefront of our customers’ needs and expectations spurred this decision.”

“Along with this expansion we plan on increasing our workforce,” said Rathbone. “There will be opportunity in the advanced skilled areas of mold making, the engineering department, as well as general manufacturing.” Today, PTI Engineered Plastics, has 230 employees and with this growth, plans to add 50-plus jobs over the next two years.

PTI Engineered Plastics, Inc.
teampti.com

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With the arrival of low-priced consumer targeted 3D printers, some users of this technology ask why it needs to cost so much and when will the higher-priced versions go on sale? A look at the inner workings of these printers answers these questions.

By Leslie Langnau, Managing Editor

Why invest in a $15,000, $35,000 or higher cost fused deposition modeling/fused filament fabrication (FDM®/FFF) 3D printing technology when there are other extrusion printers out there that are under $2000 (such as RepRap)? Well, it depends on what you want to do with your system, and, as the caveat goes—“you get what you pay for.”

The technology behind Fused Deposition Modeling was invented by Scott Crump, CEO of Stratasys. The term FDM is trademarked by Stratasys. At least one of the patents issued to Mr. Crump has expired, enabling companies like RepRap to use that knowlege to develop their versions of extrusion systems. RepRap coined the term fused filament fabrication to avoid trademark conflicts.

These 3D printer systems use extrusion to deliver material that is used to build a three-dimensional part. Extrusion is one of the six primary processes in 3Dprinting/additive manufacturing. The others are jetting; lamination; melting as in electron beam melting or direct metal deposition; photo curing; and sintering. As of today, there are more FDM® machines than any other type in the world, including the consumer targeted units.

One of the strengths of this technology is that it can use a range of materials to develop good and strong mechanical properties in parts. Another strength is that these systems can handle any geometric complexity you can create. One critique often leveled at 3D printing technology is that parts tend to take longer to build, compared to a CNC subtractive operation. Such an argument does not necessarily consider part complexity, material, and other factors. Build speed in extrusion systems is a function of the material feed rate, the plotting speed, the rate at which the material can be melted, and the weight of material. For total throughput time, you may also want to consider the programming time for a CNC, support removal for a 3D printed part, as well as curing and applying an infiltrant if necessary.

The extrusion process consists of simultaneously advancing and melting a ribbon of material through a computer controlled nozzle deposition unit. (By contrast, laser sintering systems rely on the crystalline nature of powdered material to change to a curable liquid state when hit with high heat.) The material flows through the nozzle under pressure to ensure a constant rate of flow. In Stratasys systems, for example, drive wheels push a thermoplastic filament into the heating chamber of the extrusion unit, which heats it to a flowing consistency.

As long as the flow rate of the material is coupled with the motion of the extrusion head, your parts will have consistent and accurate dimensions. Ensuring that the material and the nozzle move together is challenging, as both are constantly changing; the extrusion head accelerates and decelerates as it travels across the build platen. In addition, the X-Y movement of the nozzle must coordinate with the Z movement of the build plate for consistent material deposition. As the head speed changes, the drive wheels need to adjust the material flow rate to deliver a precise ribbon width that changes as needed to produce the part. The lower cost extrusion systems often use stepmotors that drive belts to move the plotter system, but the tradeoff is accuracy and speed. The more expensive etrusion systems use servo drives and lead screws, which deliver the needed accuracy for more precisely built parts. The Stratasys Fortus 900 mc, for example, uses ball screw drives.

Ensuring that the material and the nozzle move together is challenging, as both are constantly changing. Lower cost extrusion systems often use stepmotors that drive belts to move the plotter system, but the tradeoff is accuracy and speed. The more expensive extrusion systems use servo drives and lead screws, which deliver the needed accuracy for more precisely built parts as shown in the Stratasys example here.

In Stratasys machines, for example, the material flowing from the nozzle typically measures 0.008 to 0.038 in. wide (0.20 to 0.97 mm) and as fine as 0.005 in. high (0.13 mm). On the highest performance Stratasys machines, though, part accuracy or tolerance reaches as high as 0.003 in. (0.08 mm). By comparison, injection molding’s accuracy is 0.005 in. These measurements are not available on the lower cost consumer style extrusion systems, or even on many of the desktop personal use systems.

The diameter of the nozzle also affects the material’s flow rate, as well as minimum feature size and part porosity. These factors partly explain why extrusion-based processes are well-suited to building large parts, rather than very small parts with tiny wall thickness.

The path to accuracy

Extrusion systems build a part differently from laser-based systems. Both use a layer-by-layer approach, but in extrusion, an outline of the part is deposited first. This outline determines the accuracy of the build part’s dimensions, so the deposition speed is often slower to ensure precise deposition. Then, the nozzle fills in the outline using specific, established fill patterns of back and forth motion. These fill patterns are similar to the cut patterns used by CNCs in planar pocket milling.

The fill patterns are part of the system software used to slice the 3D CAD image into layers. Stratasys, for example, uses Catalyst EX or Insight to slice the part design into layers and generate the nozzle path for building the part. However, an understanding of build paths can influence your design. For example, fewer individual paths are preferred to minimize seaming and gap overlaps, but this may not be possible with complex designs. Consideration needs to be given to nozzle start and stop locations. Fewer individual paths are preferred to minimize seaming and gap overlaps. Alternating stop-start locations will avoid seams in an area that may be critical for fit or assembly. Another example is that you can adjust the fill style from solid to semi-porous sparse, which will deliver different properties depending on your design.

In the higher priced extrusion 3D printing units, software handles the slicing, the outline deposition, the fill-in deposition, support creation, and other printing parameters, while still giving you a choice of ranges. In the lower-cost systems, you may have to code these functions from start to finish.

Keep in mind that the nozzle may need to make frequent turns to handle corners and edges. Cornering can be a challenge in extrusion processes; how it is handled will affect build speed as well as the strength and dimensional accuracy of your parts. A concern during material deposition is that the nozzle could damage the material already laid down for the outline as it fills in the part. Also, your fill-in pattern needs to ensure that material is extruded close enough to bond layers to the outline as well as to each other well.

In general, material is extruded to either maximize precision or strength, depending on whether the material is deposited so that it just butts up against previous layers, or overlaps previous layers.

Many materials used in extrusion machines display an Anisotropic quality, where they will show different properties, such as strength, depending on the layer direction. Different layering strategies will give you different part strengths.

Be aware that as the nozzle fills in the part, there can be gaps as the nozzle changes direction, or moves into corners, or at the ends of a part. The higher end systems alternate material flow rate and speed to handle this issue.

The material should solidify quickly and bond to previously extruded material. Sometimes, this can be an added layer of complexity, as the build chamber is kept at a high temperature to ensure material flow.

Many parts built through extrusion require that you also design supports that will be built concurrently. With some extrusion systems, these supports are generated automatically through the software. Supports can be made of material similar to the build item or of a secondary material.

In some machines, the extrusion head alternates between part material and support material during deposition. Keep in mind, though, that the supports must be removed from the part without damaging the part.

Some like it hot

The material in the extrusion unit has to be in a form that can flow through the nozzle. Some systems use heater coils to keep the material in a flowable state.

The build chamber must also maintain a consistent temperature to ensure proper flow, but not be so high as to impede bonding. Depending on the extrusion system or material, the material solidifies based on heat or a chemical reaction. With chemical, the material reacts to some additive, be it a curing agent, a solvent, the air, or the process of drying.

Another factor affecting material dimension is gravity. Once extruded, gravity and surface tension may alter the final dimensions of the part.

Part cooling is not necessarily a linear process. You may see some dimension shifts and porosity develop simply because of cooling. Ensuring the proper temperature in the build chamber can reduce the likelihood of dimensional changes and porosity.

Makers of extrusion systems

Stratasys is the largest manufacturer of extrusion-based systems. The line includes the Dimension units, uPrint SE, as well as the Fortus line. The Dimension offering lets you control a few build parameters, and works with ABSplus material. The two printers in the Dimension line vary by build envelope size and layer thickness options.

The uPrint SE is a desktop version that has one layer thickness setting and one build material. These machines are primarily geared toward concept exploration. The Fortus line offers one of the largest build envelopes (3 x 2 x 3 ft), can print in different layer thicknesses, and can works with nine different materials.

Aside from Stratasys systems, other extrusion systems include the RepRap, MakerBot, BotMil, and 3DTouch units. The MakerBot and BotMil units typically come in kit form, although MakerBot also offers an assembled version.

The 3DTouch is a version of the Bits From Bytes printers, now owned by 3D Systems. It is available with one to three print heads, which will print parts in different colored thermoplastic material. The build area is about 275 x 275 x 210 mm (10.75 x 10.75 x 8.25 in.); the z-axis resolution is 125 microns.

There are good reasons why some extrusion-based 3D printing systems have a high purchase price. Their technology addresses the issues of build speed, part build accuracy and strength, production capacity, as well as maintenance to deliver as automated a build process as it technically possible at this time. Cost is only one consideration with 3D printing technology. MPF

3D Systems
www.3dsystems.com

MakerBot
www.makerbot.com

Stratasys
www.stratasys.com

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So let’s look at this complaint from the other side. If an affordable, accurate, fast, high quality, multiple material, highly reliable 3D printer is so easy to make, how come the likes of MakerBot, Bits from Bytes, RepRap, and so on have not introduced one to the market? After all, they have broken the less than $5000 price barrier. What is stopping them from introducing a higher quality, higher accuracy, faster, multiple-material unit that competes with the high-cost professional systems? Is it a need for profits? That does not seem to be influencing them.

Are patents being horded? Probably not. Such companies have demonstrated sufficient creativity and innovation to find ways around patented technology.

Could it be that developing an affordable, accurate, fast, high quality, multiple material, highly reliable 3D printer is not as simple as those who want one assume?

Developing any system that is accurate, fast, of high quality, highly reliable and affordable is neither easy, fast, nor inexpensive to do. The cost of components, like precision grade ball screws and servomotors, are factors. High-quality components are not cheap. Testing is a factor. The time and effort to ensure components play nicely together for reliable operation is always a challenge. These are just a few of the challenges engineers must overcome to develop a good product.

Technology helps reduce the costs of development, but there are costs, and they are not small. It isn’t corporate greed that did not give you the less-than-$2000 accurate, fast, high quality, multiple material, highly reliable 3D printer that you wished for. Your dream has not  come about because the technology is not there yet. Give it time.

Instead of lamenting that we don’t have a low-cost, super high quality system, we should be celebrating the engineering that enabled the introduction of a less than $10,000 high quality unit—this is a remarkable achievement!

(Note to those who don’t approve of corporate profits—if you own stock in a public company (i.e., a 401K plan), then you want a company to make profits. Their profits help fund your retirement. And if you work for a public company, you want profits—they pay your salary. Profit is a good thing.)

Leslie Langnau
llangnau@wtwhmedia.com

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Reserve your Webinar seat now at:
Here’s what you can expect:
You have an existing 3D concept?
You are looking for a flexible 3D scanner with dynamic referencing?
You would like to get a parametric 3D CAD?
This webinar explains how you can digitize fast, flexible and unique existing 3D concepts with a Creaform Handyscan 3D scanner. Then, you will see how the 3D scan data will be converted with Rapidform XOR into a parametric 3D CAD.

After registering you will receive a confirmation email containing information about joining the Webinar.

System Requirements
PC-based attendees
Required: Windows® 7, Vista, XP or 2003 Server

Macintosh®-based attendees
Required: Mac OS® X 10.5 or newer

We are looking forward to welcoming you to our webinar!
Regards,
Your Rapidform Team
www.rapidform.com

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This capability makes the inspection of complex setups, jigs, tooling, or prototyping faster and easier than before. With TRUaccuracy technology, it generates guaranteed high accuracy results, no matter the measurement environment (instability, vibrations, thermal variation, etc.) or operator skills. In addition, it can be used as a mobile measurement system for complex set-ups. Finally, it can be used for large or complex objects deformation analysis when used with Creaform’s VXtrack software module.

“We were receiving repeated requests from our MetraSCAN and HandyPROBE customers for a solution that would enable them to carry out demanding and specific applications such as deformation analysis on plane wings and presses or measure car chassis with their Creaform technology, but without having to actually move the CMM,” explained Jean-François Larue, product director. “Our R&D crew figured out a way to build upon our inspection systems’ accuracy, power and dynamic referencing capability and developed C-Link.”

Creaform
www.creaform3d.com

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From my engineering perspective, this is a sweet system. The package contains everything needed to produce models, including material (about 80 cubic inches of ABSplus in ivory and support material of SR-30 soluble) and a support-removal system. It is a genuine, patented Fused Deposition Modeling (FDM®) system, but it uses an innovative variation on traditional FDM material extrusion. The ABS material spool and the print head are integrated into a single package, called the QuickPack print engine. (QuickPack is recyclable.) Thus, every time you install new material, you are also installing a fresh print head, which significantly lowers maintenance needs. Loading this spool and print head package is easy, just like snapping in an inkjet cartridge on a paper printer. The ABSplus material lets you use this printer to develop form, fit, and function prototypes and end-use parts.

Now for some specs: The build platform is 5 x 5 x 5 in., which is just under the build platform of the uPrint SE. Mojo measures 25 in. wide, 21 in. deep, and 18 in. in height (64 x 53 x 46 cm), and weighs just 50 lb. Layer resolution is 0.007 in. (0.17 mm), which is the same as that of the Dimension Elite and the Fortus Production 3D Printer line. As with a paper printer, no training is needed to get it set up and running, and settings are selected at the host computer (Windows XP/7), not the printer itself. Mojo connects to the host computer though a USB cable.

Modeling operations are easy with the preprocessing software, Print Wizard, which helps you efficiently manage workflow. PrintWizard is like the Catalyst program used on other Stratasys machines. It provides a 3D view of printing pack, thumbnails of files, printer status preview, 3D orientation previews, and real-time auto-packing.

Support material removal is simple with the included WaveWash55. It is a self-contained, hands-free cleaning system, and it requires no plumbing. You put in your part, and it automatically removes any support material.

Todd Grimm, president of T. A. Grimm & Associates, had the opportunity to evaluate an early beta-test unit and noted: “Stratasys, who arguably started the revolution in 3D printing, is poised to shake up the market again with a complete professional system that breaks the $10,000 mark. With its new [3D printer], Stratasys is in a league of its own. It’s counter-intuitive to get a low-price product with high quality like this.”

“The name Mojo implies magic, which is how some describe 3D printing upon first witnessing it,” says Stratasys VP of Global Marketing Jon Cobb. “You can buy a less expensive 3D printer, but for the serious designer or engineer, Mojo is the lowest-priced product that offers professional-quality output, comes as a complete package system, and uses industrial-grade thermoplastic material. I expect this will be of interest not just to engineers and educators, but entrepreneurs and independent designers as well.”

If you don’t wish to purchase outright, there is a leasing option. You can lease a Mojo for $185 per month. But at this price, even purchasing managers would be happy. And even though this 3D printer is targeted specifically at professional engineers, not consumers, that lease price could make it mighty attractive to the consumer market.

Stratasys
www.stratasys.com

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The ExoHand is an exoskeleton individually adapted to the human hand. A 3D scan is made of the user’s hand, and then 3d printed from polyamide in a selective laser sintering (SLS) process.

Because all joints and their actuators exist in the form of an exoskeleton outside of the actual hand, the ExoHand can be worn over a human hand or an artificial hand made from silicone. There are eight pneumatic actuators that move the mechanical fingers. The fingers can be actively moved and their strength amplified. The hand movements can be registered and transmitted to robotic hands in real time. The exoskeleton structure supports the human hand externally and simulates the physiological degrees of freedom of the hand.

Eight pneumatic actuators move the exoskeleton. Sensors record the forces, angles and distances. Servo pneumatic open- and closed loop control algorithms allow precise movement of the individual finger joints. The ExoHand thus supports the various possibilities for gripping and touching, which a human hand has. The pneumatic components allow highly flexible and ergonomic control of the individual finger joints. High forces can thus be transmitted precisely in a small space and with a low weight without the system becoming rigid and restrictive.

The ExoHand can be used together with a brain-computer interface to create a closed feedback loop. It can help stroke patients who are showing the first signs of paralysis to restore the missing connection between brain and hand. An electroencephalography signal (EEG) from the brain indicates the patient’s desire to open or close the hand. The active hand orthosis then performs the movement. The result is a training effect, which over time helps patients to move their hand again without any technical assistance. Festo is working together with the Centre for Integrative Neuroscience at the University Hospital Tübingen on this subject.

Festo Corp.
www.festo.com/us

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At the recent Additive Manufacturing Users Group (AMUG) conference held April 23 through 26, the board  presented 18 Dinosaur Awards. The Dinosaur Award is a special award given in recognition to  industry veterans with exceptional skill that in turn contribute back to the additive manufacturing industry. For users of 3D printing/AM technology, these are the people you want to meet and get to know when you attend the conference.  They are an incredibly helpful resource for you.

The newly named dinosaurs are:

Fused Deposition Modeling
•             Duane Byerly, Xerox
•             Mike Littrell, C.ideas
•             Frank Medina, University of Texas at El Paso

Laser Sintering
•             Paul Bates, Reebok
•             David Bourell, University of Texas
•             Roger Cunningham, Integra
•             Scott Schermer, SC Johnson
•             Thomas Starr, University of Louisville

PolyJet
•             Robert Coleman, Mattel
•             Dan Mishek, Vista Technologies
•             Jason Lopes, Legacy Effects
•             Bradley Ruprecht, U.S. Army
•             Michael Zerbe, Newell Rubbermaid

Stereolithography
•             Bill Braune, Met-L-Flo
•             Larry Monahan, Becton Dickinson
•             Brad Palumbo, Phoenix Analysis & Design Technology
•             Ken Patton, Rapid Tech/Saddleback College
•             Sean Wise, RePliForm

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

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Roland DG President Masahiro Tomioka awarded the contest’s grand prize to the Lu Xun Academy of Fine Arts in North Eastern China.

Accepting the award were Du Haibin and Jiao Hongwei, industrial design professors at the university. “Our entry, a scale model tunneling machine, was part of a transportation-themed project that teaches students how to transform a 2D design into a 3D prototype,” Haibin said. “Winning the Roland award is important to our school as it provides visibility to our efforts and assists us in attaining funding for future projects.” As the grand prize, Haibin and Hongwei have selected a Roland EGX-360 gift engraver for the university.

The winning prototype was produced on a Roland MDX-540 milling machine and is comprised of several sections that were each milled separately from a variety of materials. Along its surface are many intricate contours, textures and details made possible by the precision of Roland subtractive rapid prototyping technology.

The Roland Creative Awards invited Roland businesses from more than 120 countries worldwide to submit their best work as produced on the company’s wide-format inkjet printers, vinyl cutters, engravers, 3D milling machines and other production tools. Entries spanned industries and applications, and included everything from signage, banners and vehicle wraps to personalized accessories, jewelry designs, decorated apparel and even tattoo art. The entire gallery of entries can be viewed online at www.rolandcreativeawards.com.

Roland DGA Corp.
www.rolanddga.com

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Creaform claims that these 3D scanners are the most accurate on the market, whether in lab or on the shop floor. They are easy to master and use, and they take only a few minutes to set up. Featuring Creaform’s TRUaccuracy technology, the scanners ensure highly accurate dimensional surface measurements, regardless of the measurement environment (instability, vibrations, thermal variations, and so on) or operator skills.

The combination of a MetraSCAN 3D CMM scanner and a HandyPROBE arm-free CMM makes a complete measurement system for points and surfaces, and enables geometrical and freeform inspection on the same part, with the same system.

The new handheld scanners are now offered in two versions:

• The MetraSCAN 70 offers optimal resolution. It suits projects where geometrical feature definition is key, such as sheet metal and tooling inspection.

• The MetraSCAN 210 offers fast measurement speed. Its increased stand-off and depth of field enhance scanning flexibility. It suits large surface metrology and large-scale reverse engineering requirements.

Both 3D scanners feature the same accuracy and they have been fitted with a new light carbon structure.

Creaform
www.creaform3d.com

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In its opening ceremonies, Charlie Norton, president of NCP Leasing, and Guy Bourdeau, sales manager at 3D Systems and AMUG treasurer, were honored with awards for years of support of the users group. Norton was recognized for his unsurpassed moral and financial backing of the users group over many years. He was also recognized for his role in spawning numerous new careers in the additive manufacturing industry. Bourdeau, who is stepping down from the treasurer’s position after 12 years of service, was recognized for his dedication, passion and financial stewardship.

Gary Rabinovitz, AMUG president, said, “Without Charlie Norton and Guy Bourdeau, our organization would not be what it is today. We are lucky to have many exceptional people that make AMUG extraordinary, but Charlie and Guy have shown dedication that is unmatched.”

At the annual Awards Banquet, the association named the winners of the 2012 Technical Competition. This competition recognizes excellence in additive manufacturing applications and skill in finishing additive manufacturing parts. A panel of industry veterans selected Mike Pierce of Hamilton Beach Brands for his food processor with sheet metal part as the top entry in the Advanced Concepts category.

For advanced finishing, the same panel selected Todd Reese of Realize Inc. for his fantasy character figure.

“We had 13 fantastic entries in the Technical Competition, making it difficult to select just two winners,” said Rabinovitz.

AMUG
www.am-ug.com

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The selector tool will help you reduce your ideal choices to two or three machines. At that point, you may wish to consult the manufacturer to conduct a test part or trial run.

The Make Parts Fast Rapid Prototyping configurator is an easy to use tool to help you narrow your choice of AM machine from the nearly 50 available machines.

While no system will have every convenience that you need, some machine processes require more processing on the back end, some on the front end; some require support structures, some don’t, you will find one or two that definitely fit your application.

Price is only one factor in your choice, and it is not the most important factor. Initial purchase price often does not take into account the cost of ongoing use, purchase of materials, training, waste, and so on. Price is not necessarily an indicator of quality or value; that all depends on your needs.

We spoke with each manufacturer about the selection criteria listed in the selector tool. Information on machine size, weight, laser parameters, and so on are available in nearly all brochures; so once you’ve narrowed your choice, that information is easy to find.

Use of the selector tool is free, and you can select for a couple of items to try it out. After you’ve input a few parameters, though, you will be asked for some basic information and asked to create a password. This step helps ensure that your searches are private and specific to you.

Leslie Langnau
llangnau@wtwhmedia.com

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AMUG board (left to right): Todd Grimm, Tom Sorovetz, Brad Palumbo, Gary Rabinovitz, Tim Gornet, Vince Antewenter, Bret Border and Mark Barfoot. Photo credit: Ed Winters Photography

The Additive Manufacturing Users Group (AMUG) is a unique group consisting of originators and users of additive manufacturing (AM) systems, including 3D printers, SLA, extrusion, inkjet/polyjet, and laser sintering systems. It’s a good organization to get to know as you will have access to the people who designed these systems as well as the people who work with them constantly—they are a good resource for users of the equipment.

AMUG is the organization that grew out of the 3D Systems users group. The new AMUG is open to any user of any additive manufacturing, 3D printing equipment. I found this most recent conference, held the week of April 23, 2012 at Costa Mesa, Calif., to be impressive, both in its coverage of this technology, it’s thoroughness, and it is professionalism. This is a conference all users of AM equipment should consider attending.

At the conference the current board announced its 2012-2013 board of directors. Board members are selected at the annual business meeting.

The board will plan and organize next year’s AMUG Conference, which will be held in Jacksonville, Florida, from April 14 – 18, 2013, at the Hyatt Regency Jacksonville.

The 2012-2013 AMUG board members are:

- President: Gary Rabinovitz, Reebok International

- Vice President: Bret Bordner, Laser Reproductions

- Vice President: Mark Barfoot, Christie Digital

- Secretary: Brad Palumbo, Phoenix Analysis & Design Technologies

- Past President: Tim Gornet, University of Louisville

- Event Manager: Tom Sorovetz, Chrysler Group LLC

Each of these board members is a long time user of AM systems.

Gary Rabinovitz, who will be serving his second term as president said, “We are coming to the close of a very successful and well received 2012 conference. Attendees have commented that this is the best event they’ve ever attended. That was made possible with the hard work and dedication of the outgoing board. In the new board, I see the same passion, devotion and enthusiasm, so I am confident that the 2013 conference will be even better.”

The newly formed board announced two appointments: Vince Anewenter, Milwaukee School of Engineering, was named as treasurer, and Todd Grimm, T. A. Grimm & Associates, was named as additive manufacturing industry advisor.

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. Xu Xiaoshu, Farsoon Hi-Tech, will serve as the group’s Asian liaison.

Additive Manufacturing Users Group (AMUG) is an organization that educates and advances the uses and applications of additive manufacturing technologies. AMUG members include all commercial additive manufacturing technologies for companies such as 3D Systems, EOS, Objet Geometries and Stratasys. AMUG meets annually to provide a forum for technical presentation on processes and new technologies. This information addresses operation of additive manufacturing equipment and the applications that use the parts they make.

AMUG
www.am-ug.com

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This session will reveal how intellectual property contributes to design and drive the technological innovation that helps shape the physical world through additive manufacturing.

“Pathways to Innovation: Intellectual Property Rights in Additive Manufacturing” will provide an overview of patents, copyrights, trademarks, trade secrets and IP agreements while demonstrating how State of Art and Patent Mapping techniques can establish technical trends and new product development opportunities for today’s manufacturers. Other IP issues to be covered include:

• Identifying intellectual property rights and jurisdiction

• Establishing freedom to operate without infringing upon intellectual property rights of others

• Filing for patents to protect and own the rights to a design

• Handling non-competition, development and employment agreement

• Exposing areas for new product iterations and manufacturing growth

“Nearly every facet of additive manufacturing touches on intellectual property,” says Cass. “Intellectual property allows manufacturing engineers to understand the market, review the competition’s products and look for new ways to offer improvements, design alternatives, and competing products and services.”

Cass holds a B.S. in mechanical engineering from Worcester Polytechnic Institute and a J.D. from Western New England University School of Law. He has tried cases in state and federal courts since 1988. He has been co-chair of Cantor Colburn’s Litigation Department for the last ten years. Cass combines his extensive trial experience with his engineering education to present technically complex matters to judges and juries, as well as, international audiences through speaking engagements.

“Additive manufacturing technologies are rapidly gaining acceptance in several diverse industries and are being used in the earliest stages of product design from prototype to production,” says SME business development manager Gary Mikola. “It’s important that manufacturing professionals understand how to protect their intellectual property and avoid infringing on IP rights of others.”

To attend this presentation, register for a conference pass online

RAPID
sme.org/rapid

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Since it was to be a children’s toy, safety was also a big concern. They first contacted GKS Services Corp. to perform high-accuracy 3D laser scanning on the hand-built one-of-a-kind prototype and create a 3D digital model necessary for further development and manufacture.

The 3D laser system scanned the rudimentary prototype completely and accurately in less than an hour. Design issues were easily addressed in the CAD solid model GKS created from the scan data. Because laser scanning is an efficient method to obtain accurate 3D data of complex shapes, the whole design and development process took only a couple of months to complete, versus many months with traditional manual measurement methods and 2D design drawings.

The company was so satisfied with the scanning results that they contracted with GKS for a more complex process to further develop the sbyke product and bring it to market: Finite Element Analysis (FEA) of the metal frame to assure mechanical fidelity and safety of the vehicle. Results of the virtual FEA analyses allowed the company to choose the optimal material to meet required strength, resilience, and safety standards.

Test riders determined that the sbyke’s competitors were “no match in maneuverability” and that the sbyke was superior when riders executed five-foot turns. The novel rear-steer™ system enables such precision carving maneuvers. Steve Wilson describes the sbyke experience: “The thrill of riding a sbyke is like the unforgettable sensation of skiing down freshly-powdered slopes.”

Sbyke USA, LLC, has won awards for its patented sbyke® from both Popular Science and Parenting magazines. Receiving top honors in Popular Science’s “Wheel Wars” competition and Parenting’s “Best in Play,” the sbyke® was also a hit at the 2011 American International Toy Fair in New York.

The full spectrum of GKS’s engineering service saved the company time and money in the product development phase and in the manufacturing process. The speed of laser scanning plus the expertise of GKS engineers resulted in fast, continuous service from professionals who had a deep multi-layered understanding and experience with the breadth of the entire project.

Laser Design Inc. / GKS Services Corp.
www.laserdesign.com/contact_a.php

Sbyke USA, LLC
www.sbyke.com

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ProJet™ 3500 printers use 3D Systems’ latest patented Multi-Jet Modeling (MJM) print technology, including its production-grade print head, advanced material management and intuitive touchscreen interface, to produce high definition functional plastic parts and wax patterns with excellent performance, detail and surface quality.

The extended range of new VisiJet® print materials available for the ProJet™ 3500 cover such applications as high-impact, durable plastic for functional testing, cast-friendly wax for rapid-foundry production, and specialized materials for the digital production of jewelry, dental prosthesis, dental models and medical implants. This printer comes with a five-year printhead warranty.

3D Systems
www.3DSystems.com

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By including everything needed to start building parts, the Dimension 3D Print Packs give buyers the assurance there will be no surprises. (Photo: Stratasys Inc.)

The Dimension 3D Print Pack includes the 3D printer and everything needed to print parts, including startup supplies and a support-removal system. Monthly lease packages are available in the US at $560 for the Dimension Elite 3D Printer and $610 for the Dimension SST 1200es 3D Printer. Leasing is not available outside the US.

Print Pack purchase prices are $31,900 for the Dimension Elite and $34,900 for the Dimension SST 1200es.

“The Dimension 3D Print Packs offer a complete solution to begin building thermoplastic parts,” says Stratasys Product Manager Mary Stanley. “Customers can purchase a system with the assurance that there will be no surprises or hidden costs.”

The Dimension SST 1200es 3D Printer builds parts as large as 10 x 10 x 10 in., while the Dimension Elite prints finely detailed models up to 8 x 8 x 12 in. In addition to the printer, the packages include:

• SCA-1200 Support Removal Tank

• 1 Cartridge Ivory Modeling Material

• 1 Cartridge Soluble Support Material

• 1 Case of either Ecoworks or WaterWorks cleaning agent

• 6 Modeling Bases

The Dimension 3D Print Packs are available through a global network of Stratasys resellers.

Dimension
www.DimensionPrinting.com

Stratasys Inc.
www.Stratasys.com

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Xpress3D was founded in 2001 with the premise that most of the people that can benefit from rapid prototyping have yet to discover it.

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We own a Stratasys Dimension Elite Rapid Prototyping machine and enjoy the freedom and functionality that it has to offer the many industries we service.  The Stratasys Dimension Elite is ideal for printing intricate 3D product mockups and functional models of parts such as medical devices, mobile electronics and precision instruments.  This machine utilizes ABSplus™ production-grade thermoplastic and prints models from the bottom up with precisely deposited layers of modeling and support material. Our prices for Rapid Prototyping, Engineering, Design and Cad are among the best along the Colorado Front Range due to low overhead costs, our high quality work and our timely delivery.

We offer Mechanical and Electro-Mechanical Design services using Pro-Engineer Wildfire 4.0 CAD software.

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At 3D-CAM, we have spent a good deal of time, energy, and money to insure that our facilities operate at a first class level. We are proud of our reputation, which is why we take every aspect of our business so seriously.Our own engineers continuously test our apparatus by manufacturing test parts that can be used to assure the most accurate calibration possible. We do not begin manufacturing prototypes for customers until we are confident that our machinery is performing at the highest standards. When those standards have been met, the prototyping process takes place in a controlled environment under careful supervision.

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APP has changed the way companies quote and purchase rapid prototype and rapid   manufactured parts. APP is not an online broker selling a fast online quote system only to outsource your project. APP owns the equipment used to manufacture your
parts and employs the staff that will work with you on your project from start to finish. Our Free Instant Online Quote System is a convenience tool that puts you in control of the quotation process. Our In-House manufacturing ensures the highest quality and
our 100% quality guarantee makes any transaction with APP risk-free.

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Rapid Prototyping or 3D Modeling is the process of quickly engineering prototypes or mockups of what a product system will look like. These prototypes are typically used to test the product’s technical feasibility or consumer interest.

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Our team is made up of a group of mechanical designers that like to push the CAD systems in our daily design work. We get excited when we find a better way of doing things in 3D and are encouraged to share our knowledge gains with the group every week in the Tuesday morning staff meeting.

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As a business unit of Stratasys, RedEye’s primary technology is fused deposition modeling, an additive manufacturing process that offers unparalleled repeatability, meaning that your first part looks and functions exactly like the next.

RedEye customers also have access to a number of premium services, such as Ready Part – a part smoothing process designed specifically for RedEye by Stratasys.

RedEye became ISO 9001:2008 Certified in January 2011, the first company in the additive manufacturing industry to become ISO certified. With quality systems and processes in place, we understand and can address your needs quickly.

The industries we serve include: aerospace, architecture, automotive, business machines, consumer products, electronics, medical devices, entertainment, interior design, toys and many more.

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Five Star Plastics was one of the pioneers in the rapid prototyping industry. Evolving from one of the nation’s largest rapid prototyping services in the early 1990’s, our knowledge of plastics product development has only strengthened.

Over the years, we have retained our knowledge base, edge on technology, primary staff, and equipment mix. We’ve improved our systems and tightened our focus on the details of customer service and quality of our plastic parts. Our Engineers manage your project through all phases of the development cycle.

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In the 2D Desktop Publishing and Printing world, I got used to the idea that once a page was designed on the computer, you just press “Print” and out comes your end product. I knew it wouldn’t be that easy in the 3D world, but at the time, I didn’t know what I didn’t know.

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First and foremost, note the fact that we’re building. We’re not maintaining, we’re not preserving, we are growing. It’s a challenging, but exciting time, to be a part of Spectrum Plastics Group.

Being profitable means we’re able to create jobs, have benefits to our employees, and the means to innovate, improving capabilities and working conditions while investing in new technologies. Our Customers want us to be around year after year… and placing programs at Spectrum Plastics Group is an investment in their future, as well as ours, and our Customers enjoy the confidence that we will continue to grow with them, and provide them with new services in the future.

Sustainable means our focus is building a business that will last. That means investing in new technologies that will allow us to be competitive in the future, and it means having the flexibility to change directions when our Customers and market conditions demand it. Spectrum Plastics Group is here for the long term.

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Prototype Casting Inc. has been in business for over sixteen years, working with aluminum, magnesium, zinc, stainless steel and various other alloys.  We specialize in rapid casting, getting castings for testing form, fit, and function in as little as 2 days, depending on geometry and complexity.  This will help you get a new product to market faster, with less development expenses.

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Founded in 1966, the company initially specialized in model making for a wide variety of consumer and industrial products. Over the years, Paramount has expanded its scope to apply advanced technology in all aspects of product development. Today, Paramount offers a comprehensive array of services. In addition to rapid prototyping and rapid tooling, Paramount sets the pace in direct digital rapid manufacturing of precision parts from 3D CAD digital input, utilizing advanced laser sintering (LS) technology. Paramount’s services also include injection molding, full-scale manufacturing from domestic and offshore facilities as well as assembly and packaging. Paramount is a premier prototype manufacturer.

Paramount’s team of product development specialists is among the industry’s most respected experts in successfully applying advanced technology to expand the scope of rapid prototyping, rapid tooling and new direct digital digital rapid manufacturing of precision parts from 3D CAD digital input, a landmark development that eliminates the costly and time-consuming tool-making process and dramatically accelerates the product development process.

Paramount’s principal prototyping, tooling, manufacturing and assembly operations are located at its headquarters and prototype manufacturing complex in Langhorne, Pennsylvania, just outside of Philadelphia, PA, USA. Product design and engineering services are provided by its affiliate, Definitive Design, also located in Langhorne. Offshore manufacturing is provided by another affiliate, TTM Technologies, with operations in Southeast Asia.

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A brief history:  A team of engineers and scientists from Boeing & Rocketdyne started On Demand Manufacturing (ODM) to rapidly manufacture aerospace grade hardware. The company was established under Boeing’s Chairman’s Innovation Initiative, an incubator for new business ideas. Spawned from a concept white paper in January 2001, the ODM business was incorporated as a wholly owned Boeing subsidiary on June 6, 2002 and was subsequently acquired by RMB Products, Inc., in April of 2005.

RMB Products offers extensive material knowledge that will allow for greater applications to emerge via ODM.  RMB, as an existing supplier to most major aircraft OEM’s, brings expertise with other manufacturing processes, including rotational molding, injection molding, & compression molding.

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These are just a few of the wide variety of projects that helps NRRI meet its mission of fostering economic development of Minnesota’s natural resources in an environmentally sound manner to promote private sector employment.

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These technologies provide great financial benefits and save significant amounts of time for applications in design iterations, prototyping, tooling and production. Mydea can turn concepts and designs into physical parts in under a week and sometimes within the same day. In addition to the company focus on 3D CAD modeling and production, Mydea also supports companies in all aspects of product development from concept to high-volume production.

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Known worldwide for pioneering direct parts from CAD utilizing direct metal laser sintering (DMLS), Morris Technologies offers unmatched capacity and capability.  Our Research and Design Team advances current technologies by offering new materials and developing new hardware.  They also investigate, acquire, and integrate new product offerings to maintain MTI’s leadership position.  Allow us the opportunity to positively impact your product design cycle.

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Modellabs.com and Model Labs LLC are a full-service mechanical and architectural prototype company that provides high quality prototypes and models at an affordable price.

www.Modellabs.com and Model Labs LLC were founded in 2008 in Aliso Viejo, CA.  The company was started and run by industry professionals in the aerospace engineering and residential architecture fields.  Model Labs LLC is dedicated to providing the right custom product at the right price the first time.

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Our craftsmen collaborate with clients throughout their project cycles as team members to ensure the highest quality final results.  Whether providing consultation, electronic file conversions and development, rapid prototypes or fully-developed large scale models, we strive to meet every client’s needs in a time-efficient manner.

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