3D Printing, VR & AR: HP Teams Up with Yale to Develop Blended Reality Applications for Educational Settings http://ift.tt/2mQvgG4 In 2014, HP not only announced their entrance into 3D printing, but also introduced the concept of “blended reality” with the unveiling of the Sprout, a platform that, among other features, allows users to translate physical objects into 3D models simply by placing them on a 3D scanning bed in front of the Sprout computer monitor. Once the object has been scanned into the virtual world, the user can manipulate it with his or her hands or a stylus, and then 3D print it once any changes have been made. It’s an incredible technology that HP has been further developing over the past two and a half years, and in November, the company began a collaboration with Yale to research and develop blended reality applications. Over the past six months, professors and students from multiple Yale institutions have worked in teams, using Sprout Pros, augmented reality, virtual reality and 3D printing to test use cases for blended reality in classrooms, labs, and other educational settings. The collaboration will continue through October 2017, after which the two institutions will publish a monograph entitled “Making the Future: 3D in Academe.” It will be co-authored by Gus Schmedlen, VP of Worldwide Education at HP, and John Eberhart, principal investigator on the project and member of Yale’s School of Architecture faculty.
The individual research projects include:
The final results of the projects will be published in October at the EDUCAUSE Higher Education conference in Philadelphia. The Yale collaboration is only one of the educational initiatives that HP is involved in at the moment; they’re also working on the “Reinvent the Classroom” project with Microsoft. The project includes the Digital Promise Global initiative as well as the Learning Studios network. We’ve seen some other brilliant ideas come from academics using the Sprout to design blended reality educational tools, and we can’t wait to see what comes from the final Yale projects in October. You can learn more about the HP/Yale Blended Reality collaboration here. [Source/Images: HP]
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 09:29AM
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Empa Researchers Use 3D Printed Fruit-Shaped Molds to Develop Artificial Fruit Sensor http://ift.tt/2nkcX8i You know what they say, an apple a day keeps the doctor away! I’m one of those people who has to have fruit every single day – whether it’s bananas for breakfast, or a big helping... View the entire article via our website. Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 08:54AM 3D Printer Distribution: Ultimaker's North American Resellers Up By 350%, Nano Dimension Hits Q1 Beta Customer Goal http://ift.tt/2ohX1Eq 3D printers are making waves with customers around the world – but it all hinges on their getting from manufacturers to customers. Some companies rely on resellers, while others take a more direct approach in their distribution. This week is full of good news for those interested in some of the dynamic names in desktop 3D printing as we’ve heard about forward progress in getting their products out into the world, both in terms of resellers and in a quickly growing beta program. Last April, Dutch company Ultimaker crossed the ocean once again to open their third North American office, based in Boston. It was a big move, accompanied by the naming of John Kawola as the company’s North American president, but it’s a move that has paid off, as resellers of Ultimaker’s popular desktop 3D printers have increased by 350%. It doesn’t hurt that the company’s latest model, the Ultimaker 3, introduced in October, has been such a hit, with customers extending from the automotive and aerospace industries to healthcare, education and more.
Ultimaker is so ubiquitous that it’s easy to forget that they’re a relatively young company, having been established only six years ago. They’re especially new to the professional market, having spent the majority of their time so far as a beloved supplier to hobbyists.
Ultimaker’s hobbyist base shouldn’t worry about being left behind, despite the recent news that the open source company filed for their first patent. An expanded market means more accessibility for all of Ultimaker’s customers, professionals and hobbyists alike. As the company’s resellers continue to multiply, more customers will have local access to not only products but service and support, thanks to Ultimaker’s intensive reseller training program. Ultimaker now has 26 resellers in North America, including: You can see the full list of Ultimaker’s resellers here. Speaking of companies that have been having a good year so far, Nano Dimension has announced that they’ve delivered yet another one of their DragonFly 2020 electronic circuit board 3D printers to a new beta customer. If it sounds like we just reported on this, that’s because we did; this delivery makes six so far this year – the same number of beta customers that the company delivered to in all of 2016. With this delivery, Nano Dimension has met their 2017 Q1 target. While Nano Dimension has not revealed the name or location of the latest customer, they identified the recipient as one of the 10 largest contract manufacturers in the world. The news of this latest delivery comes less than two weeks after Nano Dimension delivered two of the printers to customers in Israel within a few days of each other: Syqe Medical, maker of medical marijuana inhalers, and an unnamed PCB design bureau. The growing base of beta customers is supplying Nano Dimension with valuable feedback about the DragonFly 2020 while benefiting from faster product development, greater intellectual property security, and, of course – if they haven’t chosen to remain anonymous – bragging rights.
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 07:51AM Proto Labs Adds PolyJet Technology to Industrial 3D Printing Service http://ift.tt/2nweqJw Rapid prototyping and low-volume production facility Proto Labs, located in Minnesota, recently won its third straight Frost & Sullivan 2017 Manufacturing Leadership Award, which was a high point as founder and board chairman Larry Lukis announced his imminent retirement. The digital manufacturing company began expanding its 3D printing capabilities a couple of years ago, and currently offers CNC machining, injection molding, and 3D printing production services to its customers, and just announced that it has added PolyJet technology to its available industrial additive manufacturing service processes. We have been eagerly anticipating this addition, as Proto Labs Americas VP and General Manager Rob Bodor noted at SOLIDWORKS 2017 last month the upcoming beta launch of this capability.
Proto Labs made the announcement today at the Advanced Design & Manufacturing Expo in Cleveland. The PolyJet process will “jet out” liquid photopolymer droplets from multiple jets, and are UV cured the second they hit the build platform. Once the print job is done, the support structures are removed from the object with water and a special chemical solution, but no other post-processing or finishing is required. Engineers and product designers who use this method will be able to manufacture overmolded and elastomeric prototypes, without having to invest in additional tooling. Parts produced through the PolyJet process come out with smooth surface finishes, and are able to support complex geometries, with flexible features. Some of the more common applications for this process include soft-touch and two-tone aesthetics, seals and gaskets, and multi-material prototypes with both rigid and elastomeric materials, like medical devices and components. Users can choose a range of hardnesses, and combine multiple colors and materials into a part; Proto Labs’ materials selection includes “multiple Shore A hardnesses of tear-resistant Agilus 30for increased durability.” Proto Labs now offers a total of four 3D printing technologies:
The company uses several different 3D printers, with large build sizes and quick production times; for customers who wish to use their PolyJet process, Proto Labs utilizes its Stratasys Objet260 Connex3 and Objet350 Connex3 3D printers. The maximum build size for PolyJet parts is 13.4″ x 13.4″ x 7.9″, with a layer thickness of 30 microns (minimum feature size 0.012″). Digital Clear, Digital Black, and Digital White colors are available for Shore A hardnesses of 30, 40, 50, 60, 70, 85, and 95, and rigid. Customers can upload their own 3D CAD design files using Proto Labs’ proprietary software, get a quote instantly, and receive their 3D printed parts in just a few days. If you’re in Cleveland today or tomorrow, stop by the Advanced Design & Manufacturing Expo – you can visit Proto Labs at Booth #717 to learn more about its PolyJet process, and its other available rapid manufacturing technologies.
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 06:51AM
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As EnvisionTEC Reaches 15 Years, CEO Al Siblani Reflects on the 3D Printing Company's History and Future http://ift.tt/2nhhV4S EnvisionTEC turns 15 years old this year, and while it has a big celebration planned, the prolific 3D printer manufacturer has no intention of sitting back and taking things easy for its birthday. Over the past decade and a half, EnvisionTEC has become well known as a leader in the dental and jewelry 3D printing markets, and for good reason – the company was the first to commercialize Digital Light Projection (DLP), the preferred 3D printing technology of both industries. It has branched out significantly since then, however, and that’s what EnvisionTEC really wants to emphasize this year. In addition to the jewelry and dental 3D printing markets, EnvisionTEC also has a hand in bioprinting, with its 3D Bioplotter playing a vital role in cutting-edge medical research such as the development of hyperelastic 3D printed bone, biocompatible electronic medical devices, and even, possibly, 3D printed organs in the future. (You can read more of the research being conducted with the 3D Bioplotter here.) In addition, EnvisionTEC offers two heavy industrial 3D printing technologies: Viridis3D Binder Jetting technology, for the robotic additive manufacturing of sand molds and cores for foundries; and Selective Lamination Composite Additive Manufacturing (SLCOM), for carbon fiber composite printing. Last year saw the launch of several new printers and even new technologies, including SLCOM and cDLM, or Continuous Digital Light Manufacturing – plus the increasing popularity of EnvisionTEC’s proprietary large-scale vat polymerization technology, 3SP. It’s certainly been a successful, and extremely busy, 15 years, and now as the company reaches its crystal anniversary, CEO Al Siblani shares his thoughts about how EnvisionTEC got to where it is today. Why did you start your own 3D printer company?
How did you get the idea to bring your first 3D printer to the jewelry market?
How did you get from from DLP in 2002 to your current product offerings, which span bioprinting and 3SP to a machine that 3D prints composites and a robot that does sand castings?
You were recently invited to speak about one of your new technologies at AERODEF in Texas. How did you come up with the idea for the SLCOM, which additively manufactures woven fiber composites?
What do you think makes EnvisionTEC unique among 3D printer manufacturers?
So what’s next for EnvisionTEC? Again, the company has no intention of slowing down anytime soon, and will be introducing several new products at RAPID 2017, which will be taking place in Pittsburgh from May 8 to 11. 3DPrint.com will be there, and we’re looking forward to getting a first look at what the company has to offer, as well as sharing it with you. You can find more about what EnvisionTEC has planned for its 15-year anniversary here, and take a look at the video below: VIDEO
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 06:08AM Northwestern University Researchers 3D Print Flexible Objects with Simulated Lunar and Martian Soil3/29/2017
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Northwestern University Researchers 3D Print Flexible Objects with Simulated Lunar and Martian Soil http://ift.tt/2oyWcq9 Just a few days ago, scientists from Fotec revealed that they had 3D printed small structures from simulated Martian soil. The structures, a small conical dwelling and a portion of a wall, are miniaturized replicas of what humans may one day create from the actual soil of Mars once we finally reach its surface. The Fotec group, which undertook the research for the European Space Agency, isn’t the only research team to be studying 3D printing with simulated extraterrestrial regolith, however – far from it. As space scientists from around the world focus on the potential of travel to the moon and Mars in the next few decades, 3D printing is at the top of everyone’s list – particularly the use of native lunar and Martian soil to 3D print structures in which humans will be able to actually live and work. If humans are to stay on the moon and Mars and study their surroundings, they’re going to need somewhere to stay, and it’s become fairly certain that those who land on the lunar and Martian surfaces will be 3D printing their own habitats out of the soil around them. Before that can happen, though, we need to be sure that’s doable, and without access to actual soil from the moon or Mars, scientists have been practicing with simulated materials that replicate the composition of their faraway counterparts as closely as possible. The Fotec team used soil taken from a volcano in Hawaii to simulate regolith from Mars, and a research paper recently published by a group of scientists from Northwestern University details their work with materials designed to simulate both lunar and Martian soils. The Northwestern team points out that the entirety of the work done with 3D printing simulated Martian and lunar regolith thus far has focused on hard materials, which are obviously necessary, but no one has yet tried using the soils to create and print soft, flexible materials, which will also be important in terms of meeting the needs of people in space. To create a flexible 3D printing material, the Northwestern team used the same simulated Martian soil as Fotec: JSC MARS-1A, as well as JSC-1A, a simulated lunar regolith also taken from volcano soil. The two are somewhat similar in composition, being composed mainly of silicates, aluminates and iron oxides, but morphologically they’re quite different: lunar regolith simulant (LRS) is composed of irregular, jagged powder particles, according to the researchers, while the Martian regolith simulant (MRS) is made from particles that are rough but rounded. Both materials, however, have similar 3D printable and rheological (flow) characteristics once they’ve been mixed with other materials to turn them into 3D printing “ink.” The team created the material using a process that they’ve previously used to make ceramic, graphene, metal and metal oxide, and mixed particle 3D printing inks. The soil, sifted to remove larger particles that could interfere with extrusion, was mixed with an elastomeric binder and a solvent.
As the excess DCM evaporated, the inks thickened to a printable consistency that resembled the ceramic and metal inks the team had created with the same method in the past. They’re also shelf-stable, and can be stored for several months prior to use. When extruded with an EnvisionTEC 3D-Bioplotter, the MRS and LRS inks demonstrated fast print speed – over 150 mm/s – and required no time to dry before they could be handled. The material was viscous enough that successive layers could span gaps in earlier layers – as long as the first layer adhered successfully, which is tricky enough on Earth with any 3D printing material, without the reduced gravity environments we’ll be facing on the moon and Mars. The Northwestern team was able to get the material to adhere well at the first layer by printing on sandpaper and silicon carbide paper, which allowed for both strong adhesion and easy removal upon completion.
The resulting 3D printed structures showed impressive elasticity, able to withstand significant deformation before returning to their original shapes. You can read the full details of the study, entitled “Robust and Elastic Lunar and Martian Structures from 3D-Printed Regolith Inks,” here. Authors include Adam E. Jakus, Katie D. Koube, Nicholas R. Geisendorfer and Ramille N. Shah. Dr. Shah will be presenting a keynote in May at RAPID + TCT, along with Dr. Sue Jordan, discussing medical/biomedical applications for 3D printing technologies. Dr. Shah’s team at Northwestern has been behind some incredible advances we have been following, from materials to fuel cells to 3D printed hyperelastic bone.
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 04:49AM
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3D Printer Put to Work in Developing Cancer-Measuring Transducer http://ift.tt/2nh4G4c According to the American Cancer Society, in 2017 alone, an estimated 1,688,780 new cancer cases will be diagnosed in the US, and I’m guessing that number is pretty high for other countries as well. So it’s always good to hear about new research and projects centered around early diagnosis and cancer treatment. Medical device contractor the ITL Group (Integrated Technologies Ltd.) recently teamed up with King’s College London (KCL) to develop a cancer imaging project, which will assist with the planning and monitoring of cancer treatment through better initial identification, and sizing, of cancer tumors in the body. The project is funded by the European Commission’s Horizon 2020 framework, the biggest EU Research and Innovation program ever, with nearly €80 billion of funding available over a total of seven years (2014 to 2020). It is seen as a means to create jobs and drive economic growth, and has provided funding for multiple projects that use 3D printing, such as the MESO-BRAIN Initiative’s work with emulating accurate brain activity, and the collaborative Bionic Aircraft research project. The cancer imaging project brings together a consortium of 20 companies, including among them ITL Group, KCL, Philips, and Siemens, to combine engineering developments with Magnetic Resonance Imaging (MRI) in order to make Magnetic Resonance Force (MRF) Imaging for new cancer diagnostics applications, which could potentially give doctors a non-invasive way to both diagnose and measure cancerous tumors. ITL Group joined as a medical device design, development and manufacturing partner in 2015; once early project elements were completed this year, it became an active consortium participant. The consortium has been tasked with producing three prototypes: one each for brain, breast, and liver cancer patients. KCL came up with the initial hardware design: an advanced vibration transducer that measures cell traction forces and interstitial fluid pressure. ITL Group will continue to develop the original design, taking into account KCL’s thoughts on making the device more aesthetically pleasing and compact, easier to handle, and more efficient. The company plans to make several prototypes, which will be ready for trials and presented to Harvard Medical School this June. ITL has been hard at work, improving upon the original vibration transducers, and continuing to develop the technology that could help doctors determine the best course of treatment for cancer patients. ITL has been using a 3D printer for a trial period during this project, and it’s not the first time we’ve seen 3D printing used to make an impact in MRI research and development, from 3D printed MRIs for patient education, to a 3D printed gas delivery system for pulmonary MRI research. The technology works well with this particular project: since the transducer will be put to work in an MRI scanner, it’s imperative that all of its components are plastic. 3D printing additionally allows for a fast turnaround, offering another benefit to progress in development.
ITL has worked on a great deal of commercial projects over the past 40 years, and partnered with many of the top universities in the UK. But the grant from Horizon 2020 allows Hollands and the rest of the team the time and resources to experiment more freely, in order to really “push the design to its limits.”
[Source: ITL Group]
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 03:57AM Topology Optimization Eases Additive Manufacturing Design -- A Few Questions For: Frustum http://ift.tt/2ngYgCc Frustum and Siemens announced a new partnership at the beginning of this week, as topology optimization comes to NX software customers. While additive manufacturing offers the unique ability to create incredibly complex geometries, the right tools are still necessary for the job in the form of the right software that can make best use of what 3D printing hardware can potentially create. As Siemens continues to step up its game in this field, it turned to Frustum and its Generate platform to enhance optimization capabilities. Because sometimes “it just works,” cutting out the complexity in design can also cut back on barriers that have been in place in such processes. This is exactly what the Siemens NX module for Design Topology Optimization is set to address, and we wanted to know more on this front. We turned to Frustum’s CEO, Jesse Coors-Blankenship, to get the larger picture on what this collaboration can offer to design in AM, as we had A Few Questions For him to learn more. What barriers do you see in the way of design for additive manufacturing processes? How does this solution work to take those barriers down?
Aerospace, automotive and heavy machinery are noted as industries set to particularly benefit from this integrated software solution; what makes it a standout for these fields?
How has the partnership with Siemens been for Frustum?
How does Frustum address the idea of topology optimization as it relates to additive manufacturing?
What else should we know about the partnership/software/Convergent Modeling?
We will certainly be staying tuned here at 3DPrint.com! Don’t forget you can also benefit from Coors-Blankenship’s expertise as he leads a course on the voxel in our Advanced Design for 3D Printing course, starting next week: “The session will focus on cutting edge use of optimization techniques in design and engineering for additive manufacturing.” Who better to learn from than a leader in design optimization? We’re looking forward to continuing to share his expertise and insights. Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 03:03AM
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Metal 3D Printing is Poised to Become a New Manufacturing Paradigm, But Adoption Is Slow http://ift.tt/2oaEsFo Although metal 3D printing may seem like a new technology, it’s been around since the 1980’s, and used chiefly in production of high value, highly engineered, complex parts and prototypes. Companies have been pouring R&D dollars into 3D printing to manufacture industrial parts with geometric complexity in metal shapes at lowered costs. Metal 3D printing is now used in a wider range of metal manufactured parts in the aerospace, automotive, and medical device sectors. To get a better view of the metal 3D printing market, Sculpteo surveyed more than 400 metal manufacturing companies. We asked respondents about their short- and long-term expectations for metal 3D printing, how they are using it now and the benefits they’re realizing, or what’s preventing them from implementing the technology. With any metal 3D printing process, it is important to understand they not all the same. In fact, there are five different technologies that fall under two categories: Direct Methods, which consist of creating the object directly in metal; and Hybrid Methods that combine 3D printing with another technology to create metal objects. Before we get into the survey findings, here is a summary of each of the leading metal 3D printing technologies and methods. Direct Methods When metal 3D printing becomes a common manufacturing process, it will be due to the increasing adoption of powder bed technology. A tray filled with metal powder is heated locally to sinter the raw material. Next, a cart deposits a new layer of powder, and the process keeps repeating as necessary. There are two approaches to leveraging powder bed technology. The first is laser melting, also known as known as DMLS, SLM or DLP for use when working with titanium, stainless steel or aluminum. A high-temperature Ytterbium laser melts locally the metal powder, to create the object layer by layer based on a CAD file. The parts endure a high thermic stress during production. To reduce stress, and attain higher mechanical properties, a heat treatment is often applied after production. With density up to 99.5%, ideal applications for this technique are prototyping and production of parts that are highly resilient, and ideal for mechanical parts such as propellers, gears, etc. in industries such as automotive, aerospace and electronics. The second is Electron Beam Melting (EBM), which is ideal for working with titanium and cobalt alloys. The powder is heated locally by one or more electron beams to create the object layer by layer according to the CAD file. The process must take place in a vacuum environment to prevent oxidation of the material. EBM is faster than laser melting technologies but slightly less accurate than the laser-based techniques because of the width of beam. The temperature during the process is evenly distributed to provides good strength properties. The size of the object is limited by the size of the machine, which (today, at least) is relatively small. Another Direct Method is Laser Metal Deposition (LMD) which is ideal if you’re working with raw steel or aluminum for repair work on engines and other larger objects. LMD is the most appropriate Direct Method technology to use for repair works because it is easy to add material to an existing object and still achieve precision work. LMD resembles the plastic Fused Deposition Modeling (FDM) because the feedstock is brought and fused at the same time through a nozzle. The feedstock can be either powder or wires, and the heat source can be a laser, an arc or an e-beam. The substrate can be positioned either in a stationary position (3−axis systems) or on a rotating stage (5+ axis systems) to increase the ability of the machine to process more complex geometries. At the end of the process, the object is detached from the platform. The fourth Direct Method approach is Binder Jetting, where an inkjet head deposits a liquid binding agent on the powder according to a CAD file layer by layer. Multiple heads can be used to speed up the process. At the end, the object is extracted from the unbound powder, cleaned and prepared for the consolidation process in a hot isostatic pressing to add the complete mechanical properties of the material and to avoid porosity. The hot isostatic pressing cures the object uniformly with heat and pressure, enabling the binding agent to melt so the powder can form a homogeneous structure. Binder Jetting allows for very large, fast and cheap 3D printing, and is ideal for working with stainless steel with infiltrated bronze where it’s possible to print large sized prototypes, architectural structures, as well as gears and complex prototype parts. Hybrid Methods Manufacturers working with brass, sterling silver, gold or zinc to make jewelry and ornamental parts that do not need strong mechanical properties will commonly use the hybrid method of wax casting. The process begins by creating a 3D print a very precise wax model, and covering it with plaster or other materials to create a mold. The metal is then melted to liquid state and poured into the mold. The heat and molten metal dissolves the wax and fills the mold. When cool, the mold is carefully opened or broken to extract the part for finishing. Another hybrid method is Ultrasonic Sheet Lamination, where a roller filled with metal foils displays the material on a cutting bed to a laser that cuts the layer according to the 3D file. Then an ultrasonic consolidation welds the sheets together, and excess material is cut away. It’s used for shaping multiple materials like aluminum, brass, copper, stainless steel or steel, primarily for rapid prototyping and POC objects. Which Metal 3D Printing Method is Right for Which Application? These descriptions of the main metal 3D printing technologies might seem overly rigid, but it’s important to choose the one best suited for your application. To summarize: for mechanical parts that need to be highly resistant, use the powder bed direct 3D printing methods: DMLS and SLM. If you need a lower accuracy and a lower cost, for prototypes for example, you’ll use technologies like EBM, Binder Jet, or the hybrid sheet lamination method. For objects that need high aesthetic qualities (like jewelry), you’ll probably go towards wax casting metal 3D printing. Side Bar Survey Says: Metal Adoption Taking Off With such a variety of approaches that enable manufacturers working with several different types of metals, and the cost- and time-savings benefits it offers, manufacturers are starting to embrace metal 3D printing. Our survey found about a fifth (21%) of respondents use metal 3D printing. Of that group, most use 3D printing as a complement to traditional production modes (41%). The split between those who use hybrid methods (33%) and those who use 3D printing as a replacement for traditional production means – 33% to 26%, respectively. The most commonly-used technology is DMLS (32%), followed by SLM (23%), with stainless steel (49%), aluminum (29%) and titanium (19%) the three most common materials in use. The primary benefits respondents expect to realize by implementing metal 3D printing processes are:
While adoption of metal 3D printing is taking off, there are a few key limitations preventing more manufacturers from implementing metal 3D printing: lack of in-house expertise (28%) and cost (20%). Of those that do leverage metal 3D printing a majority (75%) seek to overcome these limitations by partnering with an external design and printing service instead of building 3D printing capabilities in-house. These survey data show that what’s keeping manufacturers from investing in metal 3D printing—a lack of expertise and tools to reduce the cost of metal 3D printing since a lack of expertise increases the number of trials needed before a successful part can be produced. As with any new technology, there is a learning curve before a technology can be used at its full potential. Overall, metal 3D printing is evolving into a technology that gives virtually any manufacturer, no matter its size or industry, the ability to manufacture objects how, when and where they are needed. Metal 3D printing is a game-changer that enables engineers and designers to produce and sell products by skipping traditional distribution networks. Identifying which technique and method is the best-suited to your project will enable any manufacturer to realize the benefits metal 3D printing offers. Side Bar Three Design Tips for Successful Metal 3D Printing Whether you decide to build 3D printing capabilities in-house or work with a partner, there are several design rules to follow, particularly when using powder bed metal 3D printing techniques. The first two pertain to print orientation. You want to avoid overhang (unsupported down facing surface) and keep in mind that an up facing surfaces will have a better surface finish. The minimum wall thickness recommended is 0.15 to 0.25 depending on the chosen material. Print orientation is also an important consideration when determining the accuracy and surface roughness of the part. In the X and Y orientation, the accuracy is located between 5 to 15 μm whereas in the Z orientation, it is located between 16 to 100 μm. Surface roughness can vary between 15 – 50 μm depending on the material you choose. If your design requires down facing surfaces, prefer curves and try to reduce angles. The self-supporting transition or radius should be less than 8 mm to be correctly 3D printed. It means that the diameter of your curved down facing surface should be less than 8 mm. Another important consideration is mass. Less mass means less printing time, less powder, and a lower cost. It also lowers the thermal stresses. Lattice and cross section help to reduce mass. when designing for metal 3D Printing, one must focus on the function and the critical surface. Finally, to limit printing failures, consider the part orientation. Choose a minimum self-supporting angle, and respect the following angle measures: Titanium Ti64= 45° Stainless Steel= 55°. You should also avoid sharp transitions and edges for better 3D print parts.
[All images: Sculpteo]
Clément Moreau is the CEO of Sculpteo, which has been working with materials and technologies increasingly including metal additive manufacturing Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 01:57AM Custom Prototypes Attempts to Claim AMUG Prize for Second Year with Stunning 3D Printed Stained Glass Window http://ift.tt/2oxIxQn I remember doing several projects in elementary school that involved “stained glass” – e.g., tissue paper dyed with watercolors, or other clever simulations. Of course, no one would ever mistake these childhood projects for anything close to actual stained glass, but they were still pretty, and fun to do. Stained glass itself is a complex and difficult art, but there’s nothing quite like it. A Toronto-based 3D printing service bureau, however, has come pretty close to replicating the actual look of stained glass – with 3D printed plastic. In December, the team at Custom Prototypes shared a story with us about how they transformed a beloved cartoon character into a 3D printed figurine for a young girl. The company loves a unique challenge, and shortly after they presented young Makayla with her lumberjack figurine for Christmas, they turned their focus to coming up with an entry for the technical competition at the recently-concluded Additive Manufacturing Users Group (AMUG) 2017 conference. Last year, Custom Prototypes took first place in the Advanced Finishing Category of the AMUG technical competition with a stunning 3D printed reproduction of Vincent van Gogh’s Starry Night. Determined to hold on to the title this year, the team decided to challenge themselves and their SLA 3D printers further by attempting to create a full-sized stained “glass” window from plastic.
The window was designed in SOLIDWORKS software and printed in four separate pieces. Then the real challenge came – figuring out a way to impart the delicate jewel tones of stained glass to the printed plastic. Creating the appearance of colored glass was difficult to do without losing the transparency of the resin, and several ideas were tried and scrapped after practicing on pieces of spare plastic. Paint was too opaque, so a dye was used, which took a great deal of time and care to keep the different colors from bleeding into each other. After the dyeing was complete, a thick coat of clear gloss was applied. Lead lines were then added by laying down a metallic spray, adding a black top coat, and texturing it with steel wool. The finished image, of a golden-haired angel in a rose-colored gown, serenely playing a violin, is virtually indistinguishable from a true stained glass window – especially after it was mounted to an ornate, arch-shaped frame, also 3D printed with an SL600 3D printer from ZRapid. The stone look of the frame was achieved by applying different types of aerosol paints with a sandstone coating on top.
We’ve seen a couple of other artists take on the challenge of creating stained glass effects with 3D printing, but not to the scale or complexity level of Custom Prototypes’ piece. We have yet to see actual 3D printed stained glass, but as glass 3D printers get closer to becoming actually accessible, I suspect it won’t be long before someone tries it. The AMUG 2017 conference wrapped on on March 23, but the winners of the technical competition haven’t been announced yet. I’d say that Custom Prototypes has a pretty good shot at reprising their victory, though. The team has also been busy creating other art lately, including a beautiful 3D printed reproduction of another van Gogh classic, “Self-portrait with Grey Felt Hat.” You can see the stained glass process for yourself below: VIDEO
Printing via 3DPrint.com https://3dprint.com March 29, 2017 at 12:50AM |
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