3D Printing "Silences" Dissention

Soundproofing 3D Print (3Dprint.com)

At RapidMade, there's nothing we enjoy more than designing and printing a creative solution to solve a client's challenge.  So we like to follow stories that describe how 3D printing has improved someone's quality of life...

Noise in multi-unit dwellings is an ongoing source of annoyance.  My daughter and her college suite mates are currently battling their RA about allegations that they make too much noise when they walk.  While an extreme example, most of us can easily think of at least one time when traveling sound created neighborly conflict.

At least one researcher, Foteini Setaki, believes the answer relies on 3D printing custom 

"sound absorbers...  based on a principle called passive destructive interference or PDI. It’s the intimate relationship between geometry and acoustic performance that makes PDI absorbers work, and she uses advanced additive manufacturing techniques to build unique, freeform geometries to test and understand the acoustics underlying the performance of various materials and shapes."

Through these trials, Setaki hopes to apply the lessons learned to engineer sound absorbing barriers that are tailored to specific spaces such as lecture halls and gymnasiums.

Unfortunately, the timing won't solve my daughter's dilemma... maybe a cheap carpet will have to suffice.

Digital Life Goes Live with Microsoft's HoloLens

During its recent Windows 10 Conference, Microsoft showcased its HoloLens prototype.  According to one attendee, PC Magazine's Dan Costa, 

“HoloLens is (an) augmented-reality headset that allows you to mix the virtual world with the real world. Put on the headset and the glass screen can project a digital overlay on top of the physical world. It can be as simple as a Skype window or as complex as a 3D model of a jet engine.”

While I think the technology is phenomenal, HoloLens' ability to create 3D models using its companion 3D modeling program, HoloStudio, excites me the most. Costa witnessed a Microsoft engineer create a koala equipped with a rocket pack.  And I mean witnessed; he could actually watch what the designer was seeing - and creating - on HDTVs stationed nearby.  Reportedly, the engineer "walked around the hologram, grabbing tools from a holographic control panel, and then used a combination of voice and gestures to build and shape the koala."  

And it didn't stop there... dozens of 3D prints designed using HoloStudio and then manufactured on a 3D printer were on display.

Other product capabilities include interactive holographic gaming and Skype - which allowed the other party to see and interface with what the caller was viewing - imagine Technical Support walking, not talking, you through a fix.  The press corp even got a bonus "out-of-this world" experience when the HoloLens 'transported' them to Mars - where they were able to roam the landscape accompanied by a virtual tour guide.

Imagine the possibilities.  Design could be truly interactive and collaborate.  And dare I say possible for even the less tech savvy among us.  

Could 3D Scanning and Printing Improve Splint Production and Fit?

This week, I graduated from a soft cast to a hand splint, custom made from low-temperature thermoplastic and Velcro.  The process was an interesting mix of art and science.  My Occupational Therapist, who specializes in hand injuries, regularly creates them "while you wait."

The procedure began with a gross sizing using a paper pattern placed against my arm to determine how much thermoplastic material would be needed.  After the two sheets were cut down, each was heated in a hot water bath and then carefully molded against my arm to obtain a form fit - a snug, protective shield whose edges roll away from the skin to prevent chafing.  Later the two splints were joined by a series of strategically placed Velcro strips.  Unfortunately, I encountered pinch points which prompted a return visit this morning... alas, as I type this post, I suspect there will be more tweaking needed. 

So I find myself debating whether the fitting process could be improved using a 3D scanner and printer.  Theoretically, a doctor's staff could quickly scan the patient's hand in the office to create a model that could then be used to make the splints.   The final fitting would then be completed during the first OT appointment, allowing the patient to begin therapy during the initial visit instead. 

But would the additive manufacturing approach be much more accurate than the current in-office process?  I suspect it might be more expensive (but I won't know until I get the bill) and since the splints are only worn (hopefully) for about four weeks, insurance companies might not approve.  But given how tender the injured body part can be, anything that minimizes the amount of handling required during the fitting would be welcomed.

If the 3D Screw Fits, Wear It

Screws and plate used to repair a hip fracture (image credit 3Dprint.com

I wish RapidMade's recent blogging silence was due to the holidays.  Alas, I was sidelined by a bad fall down a steep flight of stairs.  Shortly after I broke my foot, shattered my wrist, and learned I needed surgery, I remembered a conversation I had with an NIH representative at the FDA's meeting on 3D printing.  He expressed frustration that, despite additive manufacturing being more widely adopted in medicine, many procedures were not benefitting from its customization.  Ironically, he specifically mentioned the screws used in orthopedic surgery, saying it was frightening that patients' bones were modified to accommodate the screws and not vise versa.

I was in too much pain to think to ask my surgeon if my standard-issued screws and plate matched my bones well enough or ask how often fit is a problem, so I will have to speculate on what factors have slowed its adoption. 

First, I suspect screws could quickly and easily be cut to fit. But if that is true then why would surgeons ever alter the recipient's bones instead?     

I also wonder if the simple screw and plate designs make 3D printing them more expensive and time consuming than traditional manufacturing, especially if custom fittings are rarely required.  Interestingly, I just read about a hip surgery where Dr. Bagaria repaired a hip fracture by taking CT scans to create a 3D print that allowed him to plan the surgery and customize his approach.

“Using the model, Dr. Bagaria was able to create a 7-hole reconstruction plate that was pre-contured. They then used the model to carry out a surgical simulation prior to taking part in the real thing. The surgeons were able to drill the screw trajectories, measure the screw lengths required, and confirm the positions of the plate, all with the help of the model” (3Dprint.com).”

Perhaps a major reason 3D printed screws aren't in great demand is that surgeons don't often have CT scans of the broken bones and are therefore less likely to know fit will be an issue until the patient is on the operating table.  Honestly, fixing most broken bones is fairly straight foward - and truthfully the xrays were painful enough, I don't know if I'd have welcomed getting CT scans as well.  Having said this, I was told my wrist was worse than expected, requiring more work than expected, so who knows?

I won't know my outcome until Monday when the cast comes off, but I'm guessing screw size won't be a problem.  I'll just be happy to type with two hands.                                                 

Mouth Scanned for Same-Day Crown

Image Credit:  http://www.cockeysvilledentist.net/

Recently, I broke yet another tooth which required - of course - another crown.  But this time was different.  Today, after my dentist did the standard tooth preparation, a licensed technician scanned my tooth using a hand-held 3D scanner and then downloaded the CAD file onto the computer right next to my chair.  I got to watch her manipulate the 3D model - the dental office knew I have a 3D printing company, so they humored me.  She explained how she first determines the borders and then calculates the bite (using a scan of the tooth's chewing mate).  She then proceeded to determine the best tooth shape to ensure a proper rough fit.

The procedure used was a great example of a hybrid manufacturing process because once the file was ready, the tooth was made using subtractive instead of additive manufacturing.  A block was milled to the correct size and then further reduced by hand through successive mouth fittings.  Once the ideal fit was achieved, the uncured porcelain crown was baked for a mere 20 minutes and then glued permanently (hopefully) into my mouth.

It would have been really cool if it had been 3D printed, but honestly, this process took less time, so for now, that's good enough for me.

Skill Gap Recognized as Challenge to Additive Manufacturing

BY THE NUMBERS

17.4 million: Jobs supported by manufacturing in the United States

12: The percentage of manufacturing in the nation's GDP

$77,000: The average salary of manufacturing workers

$60,000: The average salary of entry-level manufacturing engineers

17: The percent of Americans who view manufacturing as a viable career choice

Source: National Institute of Standards and Technology, courtesy of Orange Count Register

My parents and brothers own a small box-making plant in Pittsburgh. When I was young, we would play in the scrap piles, sweep the floors, and do odd jobs to pass the time while our parents worked.  Because of this unique experience - and because Pittsburgh was a major steel producer - I knew that manufacturing was a good career choice - if you could get the work.  Unfortunately, it earned a bad reputation in the 70s, 80s, and 90s as more companies offshored and consolidated their production facilities.  I myself left the field to teach when I had to oversee Nabisco's Pittsburgh plant closing.

This experience is one reason I'm very excited about Additive Manufacturing (3D printing).  It uses advanced technology, requires high-skilled labor and conserves raw materials... things I hope will attract another generation of U.S. makers... but first, this generation will need to learn the skills required to design, scan and make 3D printed prototypes, parts, tools and models. Increasingly, schools, like some in Orange County, recognize the importance of ensuring enough workers have those skills.

According to Orange County Register reporter Tomoya Shamira, the Dean of the UC Irvine School of Engineering Dr. George Washington describes his students' experiences,

"Students at UCI receive training in a host of additive manufacturing technologies such as selective laser sintering and stereolithography."  

And this is fueling an interest in manufacturing... 

"CI engineering professor Marc Madou said 3D printing is helping young people become interested in manufacturing, partly because they can turn their design into a physical model quickly."

But not all jobs will require an engineering degree which highlights the need to partner with local community colleges as well...

"While advanced technologies are changing the manufacturing landscape, there’s growing demand for experienced welders and machinists as U.S. companies are bringing their manufacturing back home. Two-thirds of manufacturers said they couldn’t find qualified workers, according to a survey conducted by the Manufacturing Institute and Deloitte Consulting."

 

3D Printing Lets Visitors Enjoy Ancient Ruins Without Ruining Them

Image Credit:  3dprintingindustry.com

Weeks before the Egyptian Revolution, I had the opportunity of a lifetime to visit Cairo.  When I visited the pyramids, I was shocked to see so many people climbing all over them.  I had imagined we wouldn't be allowed to touch, let alone scale, something so ancient and valuable.  

Such access has taken a toll on another Egyptian site:  the burial chamber of the Pharaoh Tutankhamun.  

"It was the constant changes, caused by the humidity of the breath and temperature of the visitors that had started to make the paint on the walls crack, and the plaster to fail.

It was decided that if something wasn't done, the chamber would deteriorate to the point where valuable artifacts would be lost."

Fortunately, 3D printing has come to its rescue.  A Spanish-based 3D printing company undertook a five-year project to thoroughly 3D scan the tomb's interior and 3D print an exact replica.

Perhaps one of the most extensive examples of using additive manufacturing to preserve history, the Egyptian project is just one of many such efforts.  For years, the Smithsonian Institution has also been scanning and printing a number of its artifacts:  Smithsonian X 3D allows individuals to remotely "navigate, explore and manipulate 3D collection objects"  And other museums have begun to reproduce valuables to make exhibits more interactive and accessible.

FDA Considers Approach to Additive Manufacturing of Medical Devices

Patient-specific printed splints are used to treat life-threatening thoracic constrictions.  Work done at the University of Michigan involves laser sintering bio compatible, bio absorbable materials. 

The official purpose of this week's FDA-sponsored workshop was "to provide a forum for FDA, medical device manufacturers, additive manufacturing companies and academia to discuss technical challenges and solutions of 3D printing."  In other words, the FDA wants "input to help it determine technical assessments that should be considered for additively manufactured devices to provide a transparent evaluation process for future submissions."

The FDA is trying to stay current with advanced manufacturing technologies that are revolutionizing patient care and, in some cases, democratizing its availability...  When a next-door neighbor can print a medical device in his or her basement, that clearly has many positive and negative implications that need to be considered.  

Ignoring the regulatory implications for a moment (I'll get to those shortly), the presentations were fascinating.  In particular, I was intrigued and inspired by the Post-Printing speakers and Clinical Perspectives projects.  

STERIS representative Dr. Brodbeck cautioned that the complex designs and materials now being created with additive manufacturing make sterilization practices challenging.  How will the manufacturer know if the implant is sterile or if the agent has been adequately removed or if it is suitable? Some materials and designs, for example, cannot tolerate acids, heat or pressure. 

Wake Forest Presenter Dr. Yoo shares his institution's research on bioprinting

Dr Boland from the University of Texas El Paso shared his team's work on 3D printed tissues. Using inkjet technology, the researchers are evaluating the variables involved in successfully printing skin.  Another bio-printing project being undertaken at Wake Forest by Dr. Yoo involves constructing bladder-shaped prints using bladder cell biopsies and scaffolding.  And Dr. Liacouras at Walter Reed discussed his institution's practice of using 3D printing to create surgical guides and custom implants.

Since RapidMade creates anatomical models, one project, near and dear to my heart - pun intended - is work done at Children's National Hospital by Drs. Krieger and Olivieri.  The physicians use printed cardiac models to "inform clinical decisions" ie. evaluate conditions, plan surgeries, and reduce operating time. 

As interesting as the presentations were, the subsequent discussions were arguably more important.  In an attempt to identify and address all significant impacts of additive manufacturing on medical device production, the subject was organized into pre-printing (input), printing (process) and post-printing (output) considerations.  Panelists and other stakeholders shared their concerns and viewpoints on each topic in an attempt to inform and persuade FDA decision makers.

An interesting (but expected) outcome was the relative positions of the various stakeholders. Well establish and large manufacturers proposed validation procedures:  material testing, process operating guidelines, quality control,  traceability programs, etc.  Independent makers argued that this approach would impede, if not eliminate, their ability to provide low-cost prosthetic devices.

Coming from the highly regulated food industry, I completely understand and accept the need to adopt similar measures for some additively manufactured medical devices.  An implant is going into someone's body, so the manufacturer needs to evaluate and assure the quality of raw materials, processing procedures and finished product.  But this means, as in the food industry, the manufacturer needs to know the composition of materials.  Suppliers cannot hide behind proprietary formulations.  If manufacturers are expected to certify that a device is safe, they need to know what ingredients are in the materials they are using.

Hopefully, the FDA will also agree with the GE representative who suggested that manufacturers should be expected to certify the components and not the process.  What matters is whether or not the device is safe, not what process was used to make it.  Another distinction should be the product's risk level.  Devices should continue to be classified as I, II or III and that classification, not the process used, should determine its level of regulation.

If you are interested in submitting comments to the FDA on this topic, email them to  http://www.regulations.gov .

Laika's "Boxtrolls" Features 3D Printed Puppets

The Many Faces of Shoe (Photo Credit:  Laika)   

Portland-based Laika, recently released its third feature, The Boxtrolls.  What viewers may not realize is the stop-motion production studio, creator of Coraline and ParaNorman, relies heavily on 3D printing to create the puppet characters in its films.  To achieve this feat, Laika employs a rapid prototyping department that overseas the production of prints using color binder jetting technology.  As Brian McLean, director of the department,  described in an interview, this is often easier said than done.  Getting an outcome we are more familiar with than we'd like, he

“likend the printing process to the rendering process in CG - sometimes you input code and something you didn’t quite expect comes out... And (to make oversight more complex) the printers aren’t necessarily consistent from print to print.”

As a result, achieving the desired color and appearance requires some experimentation and a lot of expertise.  In fact, the article mentioned that Laika has developed so much industry knowledge about material and printer performance, it is sometimes contacted by the manufacturer for advice.  In between takes of course...

Mortgage Lender Offers Novel 3D Printed Give-Away as Incentive

Image and Article Credit:  3DPrint.com

I remember a time when banks gave away toasters and other items to win customers' business. One notoriously offered firearms!   Adding a new twist to an old idea, the Swiss Bank Zurcher Kantonalbank recently rewarded a mortgage applicant with a 3D print of the customer's home. Using the home's blueprint to create a 3D model, Zurcher Kantonalbank had the model printed into a replica it then mounted on wood with a plague bearing the bank's name.  That's creative and memorable advertising...  And I can understand why the bank might go to such lengths.  Housing in Switzerland is among the most expensive real estate markets in the world.  Maybe this idea will catch on with other lenders and real estate brokers.

3D Scans and Prints Show Patients What to Expect from Plastic Surgery

Dr. Avsar holds facial mask (Photo Credit: 3Dprint.com

If you've ever had plastic surgery - or had to decide whether to have it - you understand the anxiety of not knowing what you'll look like.  After being diagnosed with nasal skin cancer , I had MOHS surgery to remove the basal cell carcinoma, and while the surgery itself was successful, the skin flap used to cover the site left an obvious scar and collapsed (misaligned) nostril.  Subsequent procedures improved its appearance, but my plastic surgeon is recommending rhinoplasty to correct the deviated septum.  

Having faced (pun intended) three surgeries and post-op care, I'm not keen to go through it again - although it'd be nice to breathe better.  Yet I worry about what it will look like.  Drawings can't capture or convey exactly how my nose (with its thickened scar tissue and pulled nostril) will appear.

But now, a cosmetic surgeon is 3D scanning his patient's faces, manipulating the resulting 3D models to depict their post-operative appearances and printing "before" and "after" masks on a 3D Systems Colorjet printer.  What makes this such an effective tool is that it is a replica of the patient in his or her current and future states, reducing the unknown.

RapidMade is Moving October 1!

Our new home is just across the street from the PSU Business Accelerator at 2828 SW Kelly

After three years at the PSU Business Accelerator, RapidMade is moving on October 1 into a larger space across the street:  2828 SW Kelly Avenue, Suite B.  The 1744 square foot facility includes three offices and a conference room in the front and a large production area in the back which will house our 3D printers, post-processing equipment and additive manufacturing operations.  While we loved working at the Accelerator, our business growth and the industrial nature of our work made staying there difficult...  We've learned that carpets and 3D printers are NOT a good combination. 

Our improved manufacturing floor plan will allow us to better manage our 3D printing, product design, rapid prototyping, reverse engineering, pattern and tool making, finishing and coating, and traditional manufacturing services.  And equally important, we now have the room to add staff as needed.

Ironically, the only things changing in our address are the street name and suite number.  Our old address - 2828 SW Corbett Avenue Suite 121 will now be 2828 SW Kelly Avenue Suite B.

Our suite is the single-story section of the building that is closest to SW Corbett Avenue and our former office

Will 3D Printing Replace or Augment Craftsmanship?

Grand Concourse Restaurant:  Photo Credit:  Muer.com

In my hometown of Pittsburgh, there is a beautiful restaurant, the Grand Concourse in Station Square.  It is the site of the former Pittsburgh and Lake Erie Railroad Station.  My grandfather was a cabinet maker for the railroad, and my grandmother once told me, years later, that one of his accomplishments was the refurbishment of its ornate ceiling.  A section of the elaborate crown molding, made of marble I believe, had been destroyed.  My grandfather created a replica out of wood which was such a close match, one couldn't pick out the faux molding.  I imagine the hours of labor that went into this important project and wonder how my grandfather would have reacted to our now being able to quickly scan the molding and print a copy overnight.

Many believe that the craftsmanship of that generation has largely been lost, replaced by mass produced materials.  But perhaps 3D printing will spur a high-tech revival.  Access to 3D scanning and additive manufacturing technologies already allow us to re-create artifacts that have been lost to time.   RapidMade often gets requests to replicate facades and other architectural features.  We once printed replacement stove handles for an antique oven.  And now, digital designs and additive manufacturing enable artisans to imagine and create exotic and unique objects that would have been difficult, if not impossible, to be made in my grandfather's time.

Custom 3D Models Effective Tool to Plan and Discuss Surgeries

Image Credit:  3DPrint.com

Last month, a relative underwent what was expected to be a routine ablation procedure:  9 1/2 hours and 3 a-fib episodes later, the surgery finally finished.  Despite CT scans, X rays and EKGs, the surgeons encountered "structural issues" that complicated the operation.  I thought afterward if they had had a 3D print of his heart, they might have anticipated and planned contingencies based on what they saw.  Apparently I'm not alone in this believe...

A masters student from Drexel, Jason Kirk, released a study, "3D Printed Cardiac Imaging Data," that suggests that patients and surgeons benefit from reviewing patient-specific 3D printed replicas of their organs prior to consenting to surgery.  Feedback given to the researcher indicates that a majority of surgeons find 3D models more effective than 2D illustrations in sharing information and facilitating discussions.  According to Kirk, “Cardiac anatomy replicas can be used to facilitate Doctor/Patient communication and supplement contemporary visualization techniques by providing accurate three dimensional data which offers additional haptic and spatial feedback specific to the patient’s anatomy and pathology.”

But how is the replica made?  CT scans and MiMiC software are used to create custom 3D prints that can include cut aways to show the internal structure of the organs.  And the practice is becoming more popular:  RapidMade recently created lung models for a research center interested in using them for patient education.