RapidMade's Manufacturing Team Expands with Summer Heat

RapidMade has expanded its manufacturing staff this summer.  Please join us in welcoming:

Drew Christensen

All the way from the distant land of Wisconsin is our new Shop Technician, Drew Christensen. He's been a mold maker, fab tech, model maker, and everything in between. You can find Drew kayaking, fishing, or camping when he's not doing side woodworking projects. His ideal job would be what he's doing now, working with his hands. We're happy to have  Drew join the team.

Max Poroj

Max Poroj, a specialist in CNC programming, machining, and manual programming, is our new Mill & Machining Operator. When he's not taking wrestling with his 5 kids, he loves to go camping with them to enjoy the outdoors. He's a big fan of dark science fiction, 3D modeling, and listening to audio books and podcasts in his free time. Welcome to RapidMade, Max!

Cameron York 

Our newest 3D Print Tech, Cameron York, is an Oregon-native packaging manager and 3D modeler. He spends his off hours playing Frisbee golf, camping, and skateboarding. His dream job would be to own a 3D modeling studio. We're excited to see what you can create, Cameron!

Ryan Colindres

Ryan was recently promoted to the position of Shop Supervisor. He grew up cage-free, Oregon-raised in Eugene and is an Industrial Designer. When he's not running the shop, he's creating, modeling, and designing; he craves adventures. You can find Ryan biking, swimming, hiking, and "camping, baby". Ryan hopes some day to be a serial entrepreneur. Congratulions, Ryan!

When Are Casting and Molds Better than Injection Molding or 3D Printing?

It's important to remember that 3D printing is a means to an end, so we always have to ask ourselves, based on what a client wants to achieve, what's the best path to take to get there.  Sometimes, the answer isn't 3D printing.  One alternative is casting and mold making which is worth considering when you want:

• Low to medium part quantities - from 10s to 1000s
• Production-quality finishes with the look and feel of injection-molded parts
• To spend less -
  • Typically lower unit costs than direct part printing
  • Fraction of the tooling cost required for injection molding
• To cut lead time from months to weeks for tooling compared to injection molding
• To select:
  • Food-grade and medical-grade materials
  • Elastomers to rigid plastics ranging from 20A - 90D durometer
  • Other materials such as silicone, plaster, concrete and other composites
• To create electronics housings, gaskets, cosmetic parts, displays and low volume production

To see if this approach is suitable for your project, check out these Design Guidelines.

RapidMade CEO Promotes STEM Careers to Skyview High School Students

RapidMade supports nConnect, a non-profit organization that connects professionals and schools, to promote career planning and college preparation. 

It's always great to get back into the classroom!  On Friday, RapidMade's CEO Renee Eaton  participated in nConnect's Speed Networking event at Skyview High School in Vancouver.  Students especially enjoyed seeing all of the 3D printed objects she brought.  And they loved hearing how additive manufacturing is changing the fields of medicine, aerospace, marketing and manufacturing - and how important STEM professionals are to the industry's growth and success.

These events are always a lot of fun for presenters and participants.  Based on the questions asked, there were many highly motivated first year students.

Afterward, Renee had a chance to meet the school's Manufacturing faculty and see their bank of desktop 3D printers.

HP Jet Fusion: Have it All - Better, Stronger, Faster, Cheaper Prints

Life is often filled with compromises.  If you want something faster, you have to pay more or settle for less.  If you don't want to pay a premium, then you have to wait or compromise on quality.  Not any more...

The HP Jet Fusion's cutting-edge technology allows us to provide:

• Superior surface finish, feature detail and mechanical properties to other printed plastics including Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM)

• Isotropic mechanical properties and fully dense parts ensure balanced strength and durability in every axis

• High chemical and heat resistance

• High part accuracy of +/-0.008"

• VESTOSINT is a modified polyamide powder (Nylon, PA-12 - click here to see data sheet.) 

Get durable, accurate and repeatable nylon products at or below machined and injection-molded prices - in a fraction of the time.

Let us show you how.

K9 Helm Shields Hard-Working Dogs from Serious Injuries

RapidMade often has the privilege of working with some extremely innovative designers and entrepreneurs.  We love collaborating with clients to fast track their ideas from conception to production. We never tire of seeing revolutionary products being 3D printed!  One of our favorites is K9 Helm whose Trident helmets safeguard dogs committed to serve and protect others...  If you love dogs, you will love this video and the company's credo...

“The Trident wasn’t designed on a computer. It was hand sculpted as a flowing, organic shape that works harmoniously with the anatomy and movement of the dog. Technology has its place, of course. Original forms are scanned, transformed into CAD models, and given physical form using HP Multi-jet Fusion 3D printing — ideal for small batch production where high precision and maximum durability are desired.

​

The result is our Trident K9 Tactical Helmet. Made for dogs who engage in dangerous work, it’s our tribute to them and a constant reminder to us — never stop innovating, never compromise, and never, ever give up.”

NAS Pax River Event Features Mobile 3D Printing to Promote STEAM

NAWCAD's FabLab will be open to visitors at Technology and Arts Expo (DCmilitary.com - photo credit)

We were living in Maryland just when interest in 3D printing was being fueled by technological breakthroughs and extensive media hype.  A consortium of additive manufacturing advocates there preached its potential to accelerate business development if educators insured a ready and willing workforce.  One locale heeding its message is Southern Maryland, home to the Naval Air Station (NAS) Patuxent River.  To promote interest in STEM, NAS Pax River volunteers will host an event this Saturday at the Technology and Arts Expo at the Patuxent River Naval Air Museum.

A featured attraction will be NAWCAD's FabLab:

“a place where makers can take their ideas from concept to prototype for projects involving rapid prototyping, accelerated modeling and collaborative learning opportunities.”

— http://www.dcmilitary.com/tester/news/local/pax-volunteers-to-exhibit-lend-a-hand-at-naval-air/article_45b72b1d-984d-544d-a7f2-5fadbd0a9f18.html

The FabLab houses 3D printers, CNC mills and laser cutters and other prototyping equipment.

This region, nestled between the Potomac and Patuxent, is often better known for its access to the Chesapeake Bay than advanced technology - despite the expansive naval base.  Hopefully these enthusiastic advocates will change that perception - almost makes me miss Maryland. 

HP Jet Fusion Delivers Injection Mold Quality without the Mold

3D printed part

Mold no more!  For small and medium-batch production runs, slash cut part cost and accelerate delivery speed with HP Jet Fusion:

• No tooling costs
• Limitless iterations
• Design freedom
• Lower engineering costs
• Collapsed delivery timelines
• Production-quality parts

Contact us for a quote.

RapidMade Announces HP Multi Jet Fusion Services

In honor of National Manufacturing Day 2017, RapidMade demonstrates commitment to continuously invest in technology, training and increase our knowledge of advanced manufacturing techniques.

October 5, 2017: RapidMade announced today it is offering services based on HP’s award- winning Multi Jet Fusion technology. Based in Portland, Oregon, RapidMade offers customers expertise on materials, engineering and manufacturing processes including advanced technologies like 3D printing. On the heels of its move into a larger facility to increase capacity for larger clients, the company is delivering on its promise to expand its capabilities and invest in new technology such as HP’s Jet Fusion 3D 4200 printing solution.

“With National Manufacturing Day coming up on Friday, October 6, it is worth reflecting on our goal when we founded RapidMade in 2011,” said Renee Eaton, RapidMade CEO. “We felt there was an opportunity to capitalize on the growing additive manufacturing market, sustainably localize manufacturing and do our part to employ and educate a new generation of manufacturing professionals. The addition of transformational technologies such as HP’s Multi Jet Fusion is at the forefront of our mission.”

“We share HP’s vision for the digital transformation of manufacturing, and as we look to help our clients compete in the digital age, we are so excited about the capabilities of HP Multi Jet Fusion,” added Eaton. “Whether our customers are looking for design support, prototyping or more complex projects, the quality, speed and cost savings enabled by the Jet Fusion 3D 4200 solution will deliver.”

The HP Jet Fusion 3D 4200 solution lowers the barriers of entry to additive manufacturing by providing faster build speeds, high-quality functional parts, and breakthrough economics. The HP Jet Fusion 3D 4200 machine operates through a unique Multi-Agent printing process, offering dimensional accuracy, fine aesthetics, and superior mechanical properties. Parts can currently be printed in High Reusability PA 12. Additional materials will be available as the largest chemical companies in the world develop certified materials for HP’s Open Materials Platform, providing customers with an ever-growing portfolio of materials for different applications.  

About RapidMade

Based in Portland, Oregon, RapidMade’s knowledge of materials, engineering and manufacturing processes extends to both traditional and advanced technologies. We like to design and build things, and we like to work with clients who feel the same way. We believe that our customers’ competitive advantage stems from their ability to create, produce and market better products. That’s why we focus on applying the latest materials, manufacturing and engineering technologies to the process of developing, prototyping, manufacturing, and marketing products. And we use this knowledge to help our clients apply the right solutions to their business needs. If you are looking to create a new product, improve an existing one, find a new manufacturing solution or want a partner who can help you take advantage of the latest digital and additive technologies then we can provide you with a range of services from a simple part or prototype to a complete analysis of your product or processing needs. It is this focus and passion, together with our ability to provide these services in a unique and cost effective way, that makes us different. 

Contact RapidMade to learn more:

To request a quote, submit a Quick Quote, or email RapidMade at info@rapidmade.com.

There's a New HAAS in Town!

Our new HAAS CNC machine is "sitting pretty" in our new location.

The Tigard location is filling up quickly.  Both our HP Jet Fusion and HAAS CNC machines were delivered this week.  And they're being installed as this post is being written.  RapidMade is on track to move in and start up operations on August 1 as planned.  Help us fill up our new and existing equipment.

Hometown Pittsburgh's High-Tech Make Over...

Growing up in Pittsburgh, if you weren't directly connected to the Steel industry, you complained about the rotten egg smell and pollution.  But when the industrial giants went silent in the 70s and 80s, the complaints shifted dramatically to the economic tragedy that was unfolding - the flight of life-long residents and well-paying jobs.   Rhetoric from the recent election aside, Pittsburgh's manufacturing base is both alive and well...

“The Pittsburgh Regional Alliance (PRA) recently reported that in 2016 the manufacturing sector accounted for the most investment dollars ($6.1 billion), the most deals (50 companies expanding or relocating), and the most new and retained jobs (3,667).”

But as we've continued to see, the type and number of jobs that have been created don't resemble those of the steel-era in any way.

“Manufacturing is the most active sector in southwestern Pennsylvania,” explains PRA President David Ruppersberger. “But as technology and automation continue to transform this legacy sector, the reality is that manufacturing facilities will be smaller-footprint, high-efficiency environments where fewer workers, with advanced skills including STEM proficiency, will produce more goods. This is a trend that won’t reverse at any time in the foreseeable future.”

Hearing of Pittsburgh's adoption of additive manufacturing and other advanced technologies is encouraging if the resulting economic turnaround benefits the greater community.

Now Get Nylon Parts Faster

FASTER NYLON PARTS – A New Age for 3D Printing

A RAPIDMADE WHITE PAPER

By Mark Eaton

Getting parts on demand has been a manufacturer’s dream for many years. Since 2005, see M. Park, UNSW article, there have been cries from the 3D printing industry that additive technology would replace the need for injection mold tooling, that it would eliminate the need for machining, that casting would become obsolete. Finally, that dream is becoming a reality.

While there have been success stories such as the use of Stratasys Ultem for aerospace parts and selective laser sintering (SLS) nylon for automotive parts, until today, these components have all had restrictions on where and how they could be used. One of the biggest drivers for this has been the speed and the part cost.  Siemens, according to a recent article in Plastics Today, is using 3D printed fire, smoke and toxicity-compliant polymers to replace parts in trams, and they cite part availability as being the primary driver. The US Marines have recently experimented with printing replacement Humvee parts in the field. What all these examples have in common is they are limited in scope by the 3D printing technology restrictions. While the FDM process eliminates tooling, it is still 100x slower than injection molding or machining, and while SLS material prices have been reduced, they are still 10x more expensive than injection molding or nylon bar stock prices. So, the extent to which these older 3D processes can be deployed is still limited by cost and speed.

                                                                 Photo Credit: HP

This is beginning to change. A new breed of additive manufacturers is arriving on the market who are focused on truly using 3D printing to create production parts at costs comparable to injection molding and machining prices. These “new age” additive manufacturing companies combine faster printing technology with engineering resources to convert and certify part performance. They have integrated quality systems to ensure material, process and part conformity. And they offer parts at competitive prices compared to injection molding or machining costs without the need for tooling, set-up costs or inventory carrying costs. An example of one company taking advantage of this new age in additive manufacturing is Daimler, cited in a recent Reuters report, who has announced it will start offering plastic replacement parts printed at local service centers from a library of 3D files.

Driver’s armrest is 3D-printed from FST-compliant thermoplastic resin.Picture credit: PlasticsToday.com

As an executive board member in the additive manufacturing community, I recently got to profile one such Portland-based 3D printing company, RapidMade. After 6 years developing prototyping, tooling and engineering services to support 3D printing, this company is reinventing itself to use the new breed of additive technology being offered by companies such as Hewlett Packard and Carbon 3D. These companies have developed much faster 3D printing technologies that use faster curing, less expensive materials with all the properties of traditional polymers. The new HP MJF is being showcased by RapidMade as part of its expansion in 2017. With speeds that are 10x faster than current SLS technology and material prices equivalent to injection molded nylon or machined bar stock, RapidMade can now offer its customers a wide range of new and replacement part solutions. Where precision tolerances are required, the company uses automated machining centers linked with the printers to provide finishing operations.

                                                                Photo Credit: HP

Without the need for tooling, customers can now order parts to print using their 3D library or one provided by the service provider. The shorter printing cycle times mean that it is no longer necessary to hold more than 1-2 days’ inventory for quick use parts, and less frequently used parts can be ordered as needed with zero inventory requirements. For very low order quantities (less than 10 parts), it has always generally been cheaper to 3D print versus using traditional manufacturing. With the lower cost breakeven point of these new age 3D printing technologies, minimum order quantities (MOQ) of 500 or 1,000 will be converted to printing versus injection molding or machining. For customers already using SLS technology, they will see an immediate cost and turnaround benefit from switching to this new breed of 3D printing technologies.

The benefit of these “new age” additive manufacturing companies like RapidMade is being immediately felt by the machinery manufacturers and end users of such equipment. There is a significant cost benefit in current supply chains, PWC Strategy& estimates there will be a 20% gain in TCO (total cost of ownership) from 3D printing replacement parts. It is estimated 70-80% of that can be delivered to the end users when they engage with a “new age” additive manufacturing company. Lower prices for spare and replacement parts are possible with piece of mind that the part has been certified for use. No longer are machinery manufacturers tied to traditional injection molders who retain tooling that cannot be easily moved. Parts produced offshore can now be re-shored without needing to recreate tooling. PWC Strategy& predicts German spare parts manufacturers will derive $3Bn in benefit from adopting 3D printing. Additive manufacturing by its nature is a non-labor intensive process, and the new breed of technologies produces 10x the number of parts in the same time lowering the overhead cost per part and making larger MOQ more attractive. Companies like RapidMade retain digital libraries and ship direct, on demand parts in quantities of 1 to 1,000 in less than 24 hours. They do this by not only having faster 3D printing technologies but also using automated transaction systems, integrated engineering and lean techniques to optimize printing uptime.

                                                                Photo Credit: PwC

Whether it is Daimler, deciding to print plastic parts locally to save warehouse, shipping and logistics costs or Siemens citing the increased ability to service multiple customers with parts on demand, times are changing for the benefit of producers and end users. And to support the changing demands, these companies are turning to the ‘new age’ additive manufacturers who, in turn, are enabling US companies to re-shore production, improve turnaround time and lower part costs. If you have dismissed 3D printing in the past, it might be time to take another look.

3D Printed Shoes - A Great Fit for Adidas

Adidas' Futurecraft 4D (Reuters/Joe Penney)

It seems that 3D printed shoes are one step closer to reality.  This is a timely story for me as I just went shoe shopping this week...  Every time I need new tennis shoes, I go through the same routine:  choose from the limited selection of wide sizes and then, through process of elimination, find a pair that I can tolerate.  I speed walk, so the shoes have to be large enough to fit my feet but be snug enough to stay in place while I put them through their paces.  Based on this week's workout, the pair I just selected are not working out.  So I'm always interested in hearing about 3D printed shoes.

Adidas is apparently leading the pack pursuing a technology to allow mass produced custom shoes.  They announced a 

“new partnership with Silicon Valley start-up Carbon (which) allows it to overcome many of those difficulties to produce a sole that can rival one made by an injection mould, and at a speed and price that allow for mass production.”

The Futurecraft 4D shoe's introduction is planned for 2018 with the intention of offering shoe soles for individual fittings and limited editions.

The partnership with Carbon should allow Adidas to reduce the time it takes to produce shoes by additive manufacturing.  Its 3D printer design is reportedly 10 times faster than traditional 3D printer designs, printing soles in as little as 20 minutes.

RapidMade Helps SweetSense Make Life Sweeter for Residents in Kenya

RapidMade especially enjoys working on projects designed to improve the lives of others.  And we are thrilled when we get to see them "in action."  Recently SweetSense asked us to 3D print SLS parts that were used to produce remote sensors in Kenya that allow residents to better maintain water supplies and sanitary latrines.  

According to Taylor Sharpe, SweetSense is a "social enterprise" that is a spin-off of the Portland State SWEET Lab and partners with other agencies to provide high-tech solutions to problems faced by residents in developing countries.  

“...in one case monitoring boreholes (deep water pumps that service 100s to 1000s of people) in Isiolo and Turkana counties in Kenya; and in the other case helping manage collection routines and operator issues of Sanergy Fresh Life latrines in the Mukuru informal settlements outside of Nairobi, Kenya.”

For one of its initiatives, it has partnered with Sanergy to produce a

“rugged enclosure that contains an occupancy sensor and am RFID reader, to respectively estimate the fill level of latrines before conversion to fertilizer and to give Fresh Life Operators a direct line of contact with Sanergy HQ in the case of emergencies.”

In another, the Sat Spacer, SweetSense worked with Kenya RAPID...

“RapidMade parts were used to allow SweetSense to provide satellite-based monitoring in areas with no cellular coverage.”

3D Printing Great Tool for Displays, Exhibits and Promotions

Development model shown to Portland city council for project approval.

Capture the imagination of your Customers and Patrons with Unique Displays:

Architecture

• Turn around in as little as 24 hours means more time to perfect your designs.
• Embedded textures lets you simulate the colors of building materials like brick, stone and wood.
• Small features lets you design realistic windows, doors, beams, facades and other important visual design elements.
• Prints come directly from your BIM models.

Marketing

• Get your products in front of customers where it would otherwise be difficult or impossible.
• Customize marketing materials with logos and designs.
• Infinite customization to achieve the exact effects you desire.
• Get concept models in front of customers early in the product development cycle to get feedback before spending too much money on the wrong track.
• Get tangible products in your customers hands instead of a 2D computer image.

Promotions

• Pens and magnets are boring and forgettable. Make a promotional giveaway your customer has never before seen.
• Come to us with nothing but an idea for a promotional product and we can take care of the rest.
• Personalize your giveaways to the exact customer you are handing it to with custom messaging.
• Many promotional products require expensive tooling and long lead times to accomplish - RapidMade can make your promotional products in a week or less.

Displays

• Drive traffic to your stores at the window and sales with custom retail displays.
• Stand out and get attention at your next trade show with eye catching models.
• Capture your customers' attention and make them remember your brand
• Lean on our design team to come up with a creative solution that will satisfy your customers and be flexible for your budget.

Exhibits

• Store geometric and color data for priceless artifacts and works of art permanently with 3D scanning technology.
• Use digital object data to engage visitors online with interactive web exhibits.
• Create to-scale or re-scale replicas that let your visitors safely interact with models of priceless artifacts without endangering the original piece.
• Create complimentary pieces for your exhibit from object data scanned by other museums around the world.

RapidMade Advantages:

• Color: with almost 400,000 colors to choose from, why skimp?
• Size: scale-down huge machines or buildings to hand-held or table-sized replicas
• Logistics: avoid lugging heavy machinery to trade shows
• Creativity: turn your BIM and CAD models into tangible marketing materials
• Carefree: leave the design and fabrication to us, just supply the ideas

OMDOG Performance Canine Headgear Lets Your Dog Ride Safely in Style

RapidMade gets to work on many cool new product ideas.  Given our love of dogs - we have a dog-friendly workplace, this project has been a favorite...

"OMDOG performance canine headgear started as a simple idea — to build a custom helmet for Charlie the Dog, who rides around Portland, Oregon in a cargo bicycle. When the decision was made to duplicate and improve the design, we contacted Rapid Made. They were responsive and excited about the project. They quickly 3D scanned our prototype, reverse engineered it, and made it easy for us to review and approve the CAD model before printing. Rapid Made helped us take an idea that started as a cardboard model made from a pizza box turn it into a viable product design. They're providing us with manufacturing options within our budget and well suited for our target market. We are extraordinarily grateful to have found Rapid Made!"

Research Study Demonstrates Benefits of 3D Printing in Surgical Outcomes

Study confirms value of 3D printed models in planning wrist surgeries

If you read our blog, you know that we are especially interested in the medical applications of 3D printing.  I've written a few times about its adoption in surgery planning.  Now a recent published study conducted by Italian surgeon Dr. Nicola Bizzoto quantifies three advantages of 3D printing a patient's wrist (distal radius) fracture before operating.  

Having an exact replica of the broken bones allows the physician to thoroughly plan the surgery in advance, knowing where to place screws and which plate size to implant. This preparation reduces operating room and anesthesia times.  Shorter surgeries save hospitals money and less anesthesia improves patient outcomes.  The model can also be used to improve patient education.

I only wish this practice had become widespread before my wrist surgery in 2014. The operation took longer than planned because my wrist was worse than expected - there were bone fragments that had to be removed.  As a result, the anesthesiologist had to fully sedate me, and I ended up spending New Year's Eve in the hospital - not a Happy start to 2015, so while I hope to never go through a similar procedure again, I'm heartened by the increased popularity of 3D printing in medicine.

Fashion Industry Gets 3D Make Over

3D Printing took another turn on the fashion run way.  The revolutionary technology was on display at the 2016 Met Gala "Manus x Machina: Fashion in the Age of Technology." The gala showcased new clothing inspired by myriad technologies; among them, 3D printing was prominently featured. Additive Manufacturing, another term for 3D printing, is a fashion designer's choice to enhance and support the unique geometry of garments. There is a variety of applications though, from remote controlled clothing to printable fashion.