PolyBricks Designed to Build Homes Without Mortar

Image Credit:  3Dprint.com

We've blogged a few times about using additive manufacturing in construction.  Given the labor and time intensity around home building, entrepreneurs see the promise of automating this industry through AM.  There are a number of approaches being developed.  In China, they are 3D printing walls, allowing them to erect simple homes in a day. The D Shape printer, which uses a binding technology to create structures from sand, is touted as an alternative to Portland Cement, and others have even printed elaborate structures from SLS plastic.

Alternatively, a group of researchers from Sabin Design Lab, Jenny Sabin Studio and Cornell University have 3D printed ceramic blocks designed to fit together without needing mortar.  PolyBricks, which are produced on a ZCorp 510 powder-based printer, are seen as a hybrid method that optimizes the benefits of both traditional and additive manufacturing in home construction:

“Seeking to achieve a system that required no additional adhesives or mortar, we looked to traditional wood joinery techniques as a means of interlocking adjacent components. We developed a customized tapered dovetail in which the direction and severity of the tapering is dependent upon the local geometric orientation of each component; the tapering of the dovetail is based upon the slope of the surface being generated such that the narrow end of the tapering is always at the lower face of the generated surface. Thus, the force of gravity locks adjacent components together... 

The team believes it has "effectively designed a system for 3D printing mortar-less ceramic brick assemblies at scales and in materials well beyond existing constraints of additive manufacturing technology.”  

This conclusion intrigues me.  Given the number of bricks required to construct a typical home, the time needed to 3D print and post process most prints, and the material costs of ceramic powder, I'm wondering how they anticipate achieving these economies of scale to compete directly with brick and mortar construction.

[Sources: 3Dprint.com and 3D Printing and Additive Manufacturing]

Additive Manufacturing Revolutionizes Architectural and Construction Fields

Most people have heard the stories about 3D printed gun and body parts.  Additive manufacturing (AM) or 3D printing, as it often called, is a process where a solid object is made when a CAD model directs the printer to apply hundreds to thousands of successive layers in the required shape.  This method is in direct contrast to traditional (subtractive) manufacturing which begins with a block or billet of material that is then cut away until the desired piece is obtained or casting which involves injecting a liquid material into a mold and letting it solidify.

AM is revolutionizing the interior design, architectural and construction fields because it overcomes many of the limitations traditional practices have faced:

·         Because structures and components can be printed, design restrictions can be relaxed, allowing high complexity and customization.

·         Elaborate internal cavities and complicated assemblies can be built as single objects.

·         Structures can be printed on site, eliminating long and vast supply chains.

·         Material can be used only where it is specifically needed – and it can be locally sourced.

·         Little to no labor is required.  Beyond some need to post process, personnel can “set and forget” the printer.

And its influences are seen in the interior and exterior of homes and offices.  Engineers capitalize on the technology’s ability to improve heating and cooling efficiency; using less material minimizes energy loss and improved intricate designs maximize air flow.  Interior designers and artists are also among the early adopters of AM.  They can now design and print elaborate lighting and sculptures in an array of materials that include printed plastics, metals, and composites. 

Even more impressive are AM’s influences on building design and construction.   The Mobius House, built in the 1990s in the Netherlands, is a wonderful example of the design possibilities.  Constructed as a figure eight or Mobius loop, the designers’ intent was to mimic a 24-hour day by establishing communal living spaces in the crossing points of the loop.  But now, advanced construction methods also exist – homes are actually being printed: 

Image Credit:  Protohouse

Softkill Designs’ ProtoHouse was made from 30 fibrous nylon pieces that were printed from plastic powder and assembled to form the exotic structure.  Its creators argue that the resulting efficiencies in time, material and logistics allow it to compete with traditional construction methods.  And while its porous, futuristic appearance may prevent widespread adoption, there are at least two recent construction-specific developments that can feasibly compete.  Image credit:  ProtoHouse

In the UK, the D Shape Printer is now commercially available.  Capable of printing structures that are 6x6x6 meters, it works using a binder jetting process.  Essentially, a binder is infused into layered sand in the desired pattern, creating a marble-like material.  The surrounding sand remains as a support until the piece hardens, and it can then be recycled for later use.  According to its website, advantages of this approach include:

·         accuracy (tolerances of 5-10 millimeters are possible)

·         speed (the process is said to be four times faster)

·         design (complexity and style won’t change the production cost)

·         cost (despite the added expense of the binder, the overall costs when compared to Portland Cement are supposedly 30 – 50% lower)

·         safety (having no construction personnel involved reduces accidents).

Chinese Printed House Photo Credit CNTV.CN

A Chinese firm, WinSun, has also begun printing houses using a “sand, concrete and glass fiber ‘ink’” made from industrial construction waste.  The firm’s executive argues the resulting structure is lighter yet five times stronger, and it can be printed either on site or assembled from walls printed at the factory.  Either way, the hollow walls have beam columns printed with steel reinforcement bars inside, simplifying construction; workers then join together and pour concrete into the walls.  Although it recently erected 10 buildings in a day at a cost of less than $5,000 each, concerns exist about the material’s composition.  The use of glass fibers may pose a safety concern, so its suitability for long-term housing is questionable.   Chinese Printed Building Image Credit: English CNTV.CN

Another project uses solar energy to laser sinter sand to create structures.  Beyond the environmental friendliness of the technology, the ability to provide low-cost housing in developing countries with limited energy sources is intriguing.  Even NASA sees the potential of printing what one needs when and where it is needed – printing tools and housing in space or other planets.

Closer to home, architects and developers regularly use 3D printed models to showcase their designs.  They can be printed directly from CAD or BIM files and assemblies and include cut-aways to show interiors.  Full-color models typically range in sizes from under 1” – 15” (or larger with assembly) in composite, plastic or metal. Pricing depends on size, volume, material and quantity.  And unlike handmade models, printing can be completed in a day.

Contact RapidMade to learn more:  info@rapidmade.com

2014 World Cup Kick Off Aided by 3D Printed Exoskeleton

Photo Credit:  The Guardian and 3DPrinter.Net

Whether you like soccer (football) or not, you have to love how the 2014 World Cup is being kicked off... literally.  A paralyzed teen is expected to kick off the games using a high-tech exoskeleton and 3D printed helmet equipped with advanced mind-control technology. Strategically placed electrodes will send commands from the teen's brain to a computer that will use wireless technology to control the exoskeleton's movements.

A collaborate effort that included contributions from Colorado State, Duke University and the Technical University of Munich. While some focused on 3D printing the custom helmet or exoskeleton, others worked on the mind controls.  The event is being sponsored by Walk Again. Dr. Miguel A.L. Nicolelis, a neuroscientist from the organization and native Brazilian, convinced FIFA officials there to allow the paraplegic's participation in the ceremony - which will have a world-wide audience.

“As Dr. Nicolelelis’ work with mind-control technology gained international attention, he approached officials in Brazil to suggest that Walk Again be showcased at the end of the Opening Ceremony. ‘Sports can be a huge avenue to reach out to people that would never actually pay attention to science news,’ Dr. Nicolelis said. ‘I always wanted to show kids in Brazil how important science can be for society.’”

— http://www.3dprinter.net/3d-printed-bionic-exoskeleton-to-aid-in-2014-world-cup-kickoffs?utm_source=feedburner&utm_medium=email&utm_campaign=Feed%3A+3dprinter+%283D+Printer%29

I love soccer... all the same, I think that kick is going to be the most memorable... a game changer and a win.

Additive Manufacturing Featured at Manufacturing Leadership Council

Image Credit:  Francis Batonti

This past Thursday, I attended the Manufacturing Leadership Summit in Palm Beach as a guest. Additive Manufacturing was often described as a disruptive technology; hopefully the executives in attendance fully appreciated how they might leverage 3D printing in their own businesses.  

A high point for me was when Francis Bitonti, Principal and Founder, Francis Bitonti Studio, gave an intriguing presentation on his evolutionary - maybe revolutionary is a better description - journey from architect to product designer.  His bio read,

"Re-defining the visual and formal language of design, Francis Bitonti Studio uses a blend of computer-driven techniques and cutting-edge manufacturing technologies to realize what has been called 'alien' objects and spaces."  

His observation that computer-created algorithms can drive complex designs led to his using 3D modeling and printing: first to create a bike rack prototype for NYC - he did not get the job despite it being an elegant design because it would cost $50,000 to make - to more recently creating and printing wearable fashions.  He later explained his decision to promote the use of PLA as a material because it was compostable, allowing artists to express themselves in a more sustainable, if transient, way.  His success and exposure have prompted him to hold computational design workshops for other fashion designers interested in using the medium to create, share and make their 3D printed clothes.

The audience was clearly impressed with his accomplishments (as they should have been), but it left me wondering if people made the connection between these examples and manufacturing.  I especially felt this way later when hearing some award winners speak... at least a few would have benefited from adopting Additive Manufacturing techniques in their product design, prototyping and low-volume production projects.  I guess we'll know we're mainstream when that is standard operating procedure and no longer noteworthy. 

RapidMade Helps CreatID Produce Bud Light Living Line Now Featured in Ads

Bud Light Living Line in Action (Image Credit Dennis Veatch)

Some of our favorite projects involve printing models or prototypes for advertising campaigns.  Recently, we worked with Dennis Veatch, principal industrial designer at CreatID, who approached RapidMade about a unique – and challenging – assignment.  He had been commissioned to design and manufacture an exotic and complex phone system, the Bud Light Living Line, which needed to be fully functional – when the phone rings, its enclosure lights up and buzzes as a platform raises the phone so it can be answered.  Words cannot adequately describe it; you have to watch the videos to appreciate it.

Like many products we make, the BLLL (as we fondly call it) was produced using rapid prototyping and a hybrid approach of traditional and additive manufacturing.  One weekend, we printed a full-color model using CAD files and Solidworks, so Dennis could get Proof of Concept approval from his client.  Once the design was finalized, the prototype components were printed or machined and finished in just ten days.  Afterward, tooling for and production of parts for 22 units was completed less than three weeks later, allowing CreatID sufficient time to do wiring and assembly.

David Shapiro, Engineering Manager, played a key role in the project and observed, "This really showcased our ability to move smoothly from concept development to manufacturing. We were able to combine the strengths of additive manufacturing with those of traditional manufacturing to great effect. The grueling schedule originally worried us, but we actually delivered significant portions of the project early, much to the delight of everyone involved."

Bud Light Canada’s campaign began airing this month.  In the YouTube videos, some lucky individuals literally get the call – and then the fun begins.  In one, Steve Aoki hosts a house party for the winner; in others, groups are whisked off to NYC, Las Vegas or Whistler – where an all-expense paid vacation awaits.  The buzz the videos generate has online viewers speculating where the Bud Light Living Line will show up next and how one can get the BLLL call.

Back here in Portland, we’re just stoked we got a call that allowed us to play a part in this cool ad campaign.

Scientists Print Fruit, Create New Flavor Combinations

Image credit: guardianlv.com

An apple a day may very well keep the doctor away, but this new fruit sensation owes its existence to doctors, not farmers.  Scientists at Dovetailed, based in Cambridge, UK, have printed fruit.  And they recently shared the fruits of their labor (pun intended) at the TechFoodHack conference.

"The new demonstration by scientists working at Dovetailed, the Cambridge-based company, used a process called “spherification,” which was originally discovered back in the 1950’s. Spherification allows scientists to use liquid or puree from a fruit and then form small spheres containing that flavour. The 3D printer can then combine those spheres with others containing different flavours, allowing for the production of unique flavour combinations into whichever shape or form is desired."

Dovetailed is hoping the breakthrough will be a hit first with chefs interested in creating exotic new flavors in a variety of shapes.  They suggest the technology's speed will allow rapid experimentation and hope that, as its costs drop, it will gain a wider user base.  Given consumer push back against genetically modified foods, it's anyone's guess as to whether people will warm to the idea of manufactured fruit - it certainly gives new meaning to the term "processed food."

Food labeling requirements may be a challenge as well.  Right now, there are guidelines on the percentage (and form) of fruit required to call a product a preserve, jam or jelly.  One wonders what this new fruit product will called.

"Crash Course" in 3D Printing and Additive Manufacturing

3D Printing and Additive Manufacturing Glossary

The terms 3D printing and additive manufacturing are used interchangeably. They refer to a group of new technologies and processes that allow parts, models, and (in some cases) assemblies to be built three dimensionally.
Additive manufacturing is often best explained by how it differs from other types of production. Metal machining is a common and proven form of subtractive manufacturing: you start with a block of metal and cut away material until you are left with the desired design. Additive manufacturing, on the other hand, builds from a 3D model and only adds material where it is needed.
This is done by slicing a CAD modeled object into thin layers, sometimes as thin as 16 microns (0.0006in), and building each layer in succession. This unique manner of creating things allows for amazing new designs and geometries not previously possible with traditional manufacturing. For instance:
- Parts can now be made that have incredibly complex internal structures that cut out weight        while maintaining structural integrity
- Many design constraints (like requiring draft and undercuts) that limit traditional manufacturing  are obsolete
- Additively manufactured parts can be post-processed with traditional processes to improve  functionality or aesthetics
- Original masters for traditional casting processes can be produced easily and quickly
- Interlocking parts can be created without the need for assembly

3D printing is currently a hot topic. It's a rapidly growing market expected to reach $20 billion by 2020. Deemed “The New Manufacturing Revolution” by The Economist and Wired, additive manufacturing will dramatically affect the way things are made in the near future. Some experts believe it will help reinvigorate American manufacturing, while others believe it will democratize production of goods and every house will have its own 3D printer.
Whatever the future holds, see the reverse side of this sheet for a brief glossary of terms that will help you navigate the worlds of additive manufacturing.

Common Acronyms
FDM: short for fused deposition modeling (tradmarked by Stratsys) and also known as fused filament fabrication (FFF). See: material extrusion, thermoplastic
SLS: short for selective laser sintering. See: powder bed fusion
DMLS: short for direct metal laser sintering. See: powder bed fusion
SLA: short for stereolithography apparatus. See: vat photopolymerization

Types of additive manufacturing
Vat photopolymerization: this process builds parts by using light to selectively cure layers of  material in a vat of photopolymer.
Material jetting: this process builds parts by depositing small droplets of photopolymer    (similar  to an inkjet printer) which are then cured by exposure to light.
Binder jetting: this process creates objects by squirting a binding agent into a powdered material.
Material extrusion: this process creates objects by extruding thin filaments of thermoplastic to build layers. It is often likened to a tube of toothpaste or a syringe.
Powder bed fusion: this process selectively melts fine layers of powdered plastic or metal into solid objects using a laser.
Sheet lamination: this process builds parts by trimming sheets of material and binding them together in layers.
Directed energy deposition: This process builds or repairs parts by using focused thermal energy to fuse materials as they are deposited on a substrate.
Materials
thermoplastic: plastic that softens when heated and solidifies when cooled
photopolymer: a liquid plastic that hardens permanently when exposed to light

Common Materials

Material                   Strength               Flexibility              Surface Finish           Feature Detail
Zcorp Composite1   ★★★☆☆☆           ★☆☆☆☆☆            ★★★☆☆☆                 ★★★★☆☆
FDM Plastic              ★★★★☆☆           ★★★☆☆☆            ★☆☆☆☆☆                 ★★☆☆☆☆
Objet Plastic2           ★★☆☆☆☆           ★★★★★★            ★★★★★★                 ★★★★★★
SLS Plastic               ★★★★☆☆            ★★★★☆☆            ★★★☆☆☆                 ★★★☆☆☆
Printed Metal            ★★★★★☆           ★★☆☆☆☆             ★★☆☆☆☆                 ★★☆☆☆☆
DMLS Metal              ★★★★★★           ★★☆☆☆☆             ★★★☆☆☆                 ★★★☆☆☆
SLA Plastic                ★★★☆☆☆           ★★★☆☆☆             ★★★★☆☆                 ★★★★☆☆
1 ZCorp printers are one of the few processes that can create colored objects and can even reproduce photographs and modeling textures
2 Objet can print rigid (Shore D) and soft (Shore A) materials, giving it a flexibility range up to the maximum

3D Printing Helping Decommission Nuclear Power Plants

Image Credit:  Wikipedia/Engineer.com

One under-appreciated benefit of 3D printing is being able to 3D scan and reproduce obsolete parts - either through traditional or additive manufacturing.  For example, we've been working with the State of Oregon to reverse engineer, improve and manufacture obsolete parts for some of its correctional facilities - saving several thousand dollars for each cell door that is refurbished rather than replaced.

This same approach is now being used in England to decommission nuclear power plants.

"Sellafeld recently designed a new lid for one of its 40-ton nuclear waste export flasks. By using 3D scanning engineers were able to quickly and accurately recreate the geometry of a legacy component, saving time and thousands of dollars. From those 3D scans a new lid will be printed, saving even further costs.

That’s only one example of the way 3D printing will be used to curb expenses, engineers expect AM to play a big roll in a number of future component redesigns in both plastic and metal.

Given that the estimated cost of the two plants’ decommissioning has ballooned to $118 billion, any savings that can be wrung out of the project will be greatly appreciated by the UK taxpayers."

High-profile cases like this will hopefully help reduce one hurdle to adoption:  getting agencies to appreciate the potential cost, time and ecological savings associated with reverse engineering and additive manufacturing of obsolete parts.  

Inconel Alloy 625 Now Available for 3D Printing

Inconel 625, a nickel-based alloy is said to be the first single metal alloy for 3D printing industrial applications at greater than 99 per cent density according to ExOne which creates the metal using its binder jetting technology.

Inconel 625 is commonly used for components in the aerospace, chemical and energy sectors, with applications including gas turbine blades, filtration and separation, heat exchanger and moulding processes. The metal is considered desirable thanks to its oxidation and corrosion-resistant qualities and its ability to retain its strength in extreme environments.  

The alloy, which was developed by ExMAL, ExOne's R&D arm, is scheduled to be released sometime in June.  This introduction supports ExOne's strategy of qualifying at least two new industrial materials each year.  Of particular interest, it has reportedly seen promising results in its attempts to develop a titanium-based material.

Save Thousands and Make a Splash at Tradeshows!

Monitor produced for close to half the cost of and in far less time than traditional manufacturing

Exhibiting at tradeshows, while rewarding, can be very expensive and stressful:  transporting and staging large equipment can consume a large portion of a company’s marketing budget.  But it doesn’t have to.  Using 3D printing techniques, firms can get to-scale, full-color prototypes and models of their equipment that can easily be carried and displayed on site. 

The Client:

FlatHED, Inc. is an industrial design company which specializes in designing appealing and sleek consumer goods that are also cost effective to manufacture.

The Need: 

Not all cost-effective designs for manufacture are cost-effective in small quantities for tests and tradeshows.  FlatHED designed an all-in-one computer that would house electronics that their customer wanted to show off at a trade show.  To CNC machine the design out of aluminum would have cost over $10,000 for just one unit and then they  would have been left with an unfinished, heavy part covered in tool marks.  They needed two working devices and had only $8,000 to budget for both, so they turned to RapidMade™.  

 The Solution: 

Working with FlatHED to modify the design for a special mix of manufacturing methods, RapidMade™ was able to create a finished product out of ABS plastic, ceramic, and sheet metal.  The final part was indistinguishable from the metal design and finished with high quality automotive gloss and matte finish paint, contained all the electronic components, held the weight of a heavy computer monitor, and (most importantly) cost slightly over half the original $8,000 budget. 

To-scale, full-color model shows internal components of large equipment

The Client:

Cornell Pump Company produces some of the best pumps in the business and attends over a dozen trade shows every year for food processing, mining, agriculture, and other industries that require pumping. 

The Need:

Cornell has had great success shipping and displaying their actual pumps for view at these shows, but they wanted a way to show potential customers the inner mechanics of the pumps in an attention-getting way.

 The Solution:

Cornell asked RapidMade™ to produce tabletop models of their large pumps with color coding and cutaways.  Customers can see the inner components and compare the colors with a labeled legend near the pump.  Having a tool that helps to explain the mechanics of the pumps is a valuable sales tool; it helps customers connect the dots for application.  Seeing the 3D printed colored replica also draws the attention of browsing show attendees.  On top of all of that, the ceramic model can be easily carried under the arm of a tradeshow representative, eliminating the need for expensive shipping.

Big Area Additive Manufacturing (BAAM) to Hit Market

BAAM machine; Source: Cincinnati

Many think “bigger is better” and 3D printing is no exception.  Big Area Additive Manufacturing (BAAM) will hit this fall.  The US Department of Energy's Oak Ridge National Laboratory (ORNL) has partnered separately with two companies, Cincinnati Incorporated and Lockheed Martin, to commercialize large-scale 3D printers.  

Cincinnati's efforts are focused on creating "a 3D printer that is 200-500 times faster and capable of printing polymer components 10 times larger."  The printer is expected to be ready by early fall when Cincinnati will introduce a 3D printed "vehicle at the International Manufacturing Technology Show" (Beth McKenna).  

The Lockheed Martin project is more focused on size.  Imagine parts as large as 60-100 feet!

McKenna correctly questions whether either partnership can resolve the warping issue that plagues parts with non-uniform thicknesses but says that Lockheed will rely on carbon-fiber reinforced plastics to address this problem.

RapidMade to Print 3D Prosthetic Hand

The Engineering and Physical Sciences Research Council's Hi Tech Hand (http://phys.org/news/2013-10-future-d.html#nRlv)

In the field of 3D printing, medical advances have arguably received the most press, with good reason - 3D printed prosthesis are changing lives.  The London Science Museum is now featuring an exhibition that highlights one great example, a 3D prosthetic arm designed and manufactured by the Engineering and Physical Sciences Research Council's Centre for Innovative Manufacturing in Additive Manufacturing.  This prototype features "customised prosthetics with electronic moving parts and nerve endings, created by the research group at the University of Nottingham."

Unfortunately, the cost of high tech prosthesis like this is a serious drawback , especially when children are involved.  Kids need a medical device that won't cost an ar - well you know  the expression - their changing bodies require a less expensive alternative that can be replaced as needed to accommodate growth.

Version of McCarthy's Robo Hand RapidMade is Evaluating (http://laughingsquid.com/dad-makes-a-low-cost-3d-printed-prosthetic-hand-for-his-son/)

RapidMade is very excited to be partnering with a 13-year-old Oregonian who has a congenital amputation to customize, print and fit an inexpensive hand for him to evaluate.  Alex and his mom, Lori, visited us earlier in April to discuss the project and provide his measurements. 3D printing will allow us to size the prosthetic to match his hand instead of a "one size fits all" device. David, our engineer, has already begun printing parts and assessing design features. RapidMade hopes to make plastic prosthetic hands out of ABS plastic using fused deposition modelling (FDM) and Nylon using Selective Laser sintering (SLS) in order to better meet patients' specific needs for price and quality.   

We are grateful to Paul McCarthy who designed and shared the original version we are evaluating.  He and other designers have made their work available for free through open sourcing to drive down costs.  As 3D users already know, it is often the product design phase that is the most costly and time consuming, so to have a ready-to-print CAD file is an enormous benefit.

If this trial is successful, we hope to become part of a network that provides low-cost prosthesis to others who are similarly challenged.  Stay tuned for updates on our progress...

Hemmerling and Ulrich's 3D Printed Chair Debuts in Milan

Design Boom recently featured the work of German Designers Marco Hemmerling and Ulrich Nether. The pair used 3D printing to create their Generico Chair which is currently on display in Milan.  Instead of simply designing an elegant piece of furniture, additive manufacturing techniques allowed them to optimize both product function and production efficiency by evaluating structural, ergonomic and manufacturing requirements:

"following an iterative design strategy, a material layout calculation resulted in reducing parts of the volume, while still enabling the necessary stiffness, comfort and functional requirements to be met. a 3D computer model was reviewed using FEM-software, to measure deformation and stresses before all the findings were integrated into a final 3D model."

Normally, projects require one to compromise on scope, time or cost yet using additive manufacturing for product development and low-volume production approach allows designers to accelerate development, improve quality, and decrease costs.  

4D Printing

Advances in 3D Additive Manufacturing technologies are far too often attributed to advances in the actual 3D printers themselves, but the machines are only 1/3 of the equation.

Often times new, innovative materials and software can have an even more profound impact on available products in the industry, or in this case, any industry.

The U.S. army just invested $855,000 in multiple projects around the development of "4D printing" software. Don't let the name fool you. The structures are created using the same 3D printing techniques on the market today, but this software allows for fundamental alterations in part design that allow the final construction to be completed after the part has been created.

By making parts out of hundreds to thousands of little, jointed components we can take advantage of new properties resulting from complicated assemblies. Additionally, we can now create objects that would have originally been too large for the relatively small beds of 3D printers.

These complicated assemblies would be far too labor intensive and costly to manufacture using any other technology available today.

Useful examples would include the dress in the video which behaves differently as we vary the size and placement of the joints throughout the dress's structure. We could also create very large objects previously compressed which snap into place to create a rigid, permanent structure much larger than the compressed one.

A lofty goal of this software would be to fabricate large objects on site in remote locations, like on an air craft carrier or on a colony in space where real estate for such equipment may be at a premium.

The beauty of Additive Manufacturing is that the users see new capabilities such as 4D Printing and come up with their own amazing applications.

Eight Common Rapid Prototyping Mistakes

The good folks at Malco Design created this fantastic white paper about the common pitfalls people experience when making rapid prototypes. The eight examples are really important to understand so that expectations and decision making can result in an optimal prototype tailored to the customer's needs. They are:

1. Poor communication/coordination between designer and prototyper - There are many variables that effect the final part strength, features and dimensions, like overall part size, process used or build orientation. It is very important that the prototyper make clear where uncertainty can occur and how to minimize it and just as important that the customer make clear the critical requirements of the prototype.

2. Overestimating users' knowledge of rapid prototyping - Many services bureaus are receptacles for uploading files and producing them in order to cut down on labor. In those instances it is incumbent upon the customer to know all the rules of rapid prototyping, may of which change over the course of months as new technologies and materials are developed. Prototypers need to keep designers informed and designers need to be vigilant to fill in their own gaps in knowledge.

3. Belief that anything can be built as a rapid prototype - There is a lot of hype in the industry that rapid prototyping can build anything and solve any design issue. Vary large parts are often not suited for the process and unless doing rapid machining, same goes for tight tolerances. Sometimes when experiences don't line up with expectations, customers are wary to use the technologies again.

4. Expecting prototypes to be perfect the first time - My favorite by far! If prototypes were always perfect, you wouldn't need them and you would instantly cut your $50,000 mold. Never forget that prototyping is an iterative process and some design flaws cannot be discovered until one tests the physical prototype in front of them.

5. Using wrong materials or processes - SLA or Polyjet photopolymers degrade in UV light over time, making them not great for production parts, SLS can have rough surface texture and feature definition, Z Prints are brittle and FDM has great variance in strength between its layers. Each of these processes has innate benefits as well. Selecting the correct material and technology is essential to getting the prototype right the first time.

6. Selecting a vendor whose capabilities don't match your needs - Some vendors are fast. Some are knowledgable. Some focus on good customer service while others focus on bargain basement pricing. Research the company with whom you plan to do business. All prototypers are differentiated to work with a specific customer niche and you should make sure you are the customer that fits their capabilities and strengths.

7. Ignoring the value of prototyping - Time is money and many companies are willing to put the extra cash down to get the product right the first time and as fast as possible. Tooling up a factory for mass production is a lengthy and expensive process. The later an error is discovered, the more costly it is and the longer it takes to solve. This could be devastating for companies trying to maintain their margins or release products when consumers actually buy them (think electronics at Christmas or pool toys in the summer.)

8. Building more than is necessary - Many times designers try to make an entire assembly without being sure that each individual component works correctly first. It can save a great deal of cost and time if the components are individually created, and then, once proven, used to build a larger, more complete device.

3D Printed Casts

The technique is antiquated and could use a little something of a shake up thanks to new technology.

Setting castings in plaster is centuries old and has a variety of uncomfortable problems. Scanning and imaging of the body are common place in the medical field in order to diagnose injuries and illnesses, but the ability to create prosthesis and custom fixtures directly from those scans is brand spanking new, from printed bones and teeth implants to entire artificial limbs. The parts either fit to the contours of your body or are exact replicas of the body part which they replace. 

This technique now produces a superior cast taken directly from a 3D scan of the broken body part and 3D prints a cast from the digital negative. The cast is designed with snap fits which enclose the arm, keeping it from moving, but making it accessible to air and hands. Much more comfortble.

Just another simple example where the medical field can benefit from applying new technologies (additive manufacturing/3D printing) to ones that are already pervasive in the medical field (3D scanning and imaging.)

Additive Manufacturing in Aerospace

A stainless steel bracket optimized for weight reduction (front) and the traditional cast bracket in the back.

Additive manufacturing (AM) has long been the holy grail of Aerospace OEMs like Boeing and Airbus. Where typically the costs of metal laser sintering can be prohibitive to mass producing parts, in the aerospace industry volumes are low enough and the design optimizations can easily pay for themselves in fuel and material savings. 

EADS Innovation Works recently released a study that says implementing additive manufacturing into planes and other aircraft could reduce material use up to 75% and fuel consumption up to 40%. 

Let's set aside the obvious environmental benefits for a moment. In an industry that is a slave to fuel costs and customers who always buy the lowest sticker price ticket off aggregator websites, airlines tend to get squeezed when it comes to making their margins.

Cutting just one pound of weight out of an aircraft can save over $10,000 in fuel costs every year. Not only do AM parts cut out that 75% of the material by only using structure where it is absolutely necessary, but light weight, high cost metals like titanium are now available where they were traditionally cost prohibitive, further lightening the load.

Machining titanium parts from billet generally causes up to 90% material waste versus virtually no waste from making the parts additively. Couple that with needing less material in the part design as a whole and scores of components that used to be made from stainless steel or aluminum can now be made from the valuable metal.

This is why we now hear engineers and executives dreaming about the development of printers that are large enough to manufacture entire wings. They see the value in a future where aircraft are created entirely from printed components. 

Maybe the additional payload provided by these technologies will eventually even eliminate the need for bag fees. Unlikely, but one can dream!

6 Axis Extrusion Printing

Be warned, for this is only a prototype, although a cool one at that. Unlike your home Makrbot, or even industrial level Fused Deposition Modelling machines made by Stratasys, this 6 Axis(!) extrusion printer prototype can extrude far more than layers. Capable of printing directly on a curved object or making multi-directional print lines, this literally adds a new dimension to extrusion printing.

There are two typical weaknesses of extrusion based printing that a 6 axis printer fixes. First is that between layer lines, the strength of an object can be up to 75% weaker than along the planes of the layers. 

Additionally, machines require disolvable support material to make complicated geometries with undercuts, a technology on which Stratasys machines have an exclusive patent. The 6 Axis machine creates these geometries without violating patent law.

Cheers to novel ideas. 

Bentley Uses 3D Printing to Design Vehicles

Bentley makes to scale models in hours instead of weeks to validate designs and increase time to market.  

“We can simulate what a car is actually going to look like and show our bosses absolute reality.”

 – Kevin Baker, Design Model Manager.

This  helps speed up the approval process and make sure the concept of the design is perfect before investing too much time and money in working on flawed individual components.

Check out the video below and remember that you don't have to invest hundreds of thousands of dollars in equipment to get the same models and prototypes that Bentley makes in house if you contact RapidMade!

A Great Infographic Breakdown of the 3D Printing Market

Everybody loves infographics, almost as much as they love 3D printing. Combine the two and you get a pretty concise look at some important metrics in our field, like what technologies and service bureaus people use, the make-up of professionals in the field, and why people use 3D Printing.