Rapid Prototyping: October 2010

Stratasys FDM (Fused Deposition Modeling) Process

Stratasys FDM Process
Step 1: Pre-Process
From 3D CAD data, pre-processing software automatically slices, calculates support structures, and creates toolpaths that are optimized for the system.

Step 2: Produce Part
Parts are built layer by layer in an additive process. Extrusion heads lay down thermoplastic build and support material to create each layer.

Step 3: Remove Supports
Temporary support structures are easily removed. Soluble support material automatically dissolves in a water-based solution. Break-away supports simply snap off by hand.

For more information visit: www.stratasys.com

What Can You Make With a 3D Printer?

Pretty much anything these days!

Here are some sample parts I have made using an FDM 3D modeler.

www.printo3d.com

Please see my channel page for many more rapid prototyping videos or you can simply click on "More Videos From Team222badbrad" below.

Stratasys & Autodesk Produce First Full-Scale Turbo-Prop Aircraft Engine Model with 3D Printing

Stratasys & Autodesk Produce First Full-Scale Turbo-Prop Aircraft Engine Model with 3D Printing

Propeller Blade-Span is over 10 feet; Project Demonstrates How Far 3D Modeling Has Advanced

MINNEAPOLIS, Dec. 2, 2009 — Today at Autodesk University 2009, Stratasys (NASDAQ: SSYS) and Autodesk unveiled the worlds first full-scale turbo-prop aircraft engine model. It was produced using Stratasys FDM (Fused Deposition Modeling®) technology.

The engines design was created using Autodesk Inventor 2010 mechanical design and engineering software, and it was produced on both Fortus 3D Production Systems and Dimension 3D Printers from Stratasys. The engine model sets a new precedence in scale, and it showcases the potential of 3D printing.
Our Inventor software with FDM technology takes design innovation to an entirely new level of sophistication, says Autodesks Gonzalo Martinez, office of the CTO. Today at Autodesk University weve shown that with FDM, you can create realistic 3D models of nearly any design. We believe that Stratasys FDM technology is the future of 3D printing and production.

The engines gear box includes two sets of gears, which operate two sets of propellers that move in counter rotation to each other. With an engine length of over 10 feet, a blade-span of 10.5 feet, and 188 components, the engine model is massive in size. It includes several large parts, such as six propeller blades, each measuring 4.5 feet.

The turbo-prop engine was designed by Nino Caldarola, a freelance designer for Autodesk. He shared his concept with Autodesk who wanted to bring a full-scale model to life using Inventor software and FDM technology. Caldarolas design is a hybrid of newer engine and classic engine design and was partially inspired by the Piaggio Avanti II aircraft engine, the TP 500. Caldarola worked with engineers at RedEye On Demand prototyping and production service, a business unit of Stratasys, to make adjustments that would ensure an accurate physical model.

97% Cost Reduction; 83% Time Reduction
All 188 components were produced in 4 weeks and assembled in 2.5 weeks for a total production time of 6.5 weeks. Using conventional fabrication processes, such as machining and casting (with in-house and outside resources) a manufacturer would expect to spend 9 months or more producing a model like this. Using the FDM process in-house, a manufacturer could expect costs of roughly $25,000, versus an estimated $800,000 to $1 million for conventional processes. These numbers represent about a 97% reduction in production costs and 83% reduction in production time.
It was spectacular seeing my computer design brought to life with a 3D model, says Caldarola. I worked under a tight timeline and across geographies with both Stratasys and Autodesk, and I am very proud of the collaborative process and result. Just a few years ago, a project of this scale would have never been attempted.

This project shows that 3D printing has made the progression to large format, says Stratasys CEO, Scott Crump. Hopefully this project will help make manufacturers aware that a designer can conceive and design a product this significant, and then have it physically modeled in about 6 weeks.

Stratasys and Fused Deposition Modeling are registered trademarks, and Fortus and RedEye are trademarks of Stratasys, Inc. Autodesk, Autodesk Inventor, and Inventor are registered trademarks or trademarks of Autodesk, Inc., in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders.

Attention Editors: If you wish to publish reader-contact information, please use: info@stratasys.com, 952-937-3000, 1-888-480-3548, www.stratasys.com

How Break Away FDM Works

This is how Fused Deposition Modeling (FDM)post processing works.

This is known as BST or Break-away Support technology. Simply break away all the support structure which is grey and you have the final product.

They also have SST which is Soluble Support Technology. Simply dip the part in a solution and it eats the supports away

Milling & Machining Center Basics

Zaffran Build Process

www.zaffran.eu

Zaffran building a Rapman 3d printer!

Prototyping in Product Design and Development

Industrial Design Consultancy Managing Director Stephen Knowles talks about how prototyping can be used to accelerate the product design and development process. Includes information on how rapid prototyping can be used, and a demo of our SLA Viper machine in action.

ZCorporation Overview of 3D printers and rapid prototyping

Z Corporation has introduced more innovations than any other provider of rapid prototyping solutions, including development of the fastest 3D printers, the world's only color 3D printers, and high-definition 3D printing (HD3DP™) capabilities. Our 3D printers create physical models from computer-aided design (CAD) data by using an inkjet print-head to deposit a liquid binder that solidifies layers of powder. This cutting-edge technology supports a full line of 3D printers that deliver the speed, low operating costs, and high-quality models that product developers need to compete in today's global market.

Medical Applications of Rapid Prototyping

Rapid Prototyping of Ubiquitous Computing Applications: Tools & Frameworks

Google Tech Talks
March, 24 2008

ABSTRACT

Yang Li - RESEARCH SCIENTIST

Pervasive or ubiquitous computing (ubicomp) applications can support people's everyday activities in the physical world by leveraging advances in sensor technologies and computing infrastructures. Designing ubicomp applications is challenging because our everyday activities are more complex, dynamic and less structured than the tasks supported by traditional desktop computing. Ubicomp design is difficult, time-consuming, and requires a high level of technical expertise, especially with sensor technologies. To address this, I created a set of rapid prototyping tools and frameworks. My early work with Topiary introduces high-level abstractions, such as maps and scenarios, for designers to easily model location contexts and specify location-based behaviors. Topiary also allows a design to be tested in the field via a Wizard of Oz approach, without deploying a location sensor infrastructure. My recent work is focused on activity-based ubicomp prototyping, a process for enabling long-term activities (such as keeping fit)—a larger unit for design than the tasks that are the focus of traditional design. To support such a process, I created ActivityDesigner, a system that allows designers to create functional prototypes of ubicomp applications based on field observations, and easily deploy and test these prototypes in situ.

Speaker: Yang Li - RESEARCH SCIENTIST
Yang Li is a research associate in the Computer Science and Engineering Department at the University of Washington. He works in the areas of human-computer Interaction and ubiquitous computing, focusing on activity-based ubiquitous computing, rapid prototyping tools and pen-based interaction techniques. Previously, he was a postdoctoral researcher in EECS at the University of California at Berkeley. He received his PhD in computer science from the Chinese Academy of Sciences.

Incremental Sheet Metal Forming SPIF 1st Experiment

Incremental Sheet Metal Forming SPIF 1st Experiment
used a .250 diameter tool @ 1000 rpm 7 IPM 15% stepover

OCAS BV - Sheet Metal Fast Prototyping

Metal Sheet Based Fast Prototyping via Incremental Forming Technique

3D Printing the Works

I show you the startup and printing process of a 3d printer. Print To 3D.

Building The Dome

Three Students at the New Jersey School of Architecture undertook a project to construct a 1/8" = 1' scale model of Fillippo Brunelleschi's Dome of the Florence Cathedral. The dome was modeled entirely in Rhino 3D, a NURBS modeling tool. It was then constructed on Z-Corporation 310 3D printers, over the course of several months. The completed dome is 28" square by 26" tall.

3d graffiti - graffiti technica 3d model

3d print of using a machine for rapid prototyping. The object was created by successive layers of material over 17 hours of printing.

It was printing from a .STL file exported from one of my graffiti designs.

3D Printing for Architects

NRI 3DLabs is leading the revolution in architectural 3D Printing

Utah Valley University uses their 3D Printer for a Design Derby Contest

Watch David Manning of Utah Valley University talk about how he uses the Dimension 3D Printer to educate, excite and recruit high school students exploring educational tracks in design and engineering. David discusses the success of Utah Valley Universitys annual pinewood derby-like design contest and race for high school students. Visit http://www.uvu.edu/ for more information on Utah Valley University.

Rapid Tooling Applications - Rapid Prototyping by Objet

Rapid Prototyping by Objet - post process applications 3D printed model on an Objet polyjet 3d printers.

3D printer Connex by Objet

Corporate movie of PolyJet Matrix Technology that is used in the newest CONNEX 500 3D Printer by Objet Geometries

Plastic Injection Molding Basics

The basics of a plastic injection molding system. From BeechmontCrest.com

Rapid Prototyping | 3D Printing Material Samples Polyjet Video

Examples of Rapid Prototyping - 3D Printing Material via Polyjet Connex500. These examples show overmolding, living hinges and soft Durometer mimicking rubber feel.

Rapid Prototyping at it's finest 3D 3-D Printer

Now you can print 3D color models so quickly and affordably, you'll do it every day. Introducing the ZPrinter®450. The ZPrinter 450 makes color 3D printing accessible to everyone. The lowest priced color 3D printer available, it outputs brilliant color models with time-saving automation and an easy printing process.

Z Corporation has introduced more innovations than any other provider of rapid prototyping solutions, including development of the fastest 3D printers, the world's only color 3D printers, and high-definition 3D printing (HD3DP™) capabilities. Our 3D printers create physical models from computer-aided design (CAD) data by using an inkjet print-head to deposit a liquid binder that solidifies layers of powder. This cutting-edge technology supports a full line of 3D printers that deliver the speed, low operating costs, and high-quality models that product developers need to compete in today's global market.

Rapid Prototyping - 3D Printing Overview

This video goes over the basic process of submitting, printing, and post-processing a 3D print using the University of Michigan's ZCorp Spectrum Z510.

Realtime 3D geometry video scanner

This is a high-resolution, real-time geometry video scanner that simultaneously acquires, reconstructs and displays 3-D geometry at 30 fps with a resolution of 640x480. More info: http://www.vrac.iastate.edu/~song

What Can You Make With a 3D Printer?

Pretty much anything these days!

Here are some sample parts I have made using an FDM 3D modeler.

www.printo3d.com

ThingLab Mephisto 3D Scanner

ThingLab presents a new breakthrough scanning product. Modular and scalable, the Mephisto brings high-end scanning for under 10k dollars.

3D Printer from Thinglab in London

Fast, colour 3D printing from ThingLab in London - www.THINGlab.co.uk

3D silicone printer 2005

This is a new type of 3D printer for silicon. www.nodesignlab.net

Shapeways 3D Metal Printing

Turn your 3D model into a metal object! Shapeways 3D metal printing service makes it possible. This video shows the production process. Also check out inspiring samples of models that can be 3D printed in metal, or buy a Stainless Steel model in our gallery at http://www.shapeways.com/

Scott Summit — The Future of 3D Printing @ Singularity University

Scott Summit explains the current state and future potential of 3D printing (also known as rapid prototyping) technology.

uPrint Personal 3D Printer - Graphics Systems Corp

The New uPrint™ Personal 3D Printer Only $14,900* USD

For more info or a sample part, please contact Graphics Systems Corp. at 800-454-CADD or visit www.gxsc.com today!

With the new uPrint Personal 3D Printer from Dimension, you've got more flexibility than ever for making 3D models for visualization, collaboration, and functional testing.

We've made uPrint compact enough to fit on your desktop; simple enough for no-hassle setup and operation; and — best of all — affordable enough for most users, no matter your profession or office size.

E01 - Polyjet - Additive Technologies (Rapid Prototyping)

This is Episode 1 of a series of video blogs on Additive Technologies (also known as Rapid Prototyping).

Today we're looking at the Multi-Material Polyjet machines which can mix both rigid and soft materials together on the fly to grow parts that simulate over-molding and other complex applications. This process is great for small to medium sized parts (it's not always cost effective for large parts) and is often used for a variety of prototyping applications (the material is not usually suited for end-use applications), creating a direct tool for a silicone mold, and investment casting.

Dimension 3D Printers by Stratasys at CMTS 2009 on CityTV Breakfast Television

James Janeteas with Cimetrix, a Stratasys reseller, explains 3D printing technology with real working models printed on the Dimension 3D Printer during the Canadian Manufacturing & Technology Show in Tornoto, Ontario, October 2009. Using a 3D Printer, engineers can enhance their design process by printing concept 3D models and functional prototypes in house, saving time and money over out-sourced solutions. Dimension 3D Printers use Stratasys Fused Deposition Modeling, or FDM technology to produce accurate, durable models for testing form, fit and function.

3D Printing a human head on a Zcorp Z450 Printer

3D Print of a laser scanned human head by Rapido3d on Zcorp z450. Rapido3d, London based laser scanning, 3D Printing, and Large CNC machining.

3D printing demo -- ball bearings!

This video shows and describes the operation of the Z-corp 310 printer. It is fully functioning part with ball bearings!

3D Printing - Japanese, Karim Rashid style

A Japanese 3d printing company - Bandai, printing 3d models...excellent! Karim Rashid and Philip Starck would have been proud!

3D Systems - Stereolithography

Technology Focus - Stereolithography.
With Kevin McAlea and Brian Frazer of 3D Systems.

Rapid Prototyping Right Before Your Eyes!

Rapid Prototyping Right Before Your Eyes is presented by Print To 3D.

www.printo3d.com

This 3D printer is a Dimension 768 BST.

The cup is 1 inch tall and 1/2 inch in diameter. The base or floor of the cup is 40 thousands of an inch thick as are the sidewalls of the cup. The stem of the cup is 100 thousands of an inch in diameter.

This machine uses Fused Deposition Modeling or FDM for short.

The machine is basically a large hot glue gun!

Rapid Prototyping Video of Objet's PolyJet Process

A short video on the rapid prototyping technology of Objet's 3D "printing" (PolyJet) process. With Objet's PolyJet™-based systems and FullCure® family materials, even the most complex geometries can be built - easily, quickly and cost effectively - in an office environment.

Rapid Prototyping at it's finest 3D 3-D Printer

Rapid Prototyping Intro - part 1 - Personal Manufacturing

Hardware and digital information begins to converge. 3d printers dives in price and enables a new world where beautiful forms share and your 3D-printer print an exact replica. Look around and think of how many items the value is in the semi-rigid material such as plastic is shaped in a certain way. Both aesthetics and form in a variety of everyday objects lies in the design.

Rapid prototyping is a design concept that at each stage of a product design to create a physical prototype of the virtual design that can be used to test or demonstrate the product. Implied is that in every part of the design process also may be feedback from usage and unexpected proposal from those who only play with the prototype. The technology used in most manufacturing done through the design of 3D models, such as the automotive industry. Rapid prototyping is done through so-called solid freeform fabrication (SFF), which means technology for producing solid objects by applying energy or matter to some specific points in space. It includes, for example that with a laser (subtractive application of energy) cut out the shape of plexiglass or to use a 3D printer that plotters out thermoplastic (additive application of materials). Depending on instructions from vector based software.

Enough about the technology. What is interesting is not what makes the Audi in Ingolstadt, without the cost of these things start to come down to the levels where individuals or small groups of people can afford to get stuff. Just as we moved from mainframes to laptops and from printing presses to printers is the ability to go from factory to personal manufacturing.

2001 founded a handful of professors at MIT (Massachusetts Institute of Technology) Center for Bits and Atoms, CBA, with funding from the National Science Foundation. Center's mission was and is to see what comes after the digital revolution. What they predict is a revolution in manufacturing, a move toward personal production.

It is available on our website for Fablab Sweden who will open up a series FabLabs (fabrication lab course ...) in Sweden this year, a concept that comes from MIT's CBA. The idea is to give people the opportunity to just walk in there and produce what has completely through rapid prototyping. The idea is to FabLabs become hubs that can trigger the revolution in personal fabrication. Another is a laser cutter bit too expensive for an individual, but start up business services where you buy time / materials either in person or online, it's not so difficult to obtain purchase costs to go around.

Already, there are options for the home handyman. The sexiest machine of them all is the RepRap, which I thought to devote a separate post for. But let's just say that it is a project (in beta stage may well be said) to create a self-replicating (it should be able to manufacture all their parts) 3d-printer where the cost of materials is not currently stands at more than 500 dollars.

Reprap repraps it's electronics.

RepRap stands for Replicating Rapid-prototyping and is a 3d printer. The machine melts the plastic and drops the plastic in small stocks, until you get a large item of it. The really cool with RepRap, version Darwin, is that between 50-60% of all parts of RepRap: one, can RepRap: a self-print! This means that the machine is partly self-reproducable!

It would have been great fun if people bring their own-designed 3D objects and to print them with the RepRap.

The RepRap & Q formats. Stl. Save / convert your 3D objects to. Size, include the file to the Research Department, we write it out! We have green and blue plastic.

The goal is a RepRap can print out the parts for a copy of itself). A group within the Pirate Party (Pirate plant) have built together a RepRap for two reasons. Firstly, we are visionaries. It is not strange for us to imagine a future where you do not buy their designer goods in each specimen (compare record sales), but pushes them into the nearest RepRap.

And now Reprappers are working on printing circuits/pcb on their own:

http://blog.reprap.org/2010/09/reprap-repraps-reprap-electronics.html

WaferBoard Rapid Prototyping for Electronic Systems

DreamWafer, WaferBoard, WaferIC, IC, Integrated Circuit, wafer scale FPGA, ASIC, netlist, interconnect, embedded design, coupled to PCB tool www.DreamWafer.com

SCHIEL Rapid Prototyping dk 0910

About 3D Rapid Prototyping Machines

3D printing is a rapid process that layered build a prototype or model. The process adds layers of new material in liquid or powder form and fixes it in the desired contour. The process is controlled by a computer program, and takes place in special prototype machines that also called 3D printers.
Essential to produce a prototype of a 3D printer is a 3D data file of the part to be made.
The advantage of 3D printing is that according to a 3D data file to create a physical part quickly and cost-effective, and without the use of casting tools.
3D printing available today for example in product and industrial design, architecture and other model building, and in orthopedics and technical aids.

One of these are the MakerBot

at makerbot.com

3D printing can be an important contribution in development of new products by making a prototype that can be tested both functionally and design wise.

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