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New web site helps you ‘breed’ 3-D printable objects

Even though it is still computer-aided design, it’s not CAD in the way most of us think of CAD today. And it’s changing the job of CAD engineers. Instead of designing objects that will eventually be made and sold, the function of CAD engineers is shifting to developing programs that automate design tasks so that anyone, not just engineers, can create. CAD programs are increasingly being viewed as inhibitors to product development precisely because they require some skill to use.

Blame the 3D printing industry for the change. Said Hod Lipson, Cornell associate professor of mechanical and aerospace engineering and computing and information science, “Now that 3-D printing is taking off, the goal is to unshackle the design process, …” Lipson likens the 3-D printing industry to iPods with no music – the printers exist, but the availability of content is bottlenecked by the old methods like CAD that few people know how to use and that stifle creativity.

Cornell University is the latest organization to tackle the current design challenge; Lipson and his students just announced a website that lets anyone point, click, collaborate, and create online in the evolution of printable, three-dimensional objects. They aim to transform the design of art, architecture and artificial intelligence.

Their new interactive website, EndlessForms.com, eliminates the need for skilled engineers to draw in CAD programs, which can be complicated and non-intuitive. The site lets users design their own things without any technical knowledge and using the same principles that guide evolutionary biology. These new design tools free people to focus creativity, instead of being mired in technical details, Lipson said.

The Web site was developed by Jeff Clune, Cornell postdoctoral fellow; Jason Yosinski, Cornell graduate student in engineering; and Eugene Doan, Cornell undergraduate student in the Creative Machines lab of Lipson.

On EndlessForms.com, objects are evolved in the same way that plants and animals are bred. You pick the ones you like and they become the parents of the next generation of objects. As in biological evolution, the offspring look similar, but not identical, to their parents, allowing you to explore different designs. This grounding in developmental biology enables the evolution of complex, natural looking forms.

Users can further evolve, share, and rate these objects, creating a collaborative exploration of designs that, according to Lipson, represents an entirely new way of thinking about design. Users can then have their objects made by 3-D printing companies in a range of materials, such as silver, steel, ceramic or sandstone.

Cornell Creative Machines lab
http://creativemachines.cornell.edu

EndlessForms
http://EndlessForms.com

 

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The iconic crash-test dummy is anything but dumb. It’s a high-tech testing device with innumerable physical and electronic permutations to satisfy the unique needs of each customer, whether auto maker, airline, space agency or military branch.

This persistent demand for sophisticated new products and features explains why Humanetics Innovative Solutions of Huron, Ohio, a leader in the design, development and manufacturing of anthropomorphic test devices (ATDs), uses 3D printing technology from Z Corporation.

“ZPrinting lets us make new parts for the client in a day and a half instead of the week or more it takes when we need to machine new steel or aluminum molds,” said Humanetics Project Engineer Kris Sullenberger. “It’s also probably a 10-to-one cost savings in materials and machine work, meaning we save hundreds of dollars each time.”

A 3D printer produces physical models from computer-aided designs much as document printers print business letters from word-processing files.

Sullenberger’s team purchased its ZPrinter four years ago to execute an urgent project for the US Department of Defense during the second Iraq war. The client needed a sophisticated head model to test a new generation of goggles and face shields. The head model consisted of a dozen segments representing facial bones, each having impact data collection sensors.

“ZPrinting was the only way we could do the job,” Sullenberger said. “Time was of the essence, and ZPrinting’s speed, accuracy and resolution was best suited to the government’s needs.”

Sullenberger’s team ZPrinted patterns and mold boxes, quickly created silicon molds, and then heat-poured the urethane parts. “From start to finish, the whole product – design, building, testing and shipping – took six months. It would have taken three months of machine time alone to make aluminum molds. And revisions would have been a nightmare. Instead, we just reprinted and repoured anytime we needed a change.”

Today, Humanetics is printing about 200 parts a year, often multiple parts per build. At peak, Sullenberger’s team runs the ZPrinter around the clock for three weeks on end.

Although most of Humanetics’ ZPrinting is for mold and pattern production, the company also prints samples for marketing and sales, often helping explain concepts better than words or CAD images.

“We’ll send complete scaled-down dummies to clients, including senior executives and other non-technical professionals, or we’ll send detailed models that help explain new designs,” Sullenberger said. “People often don’t know what they’re looking at in a picture. But it drives the information home when you print a part, split it in half and let the person pick up the pieces, examine the internals, and put them together themselves.”

Z Corporation

www.zcorp.com

 

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Now this development is very cool. So 3D Systems Corp. (NYSE: DDD) announced that its BfB™ 3000 3D printer successfully completed two zero-gravity test flights in partnership with MADE IN SPACE, a start-up dedicated to providing solutions for manufacturing in outer space.

MADE IN SPACE believes that the advantages of 3D printing make it the perfect system for use in outer space. “3D printing and in-space manufacturing will dramatically change the way we look at space exploration, commercialization, and mission design today,” said Aaron Kemmer, CEO and Co-Founder of MADE IN SPACE. “The possibilities range from building on-demand parts for human missions to building large space habitats that are optimized for space.”

“We are pleased that our Bits From Bytes 3D Printer performed well in zero gravity conditions,” said Cathy Lewis, Vice President of Marketing for 3D Systems.

MADE IN SPACE plans additional zero gravity and suborbital testing over the next twelve months.

3D Systems Corporation
www.3DSystems.com

 

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The good news about a healthy additive manufacturing industry continues. 3D Systems Corporation (NYSE: DDD) reported that it earned 26 cents per share diluted, for the second quarter of 2011 on a 57% revenue increase and a 58% gross profit improvement compared to the second quarter of 2010. The company’s quarterly and annual earnings benefitted by 12 cents per share from releasing a portion of its valuation allowance on deferred tax assets.

Net income included $0.4 million of restructuring expenses, $2.2 million of legal expenses and $3.4 million of non-cash expenses related to depreciation, amortization and share-based compensation expense for the 2011 quarter compared to $2.4 million of non-cash expenses and $1.2 million of legal expenses for the 2010 period.

“We are pleased with our organic growth, record printer units sold and the continued strong revenue expansion from all our products and services,” said Abe Reichental, 3D Systems’ President and Chief Executive Officer.

For the second quarter 2011 the company delivered record revenue growth from all its revenue categories. 3D printer units sold tripled over the comparable period and accounted for a $5.5 million revenue increase.

Print materials grew by $2.4 million on strong user demand and an expanded installed base. Services, including custom parts, increased by $12.0 million compared to the second quarter of 2010. Healthcare solutions grew 32% over the prior year and organic growth accounted for 25% of the company’s total revenue increase.

“We remain focused on democratizing access to affordable and viable 3D content-to-print solutions for professionals and consumers alike. We believe that the marketplace for our products and services is largely underpenetrated and that our diversified portfolio makes us more attractive to broader audiences. While the rapid growth rate of our custom parts and printers revenue outpaced our margin expansion rate for the quarter, we remain optimistic about our future and believe that we are on track to achieve our long-term target operating model,” concluded Reichental.

3D Systems Corp.
www.3dsystems.com

 

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We recently completed a handbook on additive manufacturing. It will appear in the August issue of Design World. One of the things I became reaquainted with from working on this project is just how many options you have for rapidly prototyping (or manufacturing) your designs. It’s easy to get caught up in the idea that all we have are 3D printers, especially with all the media coverage this part of the industry is receiving today. But you have more options, including subtractive prototyping and rapid injection molding.

Under the broad umbrella term of rapid prototyping (or rapid manufacturing) you can choose additive technologies such as 3D printers, subtractive technologies such as CNC machines, and rapid injection molding (RIM) systems.

Each of these choices is available to you as either an in-house operation (with the purchase of the equipment) or as an outsourced option to a service bureau. The choice, of course, depends on the application.

With all the attention 3D printing is receiving, though, you might want to reacquaint yourself with the subtractive and RIM options.

Subtractive technologies usually use CNC machines. But CNCs are not the machines of the 1950s or 1960s. Vendors have been continually upgrading the design and operation of them so that you can simply push a button, walk away and come back to evaluate the result. Roland, for example, makes CNC machines that do not require programming in G code. And the price of some of these systems ranges from $20,000 to $60,000.

Rapid Injection Molding (RIM) involves injecting thermoplastic resins into a mold, just as is done in production injection molding. What makes the process “rapid” is the technology used to produce the mold, which is often machined from aluminum instead of the traditional tool steel used in production molds. Molded parts are strong and can have excellent finishes.

RIM is also the industry standard production process for plastic parts, so there are inherent advantages to prototyping in the same process if the situation allows. Almost any engineering grade resin can be used, so you are not constrained by the material limitations of the prototyping process.

So, when you are investigating rapid prototyping, remember to think in “threes.” One will be right for your prototyping or production needs.

 

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A positive financial report from Stratasys, Inc. (NASDAQ:SSYS) is further indication that this industry is growing. The company reported record revenue of $37.6 million for the second quarter ended June 30, 2011, compared to $30.1 million reported for the same period in 2010. The second quarter results include two months of contribution from the company’s acquisition of Solidscape, Inc., which contributed $2.1 million in revenue to the second quarter results. Excluding the contribution made by Solidscape, revenue was $35.5 million, an 18% increase over the same period last year.

“Our record second quarter results reflect strong growth in Fortus system sales and consumable revenue,” said Scott Crump, chairman and chief executive officer of Stratasys. “The growth in these higher margin products, as well as a continued favorable product mix within 3D printing, contributed to significant margin expansion during the period. These factors combined to generate the highest level of quarterly operating profit in our company’s history.”

The company renewed its agreement with HP for the sale and distribution of its proprietary 3D printers. HP plans to expand into new European markets beyond the five countries they currently serve later this year. Stratasys and HP continue to see a significant market opportunity within 3D printing and both parties remain committed to the collaboration.

“Fortus system sales sustained strong momentum in the second quarter, expanding by 67% over last year,” continued Crump. …“We believe the recent launch of the Fortus 250mc will add to our strategy with a product that combines the higher functionality of a Fortus 3D production system with the ease-of-use and affordability of a Dimension 3D printer. Initial bookings of the Fortus 250mc have been strong.”

Consumable revenue grew in the second quarter, increasing by 20% over last year. The Fortus line is driving this growth, propelled by an expanding base of systems and the product line’s relatively higher use rates, particularly within DDM. The recent introduction of a revolutionary new FDM material should create new DDM opportunities within the electronics industry. This material, called ABS-ESD7, eliminates static electricity, which can be potentially damaging during the manufacture of sensitive electronic components. The material lets you make static-free assembly aids and fabrication tools.

“The acquisition of Solidscape adds to Stratasys’ strategy of expanding into DDM applications; the subsidiary is well positioned for manufacturing applications serving the custom jewelry market. “However,” noted Crump, “as we further develop the technology, we are more excited about the new opportunities that Solidscape provides within a broader set of industrial applications.

“We were pleased to see our leadership position within the additive manufacturing industry reconfirmed in the recently released Wohlers Report 2011. The report indicated that Stratasys had a 41% unit market share in 2010, and has maintained a market leading position for nine consecutive years. We believe our position within the industry will be strengthened over the coming quarters as we execute on our new product roadmap and further develop our channel with HP and our independent reseller network.

Stratasys, Inc.
www.Stratasys.com

 

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Stratasys new Fortus 250mc is a smaller FDM machine with end-use manufacturing capability.  We spoke with the product manager for more information on this unit.

 http://podcast.designworldonline.com/2011/07/25/522/

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INUS Technology, Inc. is pleased to announce that a recent U.S. Air Force funded study evaluating CAD and reverse engineering software concluded that Rapidform XOR stands alone in its ability to create parametric solid models from 3D scan data. The study was conducted by Dr. Kuang-Hua Chang of the University of Oklahoma and published in the journal CAD and Applications (www.cadanda.com).

This study offers an unbiased, expert opinion on software used to create parametric CAD models from 3D scans.

 Rapidform XOR was released in 2006.

The U.S. Air Force frequently needs to regenerate designs of decades-old parts, and so commissioned the University of Oklahoma to study both 3D scanning software and hardware to determine the best available technology. INUS Technology had no knowledge of the study or its outcome until it was published in CAD and Applications. 

Dr. Chang and his students surveyed the landscape of software available for converting 3D scans into parametric solid models usable in CAD, evaluated and then tested the front runners using practical examples. “We used five different examples in two rounds of testing,” said Dr. Chang. “The first round was surface modeling, and in the second round, we focused on parametric solid building. We found that Rapidform was the only viable option that supported support parametric modeling and transferring the solid model to CAD systems. When we say ‘viable option,’ it’s based on two things. One is the time and effort, the other is the accuracy.”

According to Chang, other software “was able to generate a parametric solid model, but it took a long time and the solid model created was not very accurate.”

“It’s very rewarding to see an unbiased study recognizing the value of Rapidform XOR compared to other 3D scanning software,” noted Calvin Hur, INUS Technology’s CEO. “We encourage anyone considering 3D scanning technology to read this paper to make a decision on their reverse engineering software solution.”
 
The entire paper, including technical details of each tested software, is available for free download at http://www.rapidform.com/reverse-engineering-study.

INUS Technology Inc.

www.rapidform.com


 

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Engineers from NVision, Inc., using the company’s HandHeld Scanner, were able to quickly reverse engineer a large impellor for a major hydroelectric facility, sparing the facility what would have been an extended shutdown had they needed to produce a replacement impellor from scratch. In less than one week, NVision engineers scanned the original impellor and provided a computer model of it to the facility, which then used the model to manufacture a duplicate impellor for installation. In the end, only a relatively short shutdown was necessary to accommodate the scanning and reproduction of the impellor.

The turbines that move the water in hydroelectric plants employ massive impellors to get the job done. In this case, one of the facility’s key impellors had suffered damage that forced engineers to replace it. However, the engineers did not possess a computer model of the impellor, which was necessary to manufacture a replacement. Without a replacement available, the plant was facing an extended shutdown with potentially high losses in time and money.

The facility’s management contacted NVision to produce a computer model of the impellor. Two days after the initial contact, with a refurbished impellor temporarily in use as a replacement, an NVision engineer was on site to scan the impellor using the HandHeld laser scanner.

The HandHeld scanner is attached to a mechanical arm which moves about the object being scanned, freeing the user to capture data rapidly and with a high degree of resolution. An optional tripod makes the unit portable in the field. Intuitive software allows full model editing, polygon reduction, and data output to all standard 3D packages.

“The HandHeld laser scanner was perfect for this project because its ability to move freely around a part makes it possible to reverse engineer components of virtually any size and shape,” said Colin Ellis, Engineering Manager at NVision. “In this case, the spacing of the blades was large enough for the laser scanning head to fit through.”

Scanning took eight hours, and included data from three locations situated throughout the part, with data being indexed into the same coordinate system using geometric features. After the data was collected and processed into an STL mesh, a SolidWorks model was created in two days. The facility received the completed model of the impellor just six working days after first calling NVision with their problem. The computer model was used to manufacture an exact duplicate of the original impellor.

“By using laser scanning to reverse engineer the impellor the facility was able to avoid a lengthy and costly shutdown,” said Ellis. “As a side benefit of the scanning, we found that the impellor being used as a replacement was greatly out of balance, with no easy way of manually checking the part to see where the problem lay. Fortunately, using our inspection software, we were able to rotate and compare the data virtually, allowing precise indication of problem areas.”

NVision, Inc.
www.nvision3d.com/

 

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