Rapid Prototyping

Stratasys Inc. (NASDAQ: SSYS) announced the launch of its Dimension brand’s eighth annual Extreme Redesign 3D Printing Challenge. The global contest encourages students to submit an innovative new product design, a redesign of an existing product, or an original or redesigned work of art or architecture.

Educators worldwide have recognized the annual design and 3D printing contest for its positive impact on students. “Students have the opportunity to put their critical thinking skills to the test, as well as to demonstrate their creativity with this design contest,” said Jesse Roitenberg, Stratasys Education Channel Manager. “Each year they demonstrate they are up to the challenge, with the unique submissions we receive.”

Dimension 3D Printing will award nine student winners either $2,500 or $1,000 scholarships in the categories of Middle School and High School Engineering, College Engineering, and Art & Architecture. Designs are awarded based on creativity, usefulness, part integrity and aesthetics. Instructors of the three first-place student winners will receive an Apple iPad for use in the classroom. Since the contest’s inception, more than $90,000 in scholarships have been awarded to students.

Each submission must:

• be a sound mechanical design

• be realistic and achievable

• include a clear written description of the design.

This year’s contest will also feature an award category in which students may compete for a bonus prize. Students who incorporate a school-spirit theme into their designs will have a chance to win a $250 gift card.

For video, photos, and descriptions of previous winning designs, visit Extreme Redesign 3D Printing Challenge. For contest rules and regulations, visit ER Rules & Regulations.

Dimension
www.dimensionprinting.com

Stratasys, Inc.
www.stratasys.com

Source: :: Make Parts Fast ::

Shoes are not a typical design project for engineers. But 3D printers show that just about anything is possible. In this example, it also shows how these printers free your mind to explore other ideas and possibilities.

Marloes ten Bhömer is an acclaimed designer of provocative and otherworldly shoes. For some of her work, she uses a 3D printer from Object Ltd. Because of the multi-material printing capability of these 3D printers, she can design and manufacture her shoes to be modular so that they can be dismantled and reassembled for the purpose of replacing parts. One example is the Rapidprototypedshoe.

“My work is very much about liberating design – I use new materials and methods because this helps to break away from conventional approaches,” said Marloes ten Bhömer. “The rapid prototyping process stimulated the idea for this shoe, as the name suggests. I explored the technology and saw that rapid prototyping – adding material in layers – rather than traditional shoe manufacturing methods – could help me create something entirely new within just a few hours.”

Further research led ten Bhömer to Objet’s Connex range of multi-material 3D printing systems. “These printers make it possible to print an entire shoe – albeit a concept shoe – including a hard heel and a flexible upper in one build, which just isn’t possible with other 3D printing technologies,” stated ten Bhömer. “The shoe is printed as a single entity so the parts come off the printer already assembled, and you can still take the shoe apart later on. It is inspiring and opens up the possibility of interchangeable heels and creating custom designs. Also, the possibility of repairs allows for a more realistic product and changes the idea of rapid prototyping into rapid manufacturing.”

The Connex line of Objet 3D printers can combine rubber-like materials and rigid materials in a single prototype; they are used extensively in the footwear industry. Said Gilad Gans, executive vice president of Objet, “As an affordable alternative to factory-produced samples, the process encourages users to review more design alternatives, increasing the potential to produce a more creative or better designed concept.”

“Cost-wise it does make sense to use these printers, particularly for haute couture shoe design,” said ten Bhömer. “I can have prototypes printed in multiple materials with no expensive set-up costs and no minimum quantities. I also have great confidence in the quality of digital prototyping – with conventional shoe mould making, the heel is matched to its left or right counterpart by eye, so there’s always room for error and it can be a slow process. By making the moulds digitally you know the left and right shoes are an exact match and it’s also economical and easier to scale seven different sized pairs, as required for a commercial line of shoes, using specialist software and Objet 3D printing.”

Objet Ltd.
www.objet.com

 

Source: :: Make Parts Fast ::

‘WTC Triptych’ documents the cityscape before, shortly after the 9/11 attack, and the rebuild

There are as many ways to interpret 9/11 as there are people who experienced that horrible day, whether up close or at a distance. One man’s preference is documenting Ground Zero, in painstaking detail, before the attack, after the twin towers had fallen, and today, now that the site is being rebuilt.

David Munson’s amazingly detailed three-part model “WTC Triptych” is on display at the New York City Fire Museum in Manhattan’s Soho district. With each model measuring 17 in. x 17 in., it was created on a Z Corporation 3D printer.

 

 

 

 

“There are many wonderful writings, photos and artwork that interpret 9/11,” said Munson. “I think it’s also important to document the totality of it as objectively, realistically, and completely as possible, with a minimum of poetic license and a devotion to detail, on a scale the average person can absorb. These are my strengths, and this is my small contribution to ensuring people never forget.”

Munson, with a background in producing construction documents, owns the Munson3D.com architectural visualization company, and is a specialist in precise, complex representation. He drew from numerous data sources to create “WTC Triptych,” including 2D satellite imagery, Google Earth, photographs (personal and downloaded from the Internet), publicly available 3D models and Wikipedia, among others. He used Autodesk 3dsMax Design computer-aided design software as well as AutoCAD, Google SketchUp, and Adobe Photoshop as auxiliary programs.

“The data was not from one particular source but was cross-checked against multiple sources,” he said. “So I could cross-check a graphics source with http://skyscraperpage.com/, for example, or simply go to Wikipedia to find the numerical height of a building. Also, 3dsMax Design let me extract 3D information from flat photographs as long as there were enough ‘known’ points. So, I used photos for more than just applying textures on the models. There is no simple way to describe this process other than to say it is very precise for the scale.”

Though extremely labor intensive, gathering the data was only the beginning. The data was then used to create an accurate physical representation. “There is only one way to do it,” said Munson. “I needed the ZPrinter®, which not only accommodates large sizes but, because of its unique color capability, is the only way to accurately reproduce the highly detailed texture mapping used in these computer models. This process creates a whole new medium for city planning, and I hope this exhibit illustrates its potential value to a larger audience.”

Z Corporation
www.zcorp.com

 

Source: :: Make Parts Fast ::

You might have wondered just how 3D Systems was going to organize all of its recent acquisitions in its plan to “democratize access and accelerate adoption” of this technology. After all, the acquisitions made during 2010 and 2011 cover quite a range of technologies, including service bureaus and software (see the list below). It would be easy to conclude that integrating all of the acquisitions into a cohesive unit is a challenge for any company. Well, 3D Systems announced a new website that does a nice job of organizing all acquisitions and the capabilities they offer. It’s fairly easy to navigate. The “See more 3D Systems Solutions” bar is particular nice, helping you see it all in one glance.

 

 

 

 

 

 

 

 

 

 

Said Cathy Lewis, VP of Global Marketing for 3D Systems, “This new site underscores our commitment to technology leadership and showcases the high value, low volume 3D printing applications that leverage our first mover advantage in this exciting shift to on-demand, rapid manufacturing.”

Check out the website here: http://production3dprinters.com/

3D Systems
www.3Dsystems.com

3D Systems acquires Alibre

Get your complete 3d printing system

3D Systems acquires Freedom of Creation

3D Systems acquires The3DStudio.com

3D Systems buys Deelip Menzes products

Another Acquisition for 3D Systems, Print3D Corp.

3D Systems acquires Accelerated Technologies Inc.

3D Systems Acquires Quickparts

3D Systems teams up with Solidvision

Bits from Bytes acquired by 3D Systems

3D Systems acquires French prototypers CEP and Protometal

3D Systems acquires Design Prototyping Technologies

 

 

Source: :: Make Parts Fast ::

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


 

Source: :: Make Parts Fast ::

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

 

Source: :: Make Parts Fast ::

The trend to put Additive Manufacturing (AM) technology into schools continues. Stratasys (NASDAQ: SSYS) announced that it has been chosen by the Georgia Institute of Technology to provide its Dimension 3D Printers to select high schools across the U.S. as part of The Defense Advanced Research Projects Agency (DARPA) Manufacturing Experimentation and Outreach (MENTOR) program.

The DARPA MENTOR program should boost engineering skills for high school students, as well as spark an interest in engineering, design, manufacturing, math and science-related university programs. The four-year program is focused on engaging high school-age students in a series of collaborative design and distributed manufacturing experiments, including using additive manufacturing machines (or 3D printers).

“This program will provide students with skills they need to solve future design and engineering challenges, which will aid U.S. industry,” says Dr. David Rosen, Professor in Mechanical Engineering, Georgia Institute of Technology. “3D printers play an important role in the hands-on and “minds-on” learning, which the MENTOR program facilitates. Stratasys FDM technology is instrumental to this program.”

Starting in 2012, Stratasys Dimension and other brand 3D printers will be installed in more than 20 high schools selected by the DARPA program as part of the first phase roll-out. Currently, one system is already in place for a pilot institution so that educators can start to develop curriculum for the program. Additional 3D printers will be placed in subsequent phases over a four year period. “We estimate this program will generate orders for about 50 Dimension 3D printers over the course of the four year term,” says Stratasys Vice President of Direct Digital Manufacturing, Jeff DeGrange. “And we think that serious interest in 3D printing from an organization like DARPA is evidence of a solid future for additive manufacturing.”

Stratasys, Inc.
www.Stratasys.com

Dimension
www.DimensionPrinting.com

 

Source: :: Make Parts Fast ::

Independent university study evaluates material properties over time for PC and ABS plastic parts produced via Stratasys FDM process

Stratasys Inc., (NASDAQ: SSYS) announces findings from an independent and extensive performance study characterizing the effects of time, temperature and environment on the mechanical properties of PC (polycarbonate) and ABS plastic parts made through the Fused Deposition Modeling (FDM) process.

The first of its kind, this study provides critical data for manufacturers considering additive manufacturing for production parts or functional prototypes. This information is needed as additive manufacturing moves from its roots in prototyping to production of finished goods. “The finished product or prototype can be in service for extended periods of time and in varying conditions, so it is imperative to qualify the properties beyond published specifications,” the study stated.

The independent study was conducted over a 52-week period by Loughborough University, UK. The study evaluated the mechanical properties over time of polycarbonate and ABS plastic parts made with the Stratasys Fused Deposition Modeling process and how the parts stand up in the extreme environments of heat, cold, moisture, and dryness.

“Stratasys has migrated into manufacturing and other high-requirement applications,” says Fred Fischer, Director of Materials Business Development for Stratasys. “And manufacturers are hungry for data on mechanical performance of additive processes. The Loughborough study offers statistically sound, comprehensive data, which will help engineers make decisions about additive manufacturing.”

For survey overview, specifications and detailed findings:

Additive Mfg FDM Mat’ls Study / ABS

Additive Mfg FDM Mat’ls Study / PC

Stratasys, Inc.
www.Stratasys.com

 

Source: :: Make Parts Fast ::

EngineeringZONE introduces New England high school students to the wonder of making things

A great way to expand the use of Additive Manufacturing (AM) technology, intrigue students into engineering fields, and start to tackle the issues involving jobs and manufacturing in this country is for AM vendors to work with teachers and schools.

Rapidtech.org is a group that sponsors workshops on rapid prototyping and additive manufacturing for anyone to attend. This educational entity is part of the Saddleback College and is partially funded by the National Science Foundation. It assists businesses, educational institutions, entrepreneurs and community-based organizations in developing new products and designs using innovative rapid prototyping technologies, additive manufacturing, and reverse engineering. Recently, the organization held a workshop for teachers to inform them of this technology and help them communicate this information to students. Z Corporation, Stratasys, NextEngine, Rapidform, and SolidWorks were among the participants in the workshop.

On August 30, 2011, Z Corporation announced the launch of “EngineeringZONE™,” an initiative that invites high school classes to visit the company monthly for an afternoon to experience some of the latest 3D printing and 3D laser scanning technology.

Students in the EngineeringZONE program will try their hand at some introductory computer-aided design (CAD) software and will make their own 3D printed models. Interested high schools should contact Z Corporation for more details.

At the press event announcing this action, Congressman Tierney, New England Member on the House Education and Workforce Committee, applauded Z Corporation’s efforts.

Said, Scott Harmon, vice president of business development, Z Corporation, “We’re thrilled to open our doors to curious students because this is where the magic happens, where you can see a design on a computer screen turn into a physical object before your eyes. In addition to the sizzle, 3D printing brings together all of the disciplines – science, technology, engineering and mathematics – that our students so desperately need to master now and in the future. We’re honored that Congressman Tierney, was able join us on this important initiative.”

Z Corporation

www.zcorp.com

 

Source: :: Make Parts Fast ::

Do you need an in-house 3D printer? You may think your prototyping volume does not justify one. But there are a number of good reasons to consider buying a desktop 3D printer, besides the fact that prices for many of these units are $20,000 or less. Plus, these units deliver good accuracy and tolerance for form and fit, and sometimes function.

One key benefit to consider is how an in-house printer can help you get your designs to market faster. Depending on the service bureau, turnaround time for outsourcing prototypes can take as few as 2 to 3 days. While fast, this time does not include the time involved in design; and in-house 3D printers can help shrink that design time.*

Even though the other tasks involved in design (internal review meetings, approvals, and so on) can be done in parallel, you still must wait for a model to return from an outsource provider. With an in‐house 3D printer, however, you can have your prototype model within hours. Not to mention additional time saved by printing during the night or over the weekend when no one is at the office. This can effectively save weeks off the entire development cycle – and dramatically accelerate time to market of new products and new features for existing products.

Development tends to continue while a design is at the service bureau. Features often change, which can put you in a development time lag. But with the ability to quickly print 3D models in just hours, decisions can be based on accurate prototypes and data.

When prototyping is readily available and can be done inexpensively in multiple iterations, the potential for errors is significantly reduced. You can test out different ideas to find the optimal design. Small variations can be modeled and checked for function. Details can be fine-tuned and potential manufacturing errors can be caught before molds and die casts are made.

While you may spend $20,000 up front for a 3D printer, the return on investment is often quick. An outsourced prototype can cost anywhere from several hundred dollars for a simple design, up to thousands of dollars for a more complex model. Even if printing only two models per month on average, an onsite 3D printer can produce major cost savings. In addition, you will find that you use an in-house printer more often because of its convenience, which will shorten payback time even more.

Another advantage of in‐house 3D printing—it can help ensure intellectual property confidentiality. Whenever detailed designs are sent beyond the company network and outside the company’s physical premises, a potential risk is involved.

Keeping rapid prototyping in‐house with a 3D printer eliminates the need to transmit design files to any external network. It ensures that designs never leave the company premises, and intellectual property is better safeguarded.

Today’s desktop 3D printers can print ultra‐thin layers that deliver functional and visual accuracy that match and even outperform other prototyping technologies. They can print the smallest features and finest details, smooth surfaces, and even moving parts, in a single build process. And, with a choice of model materials and varied post‐processing options, it’s possible to create models with a look and feel that closely resemble the end product.

Objet Geometries Ltd.
www.objet.com

*In a survey of over 1000 Objet 3D printer owners, for example, almost one‐third reported experiencing a 25% or more improvement in product launch times, with more than half of respondents reporting a product launch time improvement of at least 10% or more.

Material for this article is courtesy of Objet Geometries Ltd.

 

Source: :: Make Parts Fast ::