The Additive Manufacturing section of this blog is for PADT customers in particular, and users of 3D Printing in general. We hope you find it useful and entertaining.
Over time we will post information below. Feel free to use the search to find specific information. We also have some non-changing information on our resource page.
Posted on March 29, 2018, by: James BarkerPADT's Salt Lake City office has been involved with fulfillment of medical 3d Printing of several cases where customers are exploring the value of multi-color and multi-material medical 3D models by using the Stratasys J750 or the Connex 3. One of those cases was presented at the Mayo Clinic’s Collaborative 3D Printing in Medical Practice 2018 course, which was held in Arizona this year. An Intermountain Healthcare facility in Salt Lake City needed help with 3D printing a patient-specific anatomy, as they were looking to better their understanding of the value of 3D printing using multi-color printer beyond their existing in-house capabilities. In the picture below, Rami Shorti, PhD., a senior Biomechanical Engineering Scientist at Intermountain Healthcare, wrote: “A patient with a horseshoe kidney and multiple large symptomatic stones, who had failed Extracorporeal Shock Wave Lithotripsy and Ureteroscopy Treatment, was used to evaluate the benefit of using different imaging modalities intraoperatively.” Working with us in Salt Lake City, Rami Shorti, PhD, prepared the patient-specific medical imaging segmentation, post-processing of the patient anatomy, and finally generated for us a 3D printable CAD model that we were able to print using a Stratasys Objet 260 Connex 3. Since our office is located just around the corner from the hospital, we were able to work closely with Rami to identify the colors and finish of the final part. The Connex 3 printer was introduced in 2014 as the only printer in the world that could combine three different model materials in a single print pass. Most 3D printers can only print with one material at a time, which is one of the main reasons why this technology is preferred for medical use cases along with its added precision. In 2017, Stratasys introduced the J750, which again is an industry first, becoming the only printer in the world that can print 6 different materials at the same time. Combinations of hard plastics and rubber materials allow for a range of shore hardness values along with the ability to mix three primary colors to print 500,000 different colors. With a quick turnaround needed, we decided to use the Connex 3 and were amazed that we were able to print the parts in two batches. Within 48 hours of receiving the STL files from Dr. Shorti, we were able to 3D print, post-process, and deliver the parts in time for the surgeon to review the time-sensitive surgical planning guides using the mockup. To enhance the transparency of the parts, we simply applied a few coats of Rust-Oleum Clear Gloss to the 3D printed part. Now we were able to relax and wait for it to dry. Below is a picture of the finished products displayed at the Mayo Clinic event. “3D printing added a level of benefit because of its ability to showcase the stones, renal pelvis, and renal arteries and veins simultaneously through the image fusion step done in Mimics software and with the use of specific materials and contrasting colors. In addition, its ability to be held and manipulated in space was observed to be beneficial especially for patient education.” - Rami Shorti, PhD., senior Biomechanical Engineering Scientist, Intermountain Healthcare PADT is excited to continue our work with Intermountain Healthcare, and grow this relationship as new opportunities arise to leverage multi-material printing.
Posted on March 16, 2018, by: Eric MillerWe are very proud of our Additive Manufacturing intern Austin Suder who just won Future Engineers “Two for the Crew” Challenge, presented by the ASME Foundation and NASA. The challenge asked to invent a multifunctional object that combined two items into one for 3-D printing by crew members aboard the International Space Station (ISS). As a winner he will receive a trip to Washington DC, a MakerBot 3D printer donated to the orginization of his choice, and best of all, his design will be printed on the ISS and used by the astronauts. Austin's design was a Carabiner Tool Clip that combined a way to easo;u secure a tool and hold the sockets and drivers that the tool needs. After designing the part he then used simulation to iterate on the design with virtual testing, and then he 3D Printed a prototype on his home 3D Printer. Austin started this project by researching what problems the astronauts faced. He found that a big problem was that tools would drift off in the micro-gravity environment of the station. This was annoying when they are working inside the station, and a critical problem when they are on a space walk. He also realized that they used a separate "holder" to keep the sockets and screw driver heads that the tool needed. Using this knowledge he developed a simple to operate carabiner to secure the tether on the hand tool to the astronaut and then use that same part to hole the sockets and drivers. But he did not stop there. He also learned what he could about the MadeInSpace 3D Printer that is on the station, and adapted the design to make sure the printer could make easily. Austin then used simulation to make sure the design was strong and robust. Then he printed his samples on his own home printer. Local Phoenix station ABC15 stopped by PADT yesterday to interview Austin and here is their story: https://www.youtube.com/watch?v=ofAZjlFOONM Much of Austin's knowledge and skill comes from his involvement in his school robotics team, and he will be donating the MakerBot he won to that team. We hare very proud of Austin's accomplishments. He works at PADT as an intern in the Advanced Manufacturing department focused on 3D Printing, doing CAD, running the machines, cleaning parts, and being our in-house expert on desktop 3D Printing. He will be graduating from High School this year and attending ASU as a Mechanical Engineer. We can not wait to see what he does next!
Posted on March 16, 2018, by: Eric MillerIn November of last year we did a press release on new Additive Manufacturing Laboratory at Metropolitan State University in Denver. Since then all of the partners have been hard at work getting the lab up and running. Last week MSUD released an interview with the University President about the lab as well as a tour of the lab. It is a great look at how academia and industry are working together to push advanced manufacturing forward. Not just on equipment, but also with internships and value added engineering at the university. Take a look: https://vimeo.com/258883677 PADT is proud to have been a key member of the team and a continued partner for the lab along with Stratasys. If you want to learn more about how PADT can help your company or university create partnerships like this or leverage 3D Printing in other ways, please contact PADT. We love this stuff!
Posted on February 1, 2018, by: James BarkerMy first time to Miami was a success! Last year, Stratasys held the partner kickoff in New Orleans and that was when they launched the F1, 2, and 3 series. Since then they have sold over 800 units of these types of FDM 3D printers in the USA. This year in Miami, they did announce something new but it still has a few quarters to go until there is an official release. To say I am excited about what is coming is an understatement! In fact, Stratasys is going to be releasing one new printer here in a few weeks. I am excited for the direction they are going. During this partner kickoff, they mentioned a huge price drop on all of their Polyjet printers! Send us a message for the latest pricing at firstname.lastname@example.org. As for PADT employees that were in attendance, we had quite the representation this year. Rey Chu (Co-Owner of PADT), Mario Vargas (Manager of Hardware Sales), Norman Stucker (Colorado Territory Manager), Anthony Wagoner (Utah Territory Manager), Kathryn Pesta (Sales Operations Manager), and me (James Barker, Sr. Application Engineer). Pictured above from left to right is Mario Vargas, Kathryn Pesta, James Barker, and Anthony Wagoner. Above is a picture of the Stratasys Panel that was open to some Q&A. 2nd from the right is S. Scott Crump who is the inventor of FDM (fused deposition modeling) printers 30 years ago. Below is a picture of the anniversary info for Stratasys along with Objet (Polyjet technology 20 years) and the merger between the two companies is now 5 years old! My introduction to 3D printers started 8 years ago with an Objet Eden 500 printer at L-3 Communications where I ran their 3D print lab. 6 months later we got an additional Polyjet printer which was a Connex 500. Amazing that we were able to justify purchasing another high quality machine after a few months of operating the Objet Eden 500! A few years later we got our first Uprint FDM printer from a sister company that no longer had a need for it. After using the Uprint for a few months, I was made aware of some of these thermoplastic materials that could only be printed on the production grade FDM machines. I created a business case to get the Fortus 450 and had every material option available at that time to print with (ABS family of materials, ASA, PC, Nylon 12, Ultem 9085, and Ultem 1010). I love both of these technologies and am confident that they provide the best solution for either rapid prototyping or tooling applications. We even have many customers that are printing production parts with these very precise 3D printers. One customer that is printing production quality parts is Laika Studios, who has produced these movies: Kubo and the Two Strings, The Boxtrolls, ParaNorman, and Coraline. The presentation they made for us on their stop motion animation was so much fun! 10 years ago for Nightmare before Christmas there were 800+ hand sculpted faces made. For Kubo and the Two Strings, there were 64,000 facial expressions that were all 3d printed with a Stratasys J750. Another fun fact about the movie is that it took 60 hours of 3D printing for one second of film time to be created which is why it takes 2-3 years to complete a film. Moonbeast is a 3ft long puppet that is entirely comprised of 3d printed parts which is the largest character they have done to date. If you have watched Kubo and the Two Strings, it appears to be computer animated but in reality it is stop animation with 3D printed parts! Here is a fun short video (13 seconds) of what the Stratasys printer looks like as it is printing and then support material being removed from the head with different facial expressions. https://youtu.be/YBoAXrlCfFA Matt Gimble, who works for Penske as a Production Manager, shared with us many of the different applications that have helped them save a lot of money since they’ve incorporated 3D printing. Racing is rapidly evolving and is very technical nowadays with a huge emphasis on engineering. 3D printing gives them the tools to meet the new challenges. There are many different great uses they’ve had for 3D printing – from a redesigned rear gear pump design, to a new exhaust tailpipe. Even production parts are made with Stratasys’ newest material, Nylon 12CF. This is a high strength chopped carbon fiber filled Nylon 12. Many that use this material are awe-inspired with its performance! The Superspeedway side view mirror is made out of this material and saved Team Penske 4-6 weeks – which is how long it takes for the mold to be made. Then what if the mold needs altering? Crew Helmet Light/Camera mount is also made in this great thermoplastic/composite material called Nylon 12CF. The above Fuel Probe was re-engineered and is lighter than its predecessor, plus more ergonomical to help with delivering fuel in a timely manner. Pre-preg carbon fiber sleeves when wrapped around a soluble support material and after the autoclave heating process, the soluble core is dissolved in a sodium hydroxide cleaning tank leaving only the carbon fiber. PADT is a manufacturer for the cleaning tanks that are sold with any Stratasys FDM 3d printer. The core is made out of ST-130 material which is perfect for this application or sacrificial tooling. Ultem 1010 was used as well to create carbon fiber layup tools in a fraction of the time it would have taken for the steel molds to be made. Typical turnaround is 1-3 days, as compared to 4-6 weeks. These are all great applications by Team Penske! Well done!! We learned a lot at the partner kickoff. Luckily I was able to get this great picture with S. Scott Crump and Mario Vargas! To this day Scott is still inventing and is a major contributor to innovating at Stratasys. While talking with him and Mario, he started talking about these many adventures that he goes on. Scuba diving off the island of Tortuga and having many sharks swimming above isn’t for the faint of heart, yet it is where Scott seems to find his happy place. My wife flew out Thursday night to come see Miami with me. It was my first time visiting Florida and we had a phenomenal time there. We put 800 miles on the rental car driving all around. Driving down the Florida Keys all the way to Key West was a blast and if you ever go to Key West, make sure to get a Cuban sandwich from the restaurant Bien! It is MUY MUY BIEN! The islands are so beautiful! We also went to the Everglades where we got an airboat tour and where I even held a 4 year old Alligator and gave it a kiss on the back of its head. My little girls shriek every time they see the picture! We had a great time in Florida! As we now look to the future, watch out for some exciting updates about new products that are coming! Stratasys, in my opinion, is going to continue being a leader in the Additive Manufacturing realm and I can’t wait to help announce some of the new equipment once it is available! Any questions you have, you can direct them to me at James.email@example.com. Thanks!
Posted on October 25, 2017, by: Eric MillerThe addition of a new UnionTech RSPro 450 further establishes PADT as the leader in Additive Manufacturing technology in the Southwestern US. With a build volume of 17.7 x 17.7 x 15.75 inches, this state of the art Stereolithography(SLA) machine will triple the company’s capacity to 3D Print with SLA technology at this Las Vegas print shop. It not only allows the printing of larger parts, it can also create multiple smaller parts in less time. It will join PADT’s two existing SLA machines along with the Fused Deposition Modeling (FDM), PolyJet, and Selective Laser Sintering (SLS) solutions currently producing parts daily for their customers across the country. “When we started the company in 1994, one of our first purchases was an SLA machine. It started our 3D Printing services business, and the technology is still heavily used today.” Said Rey Chu, a co-owner of PADT and the leader for PADT’s Advanced Manufacturing efforts. “This new system gives us added capacity in size, speed, and material choices. We looked at a wide range of SLA systems and felt that UnionTech provided the quality and robustness we need to keep our customers happy.” The new system was delivered the second week of October and will be calibrated and producing customer parts by the end of the month. One of the advantages of the machine is the easy setup and strong calibration capabilities. The team will be able to produce parts that are about 75% larger than they can currently. The additional volume and speed will allow for three times as many parts to be printed in a given week than is possible with the current two smaller and older machines. Initially, a new rigid ABS-like material will be used that produces very strong and precise parts with white plastic. PADT’s existing pre- and post-processing tools will be applied to this process with little change.
The UnionTech RSPRO 450 SLA SystemUnionTech systems are the most popular machines for SLA Additive Manufacturing outside of the United States. They have proven to be reliable, easy-to-use, accurate, and fast. They are also an open system, allowing users to use any SLA compatible resin that can usually be acquired at a more affordable price than proprietary material solutions. Stereolithography is the oldest commercial 3D Printing process. It uses photo-curable liquid resins to build parts one layer at a time. A vat in the machine is filled with liquid material, and a plate is placed just under the surface. Then an ultraviolet laser draws on the very top layer of the liquid, and all of wherever the laser traces, the liquid turns to a solid. The plate is lowered, a new layer of liquid is spread on top, and the laser creates a new layer. The process repeats until the part or parts are made. The UnionTech machine is a refined and proven application of this technology that was a perfect match for PADT’s current needs. Also, the company itself was great to work with, and the local sales and support team have been outstanding. As the team learns the system, they are finding it to be easy to use as well as simple to maintain and calibrate. The initial quality of parts has been outstanding.
PADT’s 3D Printing ServicesPADT has been the Southwest’s leading provider of 3D Printing services since the company was started over 23 years ago. The company has survived industry consolidation and a vastly changing landscape by focusing on providing high-quality 3D Printed parts to customers using Fused Deposition Modeling, Polyjet Printing, Selective Laser Sintering, and Stereolithography systems combined with one of the most experienced and knowledgeable teams in the Additive Manufacturing space. Located in the ASU Research Park in Tempe, Arizona, PADT’s advanced manufacturing facility currently features ten machines dedicated to printing parts for customers. The lab includes a full machine shop, part finishing facilities, and an advanced scanning and inspection capability. This added capability is yet another reason why so many companies large and small count on PADT for their 3D Printing needs. Contact us today to learn more about our 3D Printing Services or:
PADT Partners with 3D Printing Disruptor Carbon to Offer Production Part Manufacturing to the Southwest
Posted on October 23, 2017, by: Eric MillerThe long-term promise of 3D Printing has always been using the technology to replace traditional manufacturing as a way to make production parts. The various technologies that are considered Additive Manufacturing have been fantastic for prototyping and making tools that are used to manufacturing end-use parts, but rarely work well for production. Carbon is literally turning the 3D printing world upside down by introducing real production capabilities with their systems. And now that PADT has joined Carbon’s Production Partner Program, on-demand manufacturing using 3D Printing is now a reality in the Southwestern US. The Production Partner program establishes vetted service providers with 3D Printing and manufacturing experience as manufacturing centers. This allows customers who are early adopters of CARBON’s exciting technology, to find a trusted source for their production parts. PADT was chosen to participate because of our twenty-plus years of experience as a 3D Printing service provider and more than $5,000,000 in injection molding projects, along with in-house product development, scanning, simulation, and inspection. PADT will be adding three Carbon M2 printers to our existing 3D Printing facility at our main office in the ASU Research Park in Tempe, Arizona. The first two machines will be available for production in early 2018, and the third machine will be online by early summer. Customers will then be able to order production quality parts in volume and receive them within a week. PADT’s investment and this partnership make the dream of On Demand manufacturing of complex plastic components a reality. “We have been looking for a low volume plastic manufacturing solution that uses 3D Printing for some time.” Said Rey Chu, co-owner of PADT “Since we started the company we have been providing soft tooling and rapid injection molding. Once we saw the Carbon DLS technology in action, we knew we found our solution. The part quality and material properties are as close to injection molded as we have ever seen.”
About Carbon’s Disruptive TechnologyCarbon has introduced a revolutionary way to 3D Print plastic components called Digital Light Synthesis, or DLS. It combines their proprietary continuous printing technology with programmable liquid resins to create parts with the same strength and surface finish of injection molded parts. The part creation is fast because it is a continuous process, whereas most 3D Printing machines build up one layer at a time with pauses in-between. This continuous process is not only fast, but it also avoids the stair-steps created with layered methods. This results in textured surfaces and a surface finish that no other process can approach. https://youtu.be/23at9QglAm8 Programmable materials are the other technology that enables production quality parts. This unique approach joins two liquid resins as the build material; one that hardens with light and the other with heat. The 3D Printer creates the desired geometry of the part by using light to shape the first material. Then a second step uses an oven to harden the heat activated resin, resulting in engineering-grade mechanical properties. Moreover, since the strength comes from a heat cured resin, the properties are the same in every direction. Most 3D Printed parts that use a layered approach are weaker in the build direction. The other significant advantage of including heat activated resins is that they offer a much broader material selection than light activated resins.
PADT’s On-Demand Manufacturing ServiceIn the past, when PADT’s customers needed parts manufactured with production quality, surface finish, and strength we had to use soft tooling or low-volume injection molding. Both are expensive and take time to make tools. 3D printing is leveraged to make those tools faster, but it still takes time and labor. Production manufacturing could benefit from going directly from a computer model to a finished part, as we do with prototyping. When we first saw an early Carbon sample part we knew that this was a technology we needed to watch. As the technology matured further, it became obvious that this was the process PADT was looking for – this was the type of end-use part our customers were requesting. Then, when the Production Partner program was introduced, we knew we needed to take part. Our On-Demand Manufacturing service will be built around the Carbon Digital Light Synthesis process. Initially, we will use three Carbon M2 systems, a cleaning station, and a curing oven. This will be placed in the middle of our existing advanced manufacturing facility, allowing us to add machining, hand finishing, painting, and other post-processing steps into each production process as needed. What sets PADT’s offering apart from other providers of production manufacturing with 3D Printing is that we also provide full product development, simulation, and part scanning services to help customers make sure their designs are correct. Before parts are made, we can use our simulation and design knowledge to make sure everything is correct before production begins. And when the parts are completed, we can use our advanced scanning to inspect and our product development testing to verify performance. By adapting our proven quality to this new technology, we can ensure that every step is done correctly and traceability exists.
Next StepsYou do not have to wait till our production line is up and running. We can start working with customers now on getting their parts ready for manufacturing with Carbon’s breakthrough Digital Light Synthesis. Our experienced staff can evaluate your components and find the best fit, recommend design changes, and work with Carbon to produce samples. And when our line is up, you can hit the ground running and obtain your parts on-demand, when you need them.
- Download the On-Demand Manufacturing brochure
- View the official press release announcing the partnership
- Visit the Carbon website
Posted on September 21, 2017, by: James BarkerOn September 11th and 12th Mario Vargas (Hardware Manager for PADT Inc.) and I (James Barker, Application Engineer for PADT Inc.) attended Convergence 2017 in Los Angeles, CA. This event is held by 3D Systems and is the America’s Software Partner Meeting. Many strategic partners were in attendance from all across the USA, Canada, and Latin America. We were able to learn about some new enhancements to Geomagic that will help you with Inspection or Reverse Engineering BIG time! The first day of meetings we heard from Vyomesh Joshi (CEO of 3D Systems referred to as VJ). He mentioned that 3D Systems has committed 17% to R&D and after going to this event it is apparent! VJ briefly talked about each of their software options. The 1st being Control X and how Polyworks currently has the edge for inspection software but after this next software release, he and other 3D Systems employees seemed confident that they could surpass Polyworks. The 2nd software he talked about was Freeform which allows users to freely design parts by using a haptic device. This software would be great for creating custom shapes on a whim. If you haven’t tried a haptic device, you need to! It will blow your mind as a designer with the freedom you get by using the haptic device and this Freeform Software. The 3rd software he talked about was Cimatron which aids in the design of mold and die design. Of the top 10 largest USA mold makers, 7 of them use Cimatron Software. The 4th software is something new that will be released later this month. I would love to tell you more about it but can’t…. sorry! A little about why Mario and I attended this convention, PADT Inc. offers 3D Scanning as both a service and also as hardware or software you can buy. We use both Geomagic Design X and Geomagic Control X and have experts that are scanning parts for customers for either inspection results or for reverse engineering purposes at our Tempe, AZ office. The scanner that we use is a CMM quality scanner from Zeiss. This scanner is capable of scanning 5 million points per scan! We also offer 3D Systems Capture and Capture Mini scanners which are great tools for reverse engineering. Each time they scan a part they are capturing about 1 million points per scan. I am located in the Salt Lake City, Utah office and have a Capture Mini scanner that anyone wanting to see and demo, can come look at and evaluate at our office. Same holds true for the Capture scanner and Zeiss scanner in our Tempe, AZ Headquarters. Since we offer these services, we love knowing what new tools are available with these product releases. Jumping back to the conference, on September 12th, there were breakout sessions. We chose to go to the Geomagic Design X session to see what enhancements have been made. This software is the preferred software in all of the industry for reverse engineering parts. There were many different vendors/partners in the room we were at. There was even a rep from Faro who prefers to sell Geomagic Design X software with each Faro Arm that he sells because this software is so powerful. The neat thing about this software is all of the improvements that have been made to it. If you are accustomed to designing parts with Solidworks, Solidedge, NX, Catia, Pro-E or any of the other CAD software, you will be able to use this software with ease. Every command that you execute within Design X is editable just like the major CAD software. You have the ability to create sketches on planes or to make life even easier, there are wizards that automatically create sketches and perform a command like an extrusion or revolve that is editable after completing the wizard. After you have finished reverse engineering your parts within Design X, you can live transfer your new CAD data over to the above-mentioned CAD software. Once you have imported this data into NX or Solidworks, you can again edit any of the sketches that were created within Design X but now in your software of choice! I would love to show you how powerful this software is. There is a reason why it is the preferred reverse engineering software in the industry. Geomagic Control X session was next. It also happened to be the last session of the day. To be honest, I have only used Design X so I was looking forward to learning more about this software. From all the demo’s that I have seen in the past from this software, it appeared really hard to use. That is all changing with this new software release and is the reason why VJ is confident that it will compete and could exceed Polyworks as the preferred software for inspection. The biggest thing that stuck out to me was the ability to set up a workflow for scanned data for inspection so that you can create your inspection reports. The idea is that if you have a part that needs to be inspected for quality, you 3D scan the part and then import the CAD file. By overlaying the scanned data over the CAD data you can show the deviation within the 2 parts and you are able to have different views in a 3D PDF to share with others the actual quality of the part. As you are assigning your GD&T to this first inspection file, you are creating the first steps of the workflow. There are many options for the workflow that you can create and 3D Systems has made it easy to create the workflow. I feel that the power of this software is when you can open up the results of the first inspection report and do a split screen on your monitor to show the 100th or 1,000th part side by side and see how that part deviates from the first. I had a great time in California at this event even though all of our time was spent at the hotel. The streets looked nice from the window on the 11th floor. Maybe next time we will venture out! If anyone from 3D Systems is reading this, let’s go out to eat next time instead of eating at the hotel for breakfast, lunch, and dinner! Although the view from the dining room was nice! If you have any questions about 3D scanning whether it is for Inspection or for Reverse Engineering, let us know at PADT Inc. We look forward to helping you.
Posted on September 19, 2017, by: Nathan HuberIt is no mystery that I love my Subaru. I bought it with the intention of using it and I have continually made modifications with a focus on functionality. When I bought my roof crossbars in order to mount ski and/or bike racks, I quickly realized I needed to get a fairing in order to reduce drag and wind noise. The fairing functions as designed, and looks great as well. However, when I went to install my bike rack, I noticed that the fairing mount was in the way of mounting at the tower. As a result, I had to mount the rack inboard of the tower by a few inches. This mounting position had a few negative results:
- The bike was slightly harder to load/unload
- The additional distance from the tower resulted in additional crossbar flex and bike movement
- Additional interference between bikes when two racks are installed
Posted on September 12, 2017, by: Trevor RubinoffThe aerospace industry's adoption of additive manufacturing is growing and predicted to revolutionize the manufacturing process. However, to meet stringent FAA and EASA requirements, AM-developed aerospace products must be certified that they can achieve the robust performance levels provided by traditional manufacturing methods. Current certification processes are complex and variable, and thus obstruct AM adoption in aerospace. Thanks to a newly released aerospace package released by Stratasys for their Fortus 900mc printer and ULTEM 9085 resin, Aerospace Organizations are now able to simplify the aviation certification process for their manufactured parts. Join PADT's 3D Printing General Manager, Norman Stucker for a live webinar that will introduce you to the new Stratasys aerospace package that removes the complexity from FAA and EASA certification. By attending this webinar, you will learn:
- How Stratasys can help get more parts certified for flight quicker and easier.
- The benefits of Aerospace Organizations using the Fortus 900mc and ULTEM 9085 resin
- And much more!
Don't miss your chance to attend this upcoming event, click below to secure your spot today!If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT). You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you're good to go!
Posted on September 8, 2017, by: James BarkerOne of the newest materials available for the Stratasys Fortus 450 users (other machines could have this capability at a later date) is the Nylon 12CF. Nylon 12CF is a Carbon Fiber filled Nylon 12 filament thermoplastic. The carbon fiber is chopped fibers that are 150 microns long. This is Stratasys’ highest strength and stiffness to weight ratio for any of their materials to date as shown below. Often times, when Stratasys is getting close to releasing a new material, they will allow certain users to be a beta test site. One beta user was Ashley Guy who is the owner of Utah Trikes, which is located in Payson, Utah. He is having so much success with this material that he is making production parts with it. Watch this video to hear more from Ashley and to see some of his 3D printed parts. Talking with Ashley, he has helped us with understanding some of the tips and tricks to get better results from printing with this material. One change that he highly recommends is to adjust the air gap between raster’s to -.004”. This will force more material between the raster’s so there won’t be as many noticeable air gaps. Here is a visual representation of the air gap difference using Stratasys software Insight: The end goal at Utah Trikes is to produce production parts with this material, so by adjusting the air gap, the appearance of the parts look close to injection mold quality after the parts have been run through a tumbler. Some key things that I really like about this material is that the support material is soluble and easily removed using PADT’s own support cleaning apparatus (SCA Tank) that aid with the support removal. After the support has been removed, they are placed in a tumbling machine to smooth the surfaces of the part with different media within the tumbling machine. Any post process drilling or installing of helicoil inserts or adding bushings to the part is done manually. Jerry Feldmiller of Orbital ATK, who also did a beta test of this material at his site in Chandler, Arizona, mentions these 3 tips:
- Nylon12 CF defaults to “Use model material for Support”. 90% of the time I uncheck this option.
- I use stabilizing walls and large thin parts to anchor the part to the build sheet and prevent peal up.
- Use seam control set to Align to Nearest.
Press Release: PADT and Stratasys Announce Lockheed Martin Additive Manufacturing Laboratory at Metropolitan State University in Denver
Posted on August 29, 2017, by: Eric MillerPADT and Stratasys have worked with Lockheed Martin to establish a new Additive Manufacturing Laboratory at Metropolitan State University in downtown Denver. The Lockheed Martin Additive Manufacturing Laboratory is the first-of-its-kind facility in Colorado. It is focused on giving students and industry access to the equipment and faculty needed to develop the next generation of manufacturing tooling, based on the use of 3D printing to make the tooling. This is PADT's third successful contribution to the creation of Academia + Industry + Equipment Manufacturer lab, the others being at ASU Polytechnic focused on characterization of 3D Printed parts and at Mesa Community College, focused on training the needed technicians and engineers for running and maintaining additive manufacturing systems. These types of efforts show the commitment from Stratasys, industrial partners, and PADT to making sure that the academic side of new manufacturing technology is being addressed and is working with industry. We reported on the grand opening of the facility here,and are very pleased to be able to announce the official partnership for the Laboratory. Great partners make all the difference. Official copies of the press release can be found in HTML and PDF.
Posted on August 7, 2017, by: Trevor Rubinoff
Introducing the Stratasys J750 - Webinar
August 30th, 2017 - 11:00 AM - 12:00 PM MST
The Stratasys J750 3D printer delivers unavailed aesthetic performance including true, full-color capability with the texture mapping and color gradients. Create prototypes that look, feel and operate like finished products, without the need for painting or assembly, thanks to the Stratasys J750's wide range of material properties.
With this, students can easily experience both the prototyping and testing stages of the manufacturing process, helping to prepare them for what they will experience once they enter the workforce. The high quality materials available with the J750 also allow for the creation of highly intricate and realistic models, perfect for helping medical students with research.
- Concept Models
- Medical Models
- Jigs & Fixtures
- Colored Textures
Posted on August 3, 2017, by: Eric MillerNothing makes us happier here at PADT than seeing a customer be successful with technology we worked with them on. When Jack King of DustRam came to us for a prototype for a part on his dust free tile removal product it was just the start of a fantastic journey that showed off the power of 3D Printing. After a few iterations Jack was able to replace his expensive and long lead metal mouthpiece with a plastic one that he could manufacture on demand in his own shop using his Stratasys 3D Printer. It was such a great story that two publications were interested and wrote far better writeups than I could. The first is interesting because it is an industry trade magazine for people in the floor installation business. Their perspective is refreshing for those of us who live in the engineering world, getting more into the practical application of the product: contact us today.
Posted on July 27, 2017, by: Eric MillerPADT recently hosted the Aerospace & Defence Form, Arizona Chapter for a talk and a tour. The talk was on "Additive Manufacturing & Simulation Driven Design, A Competitive Edge in Aerospace" and it was very well received. So well in fact, that we decided it would be good to go ahead and record it and share it. So here it is: Aerospace engineering has changed in the past decades and the tools and process that are used need to change as well. In this presentation we talk about how Simulation and 3D Printing can be used across the product development process to gain a competitive advantage. In this webinar PADT shares our experience in apply both critical technologies to aerospace. We talk about what has changed in the industry and why Simulation and Additive Manufacturing are so important to meeting the new challenges. We then go through five trends in each industry and keys to being successful with each trend. If you are looking to implement 3D Printing (Additive Manufacturing) or any type of simulation for Aerospace, please contact us (firstname.lastname@example.org) so we can work to understand your needs and help you find the right solutions.
Posted on July 27, 2017, by: Dhruv Bhate, PhD
Download all 5 parts of this series as a single PDF here.This is my final post in our 5 part series discussing things we learned installing a metal 3D printer (specifically, a laser powder bed fusion machine). If you haven't already done so, please read the previous posts using the links below.
- Part 1: Equipment
- Part 2: Facilities
- Part 3A: Safety Risks
- Part 3B: Safety Risks - Prevention & Mitigation
- Part 4: Environmental
1. The 3D PrinterAll 3D printers need to be routinely cleaned, but for powder based metal 3D printers, this needs to be done after every build. Three steps need to be performed during cleaning of the printer:
- Powder Retrieval: After the build, the powder is either still in the dose/feed chamber or not. All powder that is not in the dose chamber needs to be brushed to the overflow chamber for recycling. While it is possible to vacuum this powder, that is not recommended since it results in greater loss of powder and also increases the burden on cleaning the vacuum and creating wet waste.
- Process Chamber Cleaning: The process chamber after a build gets covered with fine combustion particles (soot) that need to be wiped away, as shown in Figure 1. The recommendation is to do this cleaning using lint-free or clean room wipes moistened with an ammonia based cleaner like Windex Original.
- Lens Cleaning: Special lens cleaning wipes are to be used to clean the protective lens that separates the chamber from the laser. Standard lens cleaning wipes can be used for this, in a gentle single-pass movement.
2. Wet SeparatorThe wet separator (vacuum) sucks up stray powder and suspends it in a water column. The metal particles will descend to the bottom of the water column (as shown in Figure 2) and need to be routinely cleaned out. This cleaning procedure is recommended daily for reactive metals - failing this, the metal particles will weld themselves to the metal container and prove to be very difficult to scrape out. For non-reactive metals, a daily flush may be excessive (since this will add to the cost in terms of labor and disposal) and a weekly routine may be preferable for a wet separator that serves 1-2 machines. To reduce the water needed to flush out the powder sludge at the bottom, a standard pump sprayer is very effective. Further reduction in water usage and disposal can be achieved by a filtration device such as the one developed by the folks at Kinetic Filtration.
3. Filter ChangeFilters need to be changed periodically as shown in Figure 3. A video below (set to start at the 2:58 mark) shows how the filter change is performed for our MLab, for a non-reactive metal, so I shall not describe the procedure further. A reactive metal alloy filter needs to be stored in water to passivate it at all times, even through disposal. Other OEMs recommend sand and other materials, so it is important to follow the specific instructions provided by your supplier for passivation. https://youtu.be/0wQhXle6VEA?t=2m58s
SummaryGood housekeeping for metal 3D printing is vital and more than just aesthetic - there is a modest chance that failing to follow your supplier's instructions on one or more of the items above will result in a safety incident. This is especially true for reactive alloys, where filter changes are recommended after each build and wet separator clean on a daily basis.
- This is intended to supplement the supplier training you must receive before using the equipment and not meant to replace it – in case of conflicting information, your supplier’s training and equipment requirements override any discussion here. PADT and the author assume no legal responsibilities for any decisions or actions taken by the readers of this document.
- My personal experience derives specifically from the use of Laser-based metal 3D printing tools, specifically Concept Laser’s MLab Cusing R equipment. I expect majority of this information to be of use to users of other laser based powder bed fusion metal systems and to a lesser extent to Electron Beam systems, but have no personal experience to vouch for this.