Arizona Chief Science Officers Design Their Own 3D Printed Name Badges

az-scitech-cso-badges-3d-printed-0The Chief Science Officer program is a program for 6th-12th grade students to represent their school in STEM. And what better way is there for them to identify themselves then with 3D Printed name badges?  The program’s sponsors, the AZ SciTech Festival offer a training retreat for the kids who get elected as their school’s CSO and we all thought introducing design and 3D Printing would be a great activity.

As part of the 2015 Fall CSO Institute, PADT’s Jeff Nichols joined local designer and artist John Drury to spend some time with the kids explaining how to work with logos and shapes to convey an idea, and how to design for 3D Printing.  The kids worked out their own design and sent it to PADT for printing.

We converted their sketch into a 3D Model, starting in Adobe Illustrator. The sketch was traced with vector geometry and then a generic name was added. This was then copied 144 times and each name was typed in, with a few extras. This step was the only boring part.

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The design worked great because it is a simple extrusion with no need for support material.    The outline of their names were exported as DXF from Illustrator and then imported onto the 3D Model and extruded up to make a solid model of a badge. This was then copied to make a badge for each student. Then the names were imported and extruded on the patterned badges.

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The was a simple extrusion for each feature, allowing for contrast and readability but keeping things simple.
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This project was a great opportunity to use both patterns and importing 2D drawings. By laying everything out in a grid, we only had to make one badge and copy that. Then import the names and extrude those on the patterned badges.

STL files were then made and sent off to one of our Stratasys FDM 3D Printers. The FDM (Fused Deposition Modeling) process extrudes an ABS plastic filament, and you can change material during the build. So, to add a bit of contrast, we changed the filament color after the base of the design was done, making the logo and student names stand out.  The final results came out really nice.

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This is what they look like right out of the machine. We swapped out two color for each build. With some clever packing, we were able to get 12 badges on each platform.
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The final products really stand out.

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This project was a lot of fun because we were able to work with the students. They got what John and Jeff taught them and did a great job.  We know they will be placed with pride on back backs and jackets across Arizona.

To learn more about the CSO program, visit their website: http://chiefscienceofficers.org/ Check out the blog.  Some of these kids can really write well and their insight into Science, Technology, Math, and Education is insightful.

3D Printing the 4th Dimension – GISHWHES 2015 Scavenger Hunt

padt-sundial-insun-apple-watch-wGISHWHES is a huge international scavenger hunt. Every year teams around the globe comb through the list of 215 tasks and pick as many as possible that their team can do.  Last year they introduced 3D Printing as a task, and we helped a team 3D Print a quill pen. That was a lot of fun, so when this year’s list included an item on 3D printing, we jumped at the chance to be involved.

The item was:

110: VIDEO. Use a cutting edge 3D printer to 3D print your representation of the 4th dimension.62 POINTS

Being engineers we said “4th Dimension?  Time.”  Then it became a choice between the way mass distorts the space-time continuum or some sort of clock’ish thing.  The distortion thing seemed difficult so we focused on a clock.  Being that we were constrained on budget and time we decided to do a sundial.

The result can be seen here in this YouTube video.

It was a fun project and the team spent a bit of time in the 112F sunshine trying it out.  We can’t wait to see what we will get to do for the 2016 scavenger hunt.

Making the Model

A couple of people have asked if we downloaded the solid model for the sundial or if we made it. We actually made it. After a little bit of research we found that making a simple horizontal sundial like this one is very easy. Here are the steps we took:

Get Geometry Values

So it turns out that the angle of each hour line is determined by the latitude of where the dial will go. The angle of the pointy thing, called a gnomon, is also the latitude.  So for Tempe, AZ that is 33.4294°.That gets applied to the equation:

angle(h) = arctan(sin(L*tan(15° · h))

h = integer of the hour, 6 am to 6 pm
L = latitude

I plopped that into Excel:

=ABS(DEGREES(ATAN(SIN(RADIANS($C$3))*TAN(RADIANS(15)*B7))))

and got the following:

Latitude 33.4294
Hour Angle
6 90.00
7 64.06
8 43.66
9 28.85
10 17.64
11 8.40
12 0.00

Build the Solid Model

The next step is to build the model. I used SolidEdge because I know it real well and was able to knock it out quickly.  But all CAD tools would be the same:

  1. Pick a center point.
  2. Add lines as rays from that using the angles in the table above for each hour.
  3. Design the shape of your sundial to look cool. I did a simple circle .
  4. Mark the hours using the sketch. I raised up thin rectangles.
  5. Model the gnomon using the latitude as the angle.  Make this as fancy or simple as you want.
  6. Add whatever doo-dads you want.
  7. Label the hours if you want.
  8. Save to STL

Here is what my sketch looked like:PADT-sundial-cad-model-hour-sketc

And the final solid model looked like this:

PADT-sundial-cad-modelWe sent this to the printer as shown in the video, and got a sundial.

 

 

 

 

 

 

Real World 3D Printing: PADT Helps ULA Save with Stratasys Digital Manufacturing

Every once in a while a customer hits a home run with Additive Manufacturing, and United Launch Alliance had done that with their application of Stratasys technology to the production of flight-ready components for their rockets.  They were able to leverage 3D printing to take one component from 140 parts to 16, reducing the risks associated with creating the assembly, the piece part costs, and the assembly cost. And PADT is proud to say we were partners in this effort with ULA and Stratasys.

If you are not familiar with ULA, they are the worlds premier launch service company in the US.  It is a joint venture of Boeing and Lockheed that launches the majority of military and civilian payloads that are sent in to space. True "rocket scientists" who are headquartered down the street from PADT's Littleton Colorado office.  They just released a ton of information on how they are using the Stratasys devices they acquired through PADT as an example of what the technology can achieve. 

Here is a picture from Stratasys of one of ULA's structural engineers, Kyle Whitflow, holding an ECS duct they created on the Stratasys Fortus 900mc they purchased through PADT: 

Stratasys just released a great video on how ULA is using the technology. This is a great example of the right people, using the right technology, in the right way:

You can also read the official press release here

We are highlighting his application as a way to let people know that 3D Printing is not just about makers, nor is it just about engineering prototypes. Every day users are creating production hardware to produce usable parts that save them time and money.  Ducts for rockets are a perfect use of the technology because they are complex, low volume, and can make single parts that need to be made in multiple pieces using traditional methods.   This application also highlights the power of the material choices available to users of Stratasys FDM technology.  ULA is using ULTEM 9085 for these ducts because it is durable, lightweight, and can stand up to the heat of the launch event. 

Those of you familiar with the process will notice the dots on the duct. Those are target dots for 3D scanning. ULA took the technology one step further and scan the completed hardware to make sure the manufactured part is within specifications. 

environmental-control-system-duct

The team at ULA has been a pleasure to work with.  They saw the promise of Additive Manufacturing but dealt with it like the seasoned professionals that they are. They started by making engineering prototypes, then as they got a feel for the technology they switched to the production of tooling for manufacturing.  They have now developed the confidence needed to move to flight hardware.  In addition to supplying the machines, PADT consulted with ULA early on, touring their manufacturing facilities to better understand their needs and taking them to see how others are using FDM for manufacturing.  We were fortunate enough to even be invited to attend the launch of their Orion spacecraft from Florida as their guest.  

We are very excited about the additional uses ULA and other companies will develop in the near future for Additive Manufacturing.

 If you want to know more, or would like to have PADT help you in the same way we assisted ULA, please reach out or email info@padtinc.com. If you need promotional services or banners (e.g., to buy Thanksgiving banners online) – feel free to contact us.

Six Things to Do when Shopping for a 3D Printer

Stratasy-Mojo-3D-Printer-in-Shopping-CartPADT has been in this prototyping business for a while, even before we called the machines that make physical parts directly from computer models a 3D Printer.  When we started it was rapid prototyping and we have purchased maybe a dozen machines for our own use, and sold several hundred to our customers.  As the cost of these systems comes down and the number of people interested in having their own 3D Printer goes up, we thought it would be a good time to share our experience with choosing systems with the community.

Here are six things that every person should do when they are shopping for a 3D printer. We even recommend that you write these down and fill out a form before you contact the first vendor.

Thing 1:  Understand What you will use your Parts For

This seems obvious. You would not be looking for a 3D printer unless you knew you needed one and you knew what you needed it for.  But in reality it is very easy to get caught up in how powerful and just plane cool this technology is and you start thinking about what you can do, and you forget what you need to do.  The best way to approach this is to not think about which technology you may end up with, that will point you in one direction or another. Just assume you push a button and a prototype of your part comes out. What would you actually use it for?

The key here is to be honest. If the reality is that your receptionist really likes models of Japanese Anime characters, and you plan on making models of such in an attempt to get her attention, then be honest about that. You need a printer with the detail and perhaps color capability for that. But if you really think about it you probably need one to make patterns for doing custom composite layups, so your use will be very different and the so will the system you need.  She probably will be just impressed with your layup tooling. Well, maybe not but your boss will.

image

Our experience tells us that customers often get hung up on features that they get excited about, but when you look at the end use of their prototypes, they really do not need some of those features.  We have seen people buy a machine because it was the only one that did this one thing they got fixated on. But in the end, they only make two prototypes that need it a year and the other 137 prototypes they make are kind of sucky.  Make a list of all the uses and put a guess next to them that shows the percentage of parts that fit into that use.  A typical example would be:

  • 35% Mockups for design reviews
  • 25% Models for the machine shop and vendors to help them plan machining
  • 15% Fixtures for testing
  • 10% Consumer testing and marketing mockups for ad campaigns
  • 10% Fit models to build
  •   5% Other

Thing 2: Benchmark the Machines on your Geometry

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When we run into someone that is unhappy with their 3D Printer, three out of four timeswe find out that it just does not perform like they thought it would.  And if we dig deeper we find out that when they were shopping for a printer, they just looked at parts that the various vendors gave them. Demo parts. They never made a variety of their own typical parts.  This is especially true if they ended up buying a lower cost machine.

Here is a secret of every person selling a 3D Printer, that probably is no secret to you. They pick the demo parts they show you because those parts look really good on their technology. And if you are not closely familiar with the strengths and weaknesses of each technology, there is no way for you to know that the parts they showed you may be the only parts that actually look good on that technology.

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Get four or five parts that are typical parts that you would prototype, and have them made on each technology.  Even if the vendor tells you they can only afford to make one sample part for you (with the cost coming down the margins on these machines is low so few in the business can do a bunch of free parts for every potential sale),  go ahead and pay money to get your geometry made.  You may be shocked by the results, especially on some of the newer low cost machines.

Thing 3: Ignore Hype or the Herd

Any fast growing industry has a lot of hype, and a lot of mob pressure to go with one technology over another.  3D Printing is no different, and in fact it is worse because this technology is so cool and interesting.  The problem with hype and herd mentality is that the company with the best public relations people or with the “hippest” story gets all the attention regardless of the technology. And it feeds on itself. They get more attention because they got more attention.

A case in point is the recent introduction of a hand-held fused deposition modeling system.  Very cool, lots of hype and interest.  But really, who could use that for real work?  Even a hobbyist is going to struggle with making anything useful with a tool like that. But there is a lot of hype around it right now and a huge amount of interest. I’ve had a taxi driver mention it to me when he asked what I do.

It is human nature to want to be part of something big. So it is hard to push that aside and look at each 3D Printer you are evaluating on its own merit. Not what the press is saying, not what other people are touting, not what is the newest and flashiest.  We are talking basic “make me a useable part” here.  Look at it with basic and non-influenced eyes.

Thing 4: Calculate the Total, Long Term Cost

Of all the things listed here, this may be the hardest to do. There are so many costs that go into making prototypes. The initial cost of the machine is small compared to all the other costs. What we recommend you do is make a spreadsheet and list cost items in the first column, and create rows for each 3D Printer you are looking at, then fill it out. We like to put in the cost over three years.

Here are some cost items we recommend people include:

  • System
  • Cleaning system
  • Facility modification costs
  • Build and support material
  • Cleaning materials
  • Maintenance fees
  • Labor to prepare jobs
  • Labor to post process jobs
  • Facility square footage for machines, cleaning equipment, material storage, etc…
  • Scrap rate cost (some systems have a higher scrap rate, you need to include the cost of lost time and material because of that)

Thing 5: Honestly Prioritize the Features you Want and Need

It is always a good idea to make a “want” and “need” list, regardless of what you are purchasing.  When you are dealing with a set of technologies with so much buzz around it, we feel it is doubly important.  Sitting down and making a list, then justifying it to someone else clarifies what you should be looking for more than anything.

We also recommend that you prioritize the list.  Marking things as Want and Need is a first step, then every one of those should also be ranked in order of importance.  You can use a point scheme or you can just put them in order from most to least.  This will help you sort through the gee-whiz stuff and truly understand where the value of your investment in 3D Printing can be found.

Needless to say, it is critical that you finish Thing 1, and refer to it, when completing this step.

Thing 6: Figure Out what is Good Enough, then Ask for More

OK, maybe this one sounds like a sales pitch: “You know what you really want, but really, trust me, you need more.”  Experience tells us that this is actually true. When you are talking 3D Printing we run into customer after customer that felt the system they purchased was “good enough” for their needs then they realize it does not do what they need.  And in most cases it is because they really needed a bigger machine, or they needed a more robust material than they thought.

The last thing you want to do is invest in a 3D Printer then six months later try and turn it in to get one that is bigger, faster, more precise, or that runs a better material.   Now you are still paying for the more expensive system and you wasted money on the less expensive one.  Be honest, upgrade in the beginning to what you really need in the long run not what you think you can get by with in the short run. Because, in the end, you will save money and have better parts.

Doing the Six Things and Getting that 3D Printer

You know you want one. You actually probably need one. We have been doing this for a long time and almost every customer that has made an intelligent investment feels like the investment has been a positive one. And by intelligent investment, we do not want to imply that they bought a system from PADT (although statistically that may be true). What we have found is that these companies took their time, they used some variation of the steps listed above, and they treated their purchase as a long term investment.

You too can make a smart choice and make in-house 3D Printing part of your company, job, or even hobby.  PADT is here ready to help you with that choice.  We can show you the complete line of fused deposition and Polyjet 3D Printers from Stratasys. We can also provide some advice on what we think is a good fit for your needs, and help you capture data for the six things we have outlined here.  And don’t forget, we have a full 3D Printing services offering, with all the major systems and materials. So we can show you the advantages of all of them by providing you with your outsourced parts while you look for an in-house solution.

Stratasys Objet Polyjet Systems

Retail 3D Printing at the Beginning of 2013

I just came across a posting from Terry Wohlers that he did in December with some interesting observations on the growth of 3D Printing in retail stores:

3D Printing at Retail Stores

I have to agree with Terry’s assessment that these efforts in Africa and Europe to bring this new technology to a mass market through old business models may not click.  Some of the efforts here in the US seem to be a better fit.  Reading the article, and the fact that non-technical people are constantly bringing up 3D Printing around me, got me to thinking about the retail space and where it is headed.

Is Online the Future for Retail 3D Printing?

Shapeways_websiteIn New York, the VC backed experiment at Shapeways seems like a more viable option for mass retail 3D printing.   There was an interesting interview done in December by the Business Insider that sheds some light on how things are going, but does not discuss the business aspect too much.  What I am interested in knowing is what type of margin Shapeways is making on their parts with the prices as low as they are, or are they using their buckets of VC money to build market share in hopes that volume will bring their margins up?  It would be interesting to know.

A French company called Sculpteo has a similar model. I’m sure there are others.

3D Systems, along with buying up as many technologies as they can, has launched their own retail competitor to Shapeways called Cubify.   Their advantage is that they do not have to pay full price for machines or materials.  It is early days and in some ways it looks like a vehicle for promoting their low-end FDM CUBE machines, but the reach of 3D Systems may make a difference.

The Brick and Mortar Store

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Although these online based models have the advantage of access to the masses to grow their markets, storefront retail outlets for 3D Printing also seem to be taking off.  Makerbot, the kings of getting media attention for low-end 3D printing, has a showcase store now in Manhattan. This store may be more for marketing than a direct revenue generator, but it starts a trend.   A new startup, 3DEA is also in New York City and they are trying to use similar low-end FDM technology to provide 3D printing to the masses through a corner store, literally.

Here at PADT we are aware of several companies starting the same thing in the west and they seem to have good solid business models that will not only go after the art/accessory/gadget market but they are also looking at other more practical retail applications.  We think this broader and more balanced approach has merit.

Is New York the Center of Retail 3D Printing?

Are you seeing a trend here? Retail 3D Printing in the US seems to be focused on New Your City. There is a store in Pasadena called Deezmaker, but it is more hacker-centric selling more kits than home machines or direct to consumer printed objects.

Is this NYC bias because the market for consumer 3D printing is huge there? Or is it the art community? Or is it a tech-infiriority complex with the west coast?  A “we missed all this computer based stuff, so we are going to lead on this 3D printing thing” effect?

I suspect it has more to do with the proximity to Wall Street and the mass media than anything else.  Which may or may not be good for the additive manufacturing business.  It means cash and exposure for something that really captures the imagination of the general public. But is this a bubble that will grow and pop for the full industry? Or will it just be the retail side?  Only time will tell.

FDM Rules, but not Necessarily Good FDM.

One other take away from this retail trend is the dominance of Fused Deposition Modeling (FDM) technology that is making much of this possible. Although Shapeways seems to use almost all of the technologies, most of the startups that are trying to get the cost down and the volume up are using some sort of low-cost FDM technology. This is reflected in the lower costs and in the poor finished part quality that is seen on most of the websites. It is too bad more are not looking at technology Stratasys, the originators of FDM and producers of machines that make very high-quality parts.

stratasys_mojoI bring this up not only because PADT is a long time Stratasys reseller, but because the poor part quality might result in a black eye for the industry as a whole.  And the concern is not just about aesthetics, but also about part strength.  There is a lot of excitement over making replacement parts for appliances, toys, and consumer electronics.  Delamination in low-cost FDM parts is a real concern.

I also wonder if the merger of Stratasys and Objet might allow for the development of low cost and reliable 3D Printing based on the Objet inkjet printing approach as a compliment to FDM based systems.

What is the Future?

rasputinAnyone that is in the RP business knows that the use of additive manufacturing for prototyping, tooling, and even production is growing and getting better. Machines are faster, more accurate, and offer much better material choices. And the cost of systems that make strong, high-quality parts is coming down. So the non-retail side of this market should see continued strong growth.

The retail side of things is seeing a lot of buzz, a lot of press, and a lot of interest from average consumers.  As with any new market it is hard to guess where it is going.  But history has shown us that something like this that shows the potential of being a disruptive technology will have a big impact, and the market will whipsaw back and forth a few times before the technology finds its place and becomes mainstream.

For the record, just to see how close I get, I predict the following landscape for retail 3D Printing in five to ten years:

  • Two or three large on-line outlets, focused on art, fashion, and accessories as an outlet for small designers.
  • One or two large business supply/service chains that offer 3D Printing alongside traditional printing and copying using high quality FDM technlogy
  • A variety of specialty local almost neighborhood stores that offer duplication using 3D scanning and printers along with part printing.

Hopefully someone will remind me of this post in the future and we can see how far off I am.

 

 

Stratasys and Objet Merger Complete

Stratasys

It is now official. Stratasys and Object have completed their merger to form a company worth over $3.0 Billion.  Actually, as we prepare this update it is up to $3.37B.  Obviously the markets thing this merger is a good thing.

And now Stratasys has a new logo and what we think is a great slogan: “For a 3D World”

You can read the press release here.

As a long time Stratasys distributor and a user of Objet’s and Stratasys systems in our rapid prototyping services business, we are very familiar with both product lines and look forward to the synergy of the merger.  These are two truly complimentary product lines.

Right now this merger will have no impact on how we do business with our existing customers for any of the product sales or services we offer, including sales of new systems, maintenance of existing machines, material ordering, or prototyping services with either FDM or PolyJet.  As the two companies combine organizationally we will keep everyone informed.

Learn more about the Stratasys line of Mojo, uPrint SE, Dimension, and FORTUS 3D Printers here.

Rapid Prototyping Technology Animations

Every once in a while we get asked to go out and do presentations on Rapid Prototyping. As part of that, we like to explain the four major technologies: SLA, SLS, FDM, and Polyjet. No matter how many hand gestures we use people just don’t seem to get it unless we show an animation.

So we thought it would be good to share those with the community so that they can either learn about the basics of the technology or use these to help educate others. They are crude, we are engineers and not artists.  But they get the point across. We hope to have time to update them and add text.

They are in the form of animated GIF’s, so you can put them on a website or throw them in a PowerPoint and you don’t need a viewer or special software to view them.  Click on the images to get the larger version.

Use as you see fit, just remember to mention where you found them: P – A – D – T.

FDM-Animation

PolyJet_Animation

SLA-Animation-3

SLS-Animation