Recently I had the chance to start printing parts on PADT’s new Stratasys Origin One 3D printer, and now I can’t get enough of it. It creates parts by curing a shallow tray of liquid resin, a full layer at a time, based on DLP (digital light processing) technology. That means, whether you print just one part or as many as can fit on the build-platform, the print-time is the same. If you’re accustomed to filament-based printing, this system is FAST, and the resulting surface finish rivals that of injection-molded parts.
Completed build of 24 threaded bolt “sleeves” printed on a Stratasys Origin One P3 printer. (Image courtesy PADT Inc.)
The Origin One’s DLP process is termed Programmable PhotoPolymerization (P3, for short, because of course we need another acronym in this field). The photocurable resins it uses are single-component materials, which simplifies the build process compared to those that require two-part epoxies: there’s no waste since parts can print overnight, and each open resin vat can stay open for a week.
In addition, unused resin can be strained and returned to the bottle, easily lasting a month, while unopened resins display a six-month-to-one-year shelf-life. And what a range of resins and applications! The Origin One system is open; several material companies (Henkel Loctite, Covestro Somos and BASF) have already worked with the printer’s developers, matching the hardware’s operation with the best build-prep parameters for their formulas.
All P3 resins are tuned to 385 nanometers. The combination of this wavelength, shorter than that of other DLP and LCD systems, along with a 4K light engine, supports feature sizes as small as 50 microns and strong molecular cross-linking for exceptional material properties. Printing across a build platform that is 7.5 inches by 4.25 inches, the typical build layer is 100 microns, and the proprietary pneumatic release mechanism (key to great adhesion plus speed) easily supports layer print-times of 15 seconds. The build volume height is 14.5 inches, which can accommodate a decently large number of parts; you may have seen how Origin helped develop and print thousands of certified nasal-swabs in the first months of the COVID pandemic (approximately 1500 swabs every eight hours).
PADT Inc.’s Origin One DLP 3D printer, with a completed build. Parts print upside down and need only a shallow tray of resin, as the DLP system projects an image of each layer from below through a glass cover and the clear membrane mounted at the tray’s lower edge. (Image courtesy PADT Inc.)
Print Setup
Print set-up in Autodesk netfabb software, ready to print on the Origin One printer. These parts built directly on the build-platform and did not require any support structure. (Image courtesy PADT Inc.)
If you already have Autodesk netfabb Premium software, you’ve got what you need to prepare an STL part file for printing; if not, the Origin One printer comes with the first-year free of netfabb, or you can use other file preparation software such as Materialise Magics. Depending on the part geometry, you may place the parts directly on the build platform (as with typical DLP printers, the parts print upside-down), or you can choose to add supports of many styles; these will be snipped off during post-processing.
Post-Processing
Bolts printed in BASF ST45 on the Origin One printer, ready to be popped off the build plate with a putty knife or razor blade. Post-processing is quick and easy with IPA and a small UV oven. (Image courtesy PADT Inc.)
This is fast, too! I found I could complete the post-processing workflow in 30 minutes to an hour, and of that only about 20 minutes was hands-on time. Here are the recommended steps:
Swish the build-platform with the parts still on it, in a tub of IPA, for about 5 seconds.
Slide the parts off with a putty knife, or just pop them off with gloved hands.
Rinse the parts in agitated IPA for five to ten minutes. (We use an automated shaker-table unit, but sonicator units are also an option.)
Air-dry the parts with compressed air.
Cure the parts in a UV oven for anywhere from 30 seconds to 20 minutes or so, depending on the material, geometry and oven power.
Done!
Geometry Design Capabilities
The feature size that can be achieved with this system is pretty impressive:
– As small as 0.5mm diameter cylinder (8mm tall),
– As small as 0.2mm diameter horizontal through-holes, and
– Up to a 3mm unsupported 90-degree overhang.
Inner section of two-part 3D printed “bolt” which will be mated with its reverse-threaded outer sleeve. These parts also printed directly on the build-plate of the Origin One printer. (Image courtesy PADT Inc.)
Material categories
So far, Stratasys has qualified the set-up parameters for 12 resins, some of which are available in more than one color or in clear. These materials offer options for the following use cases.
Heat-resistant
Tough
General purpose
Elastomers
Medical
The parts I printed in these photos were done in BASF Ultracur3D ST 45 Black; that material is considered a general-purpose resin but I find it also tough and smooth – so smooth that we were able to print a threaded bolt with a reverse-threaded sleeve that unscrews to display fine lettering both raised and indented (shout-out to PADT’s new 3D Printing Application Engineer @ChaseWallace for the design). The ease-of-motion when assembling both parts is terrific.
Components of the two-part bolt, plus final assembly, printed on the Origin One printer. (Images courtesy PADT Inc.)
In the first week of November, I’ll be headed to Stratasys headquarters for official hands-on training with the Origin One printer and a variety of materials. I can’t wait to print more parts that push the limits of surface finish, minimal support structures and end-use-part durability.
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing/3D Scanning products and services. For more information on Stratasys printers and materials, contact us at info@padtinc.com.
When we applied for a NASA Small Business Technology Transfer (STTR) grant with Arizona State University in 2018 we had high hopes around that the idea of developing simulation and manufacturing techniques that would allow engineers to mimic structures found in Nature. Today’s win of a rare Phase III grant from NASA exceeded those hopes and further showed the space agencies’ interest in the research that PADT, ASU, and now Penn State are engaged in.
Inspired by the research of former PADT engineer and now ASU professor, Dr. Dhruv Bhate, the idea was to take a look at how nature uses repeating structures and responses to loads to optimize structures and to use 3D Printing as a way to create the derived shapes, growing geometry just as nature does. That Phase I was received well and led to a Phase II grant in 2019 to dig specifically into lattice structures. In addition to that work was the development of a topological optimization tool that could look at multiple types of loads and create aperiodic lattice topologies.
Researchers at NASA like those results enough to then grant PADT a Phase III project to further the development of the optimization tool and to connect it to a fluid-thermal optimization tool developed at Penn State under a separate NASA project. The study is called “Thermo-Fluid and Structural Design Optimization for Thermal Management” and it will look at creating structures that are strong, light weight, and have the thermal performance required for difficult launch and space-based missions.
You can read more in the press release below or here: PDF | HTML.
We are exceptionally proud of all three phases of this project because they show:
PADT’s ability to work with academia for R&D that results in useful tools
Our deep and broad understanding of simulation across physics
How our unique expertise in Additive Manufacturing can be combined with our simulation knowledge to turn theory into practical hardware.
If you have needs in any of these areas or are just looking for a strong R&D partner that can help make your innovation work, reach out to PADT.
Press Release
NASA Awards PADT and Penn State University a $375,000 Phase III STTR Research Grant
The Grant is a Continuation of PADT’s Topology Optimization Research, Which Will Fund “Thermo-Fluid and Structural Design Optimization for Thermal Management”
TEMPE, Ariz., September xx, 2021 ─ In a move that acknowledges its excellence and expertise in R&D for numerical simulation and 3D printing, PADT today announced NASA has awarded a $375,000 Phase III Small Business Technology Transfer (STTR) grant for PADT to collaborate with Penn State University. The partners will expand research into thermo-fluid and structural design optimization to provide engineers who design next generation launch and space crafts with better ways to design more robust and efficient structures that experience loading fluids, forces, vibration, and temperatures.
The Phase III STTR grant is a continuation of the original $127,000 Phase I and $755,000 Phase II grants awarded to PADT and ASU’s Ira A. Fulton Schools of Engineering in August 2018 and December 2019 respectively. This is PADT’s 17thSTTR/SBIR grant since the company was founded in 1994.
“Furthering our research in simulation and 3D printing for topology optimization and thermal management is critical to the future of aerospace development,” said Alex Grishin, Ph.D., consulting engineer, PADT. “This Phase III award underscores how valuable NASA found the work we did earlier with ASU and signals their desire to have PADT work with other universities to transform it into a tool that engineers can use to design better launch and space-based structures.”
The objective of the joint effort between PADT and Penn State University is to successfully demonstrate the integration of 3D data output from Penn State Mechanical Engineering Experimental and Computational Convection Laboratory’s (ExCCL) thermo-fluid optimization code, developed under a NASA Aeronautics Fellowship grant, into PADT’s topology optimization tool. The latter was developed by PADT under the STTR Phase II contract.
In Phase II, PADT partnered with Arizona State University (ASU) to develop and test a novel shape optimization tool that used a unique methodology for topological optimization, taking both the thermal and stress response of a part into account. 3D printing was also used to create the geometry produced by the optimization approach. Phase III will connect PADT’s tool to Penn State’s tool, which uses genetic algorithms to better handle the optimization found in thermo-fluid problems.
“Taking our tool and connecting it with the optimization capability that Penn State developed has the potential to benefit aerospace design engineers worldwide,” said Tyler Shaw, PhD, PADT’s VP of Engineering and the leader of the group responsible for this work. “This project will take the joint research one step closer to delivering on an optimization approach that, just as in nature, takes into account all loads, regardless of physics.”
The ultimate goal of the project is to continue research with internal and government funding to create a commercial product that engineers can use as an alternate way to optimize the shape of structures that see loading from multiple physics.
To learn more about PADT and its advanced capabilities, please visit www.padtinc.com.
About Phoenix Analysis and Design Technologies
Phoenix Analysis and Design Technologies, Inc. (PADT) is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 80 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
The two cars have become one! The body of the 1961 Volvo PV544 is now welded to the chassis-frame of a new 2019 Volvo S60 T8 Polestar Engineered sedan. (Image courtesy PADT Inc.)
If you’ve been following Girl Gang Garage on LinkedIn or Instagram, you know there’s been a ton of progress on the Iron Maven Volvo-rebuild project since PADT’s last post in July. Back then, most of the work had focused on gutting the 1961 Volvo PV544 body and interior, and PADT was able to capture much of the sheet metal shape and dimensions with its GOM Tscan Hawk 3D scanner. We also started brainstorming various 3D printed parts to enable new component designs produced on Stratasys 3D printers.
Since then, Bogi Lateiner, co-owner of Girl Gang Garage (and TV host of Motortrend’s All Girls Garage and Garage Squad), co-owner Shawnda Williams, and a rotating team of volunteer women have turned their efforts to disassembling the second vehicle: the new 2019 Volvo S60 T8 Polestar Engineered sedan (donated by corporate sponsor Volvo) and merging its chassis with the PV544 body.
Sounds simple, sort of? It might be if it weren’t for the facts that:
a) the wheelbase (front-tire center to rear-tire center) of the two cars differs: the PV544 clocks in at 102.5 inches but the S60 is quite a bit longer, at 113 inches. Also,
b) the track width (axle length) differs – this time the PV544 is about 12 inches narrower at the front (51 inches versus 63 inches), which means the Girl Gang team needs to expand both of the front fenders by half that amount to accommodate everything in the engine compartment. And, lastly and conversely,
c) the S60 dashboard is so wide that it needs to be reconfigured from 56 inches down to about 50 inches or less, to fit the interior dimensions.
Growing Fenders, Redesigning a Grill
Original PV544 front bumper/grill housing and fenders. It all looks huge, right? But with the track-width difference between this design and that of the new Volvo S60 chassis, the Girl Gang Garage team needs to splice in about twelve more inches, probably incorporated in the fenders. (Image courtesy PADT Inc.)
The old-school approach to reconstructing the front bumper-grill section and fenders would involve cutting the original sheet metal, shaping new metal splices by eye and tape-measure, and welding everything together with skilled handwork. This time, although the first and last steps still apply, that project becomes a much more precise, and predictable, task thanks to the digital workflow of 3D scanning -> data processing -> CAD design. These steps are now underway and will set the stage for a cool new grill and fenders that will act big but fool the eye just a bit to keep the overall lines intact.
3D scan of passenger-side fender of PV544, ready for conversion to CAD and creative expansion. (Image courtesy PADT Inc.)
PV544 front bumper/grill scan data acquired with a GOM Tscan Hawk handheld laser 3D scanner. (Image courtesy PADT Inc.)
It’s pretty clear that this front-end has seen better days, so the analysis and measurements of the existing surface needed to be carefully analyzed. Donated expertise for this task came from Chris Strong and Hayati Dirim of Rapid Scan 3D, who mapped the scanned mesh onto planes and surfaces that define the current grill-mount opening.
Surface data file created from the PV544 bumper/grill scanned mesh. Note the reference plane constructed along the left side. File conversion and measurements completed by Rapid Scan 3D. (Image courtesy Rapid Scan 3D.)
This information has been handed off to the CAD support team. Working hand-in-hand with the Girl Gang Garage experts, the team is using Fusion 360 CAD software, donated from Iron Maven sponsor Autodesk, to analyze these defining surfaces and design a new grill in CAD, which we expect will be 3D printed and painted to match the updated (not yet announced) body color from sponsor BASF.
Knowing both the fender and grill/frame exact dimensions also supports the team in defining the connections and shape of the widened fenders.
Critical surfaces and dimensions extracted from the bumper/grill scan, converted into CAD and brought into Autodesk Fusion 360. The four planes define the current limits of the opening for the grill. This information will guide the CAD-layout of the brand-new grill design and also serve as boundary layers that mate up to the expanded fenders. (Image courtesy PADT Inc.)
Dashboard Surgery
How do you remove the dashboard from a car, intact? Very carefully – especially when the dashboard comes from one of only 19 ever-made vehicles. Here, Bogi Lateiner (at right) and volunteer Ally Abel work to disengage every electrical component, screw and snap-fit connector keeping the S60 T8 Polestar dashboard in place. (Image courtesy PADT Inc.)
The brand-new 2019 Volvo S60 T8 Polestar Engineered sedan was almost too cool to cut up – but Girl Gang Garage knew that something even better would emerge in the end. Before the roof was cut off (see the video on LinkedIn), the work timeline required removing the dashboard with all its electronic components.
Here’s the extracted S60 dashboard, viewed from the bottom and front:
And the frame behind it:
And here are the existing red PV544 dash and the black S60 version side by side (the dots are the reflective targets used with the 3D laser scanner). The S60 configuration needs to fit in the original PV544 space. To compress this at least five inches, the glove-box probably has to go.
Once again, the team is turning to scan data, and that analysis is in process.
Top view of the S60 dashboard, as scanned with the GOM Tscan Hawk 3D scanner. (Image courtesy PADT Inc.)
Stay Tuned
Due to the scheduling and travel challenges presented by the ever-shifting COVID scene, Girl Gang Garage has decided to complete the Iron Maven for presentation at the 2022 SEMA Show (highlighting automotive specialty products). This also allows more time for 3D printing the new components which are coming off the Stratasys F370 printer. PADT will be documenting updates and sharing cool photos of this one-of-a-kind project in the months to come.
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on GOM 3D scanners and Stratasys printers and materials, contact us at info@padtinc.com.
One of the first things PADT did when we got our first multi-color 3D Printer was figure out how to convert a result in Ansys Mechanical to something to be printed. If you go back to earlier blog posts (2014, 2020) on the topic and find that our earlier methods were – well cumbersome would be kind. There was no easy way to get Ansys Mechanical results into a file that contained color contour information on the surface that could then be printed with a color Additive Manufacturing system.
That is when our Matt Sutton stepped up and used Ansys ACT skills and knowledge on graphics programming to create simple plugin that converts any result object on a solid object in Ansys Mechanical into a 3D Manufacturing Format (3MF) file: AM Result Printer. The 3MF file can be read by Stratasys Grab CAD, the standard tool for Stratasys color systems and, because 3MF is an accepted platform across systems, it should work with any newer color additive manufacturing system.
The plugin is available at the Ansys Store here. It is free, and the download file contains installation and user instructions, or read on to learn more.
Installation
Instaillation is simple. For each installation of Ansys Mechanical, do the following:
Download the ZIP file from the Ansys store
Extract the files in some scratch location
Go into 2021_09_00-3MF-Writer\AM_Result_Printer_v1\Incoming
Then also expand the bianary.zip file. This contains the plugin for various versions of Ansys Workbench
You need the right Visual C++ Redistributable package, so doublick on “vcredist_x64.exe” to make sure its installed. Follow the prompts until its done.
Add the extension through Ansys Workbench. On the project page, go to Extensions > Install Extensions
Go into the binary folder and find the “Additive Manufacturing Result Exporter.wbex” in the proper version folder.
Then to into Extensions > Manage Extensions and click the check box for the Additive Manufacturing Result Exporter.
Now, when you got into your model in Ansys Mechanical, you should see the extensions listed at the top, and if you right-mouse-click on the Solution part of you model, it should be a choice.
How to use it
Make sure you insert any result objects you want to 3d Print and scope them to the things you want printed. Then, for each 3MF file you want, insert an “AM Result Export” into the tree. Then select the result you want a file for, they type of contour, and the number of bands.
When everything is ready, Generate the model to create the file or files.
How it works
This little tool is a great example of using Opensource libraries with the Ansys ACT interface. Matt used the VTK and lib3mf libraries. When you generate the object, the following happens:
Converts the mechanical mesh scoped to the result body to a VTK unstructured mesh.
Export out the result data from the result object as nodal values to a temporart file.
Apply these nodal values to the VTK mesh.
Contour using an appropriate VTK algorithm.
Extract the VTK contour data as a series of triangular facets.
Group the facets by color for banded, or extract the individual vertex colors for smooth.
Write that data to the .3mf format using the lib3mf library.
Need more information?
If you would like more information or have any questions or need support on the tool, please email info@padtinc.com or give us a call at 480.813.4884.
This is also a great example of the type of custom application that PADT creates for a wide variety of customers to improve and enhance their simulation experience. If you have any questions on software development or customization needs around simulation, please reach out to info@padtinc.com or call 480.813.4884 as well.
Press Release
This article is getting posted as we also do a press release on the V1 posting of the program to the Ansys Store. You can also find the official press releases as a PDF and HTML.
Free Extension Designed to Export Ansys Mechanical Results as Color 3MF Files for Additive Manufacturing Released by PADT
Custom Plugin Allows Users to Create 3D Printed Full-Color Models with Results Contours
“PADT is an industry leader in off-the-shelf and custom 3D printing and simulation tools and products,” said Tyler Shaw, PADT’s VP of Engineering. “When customers requested a way to export Ansys Mechanical results as color 3MF files, we saw an opportunity to develop a custom program and share it with our community for free.”
The PADT Scientific & Technical Computing team work on small extensions like the AM Result Printer, large standalone programs, and a multitude of tools that make simulation more efficient and useful. The AM Result Printer extension was written by Matt Sutton, PADT’s Lead Developer for Scientific & Technical Computing using the tools provided by Ansys through their API and several publicly available libraries for working with tessellated geometry and the 3MF format.
Any Ansys Mechanical user can install the extension for free by first downloading it from the Ansys Store where it is listed as “AM Result Printer.” The download includes installation instructions. Once installed, users can easily add an AM Result Object to any result object and then create the 3MF file. This file can then be used in any additive manufacturing system that support the 3MF format and prints in full color, like the Stratasys J55, J826, J835, and J850 PolyJet systems.
“This simple program is a fantastic example of how our software experts, who are also Ansys experts, create applications that greatly enhance the already strong capabilities of Ansys products,” said Sutton. “We’re proud to make this powerful tool available to the Ansys user community.”
For more information on how to customize Ansys programs or to speak to PADT for help with writing custom tools and programs, please visit the PADT website at www.padtinc.com, contact info@padtinc.com or call 480.813.4884.
About PADT
PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
What do you get when you cross a 1961 Volvo PV544 retro-look car with a sleek 2019 Volvo S60 T8 Polestar Engineered sedan – and why would you ever do that?
You get a custom head-turner hybrid vehicle designed to get people talking, especially about women in automotive trades. That’s because this blended vehicle project is being disassembled, redesigned and rebuilt by an all-female team based at Girl Gang Garage in Phoenix Arizona.
Bogi Lateiner and Shawnda Williams, co-owners of Girl Gang Garage, stand next to the stripped-down body of a 1961 Volvo PV544 that will soon be retrofitted on the chassis of a brand-new 2019 Volvo S60 T8 Polestar Engineered sedan. The rebuild project provides a rare hands-on learning opportunity for women of all ages and skill levels, from around the U.S., to come and learn (or improve) skills in welding, cutting, transmission work, body repair/painting, electronics, upholstery and more. (Image courtesy Girl Gang Garage.)
Girl Gang Garage founder and co-owner, Bogi Lateiner, TV host of Motortrend’s All Girls Garage and Garage Squad shows, is well on the way to transforming these vehicles as the third major public project she has undertaken. Along with co-owner Shawnda Williams, Lateiner offers women of all ages, experiences and skill levels the chance to lend a hand, learn a tool, and possibly discover a new career-path in the automotive trades.
The front showroom of Girl Gang Garage (Phoenix AZ). At the left is the group’s second all-female build dubbed High Yellow 56, displayed at the 2019 SEMA Show. Partially hidden in the center is the first (2017) Girl Gang build, the Chevy Montage with its BMW engine, and at the right is the early-stage PV544 rebuild slated for showing at the 2021 SEMA Show. (Image courtesy PADT Inc.)
Lateiner and Williams apply well-honed old-school skills but have been increasingly interested in the possibilities offered by today’s digital workflow. That’s why early in 2021, after conversations with the fellow re-build team at Kindig-It Custom Car Fabrication, Lateiner reached out to Stratasys to see how they might work together to incorporate 3D printing in the PV544 project.
At Stratasys, Pat Carey, Senior Vice President Americas Products & Solutions, and Allen Kreemer, Senior Strategic Applications Engineer, were immediately onboard with the chance to help Girl Gang Garage move into the digital world while widening their circle of women with automotive skills and interests. They loaned the team an F370 FDM 3D printer and accompanying support-removal SCA tank and offered to supply filament material for a two year try-whatever-you-want time period. Moreover, they pulled together a volunteer team of women across the country who could support the effort on multiple fronts.
Every 3D printer looks better with a cool scooter in front: the Stratasys F370 FDM printer, installed at Girl Gang Garage. (Image courtesy PADT Inc.)
A Virtual Team and a Digital Workflow
The team includes engineers whose day-time jobs have them working at Stratasys, Link3D, Autodesk, Xerox, Collins Aerospace and Ford Motor Company or as independent consultants. Printer installation and local support is handled by PADT Inc, a Stratasys reseller and 3D printing/design/simulation company located just 16 miles away from Girl Gang Garage. In addition, members of Women in 3D Printing offered to coordinate many of the publicity efforts and even sponsor a related design competition targeted at young women in high schools and colleges who are learning CAD skills. (More on that to come.)
During the first few Zoom meetings that introduced Lateiner and Williams to the technical capabilities of the different team members and the printer, the basic rebuild plan was presented: strip the PV544 down to bare metal (removing every mechanical and electrical component), disassemble the S60 down to the chassis, engine, drive-train and hybrid motor system, and figure out how to make the two sections fit!
Traditionally, that workflow depended strictly on the classic tools of the trade, from cutting wheels and a Sawzall to hand-grinders and pneumatic drills. Those components are still coming into play on the current project under the skilled eye of the Girl Gang Garage leaders, but now complementary digital processes are being added.
It Starts with Scanning
Using the GOM Tscan Hawk hand-held 3D laser-line scanner to digitally capture reference points, surface curvature and details on the PV544 body. (Image courtesy PADT Inc.)
PADT recently became a reseller of GOM 3D scanning hardware and software tools, and the timing was perfect to bring the new handheld Tscan Hawk system on-site. Operating with both red-line and blue-line (different wavelength) laser scanners plus stereo cameras, the Tscan Hawk captures millions of spatial 3D-point-coordinates (termed clouds of data) which are converted into a standard STL mesh file format for several end-purposes. The red lasers generate measurements across medium to large surfaces while the blue-wavelength sensors capture fine detail, with accuracy down to 20 microns.
GOM Inspect software records reference points, captures the individual coordinate data and allows interrogation of that data to provide dimensions, such as the distance between the engine frame mounts or the diameter of the hole into which the headlamp fits.
(Images courtesy PADT Inc.)
These three images show a) the reference-point data that appears on the laptop screen as the shape of the PV544 vehicle’s underside is captured, b) the completed scan showing the 3D details of the as-built sheet metal and c) a report page from GOM Inspect software with dozens of dimensions extracted from the scan, such as the length of the trunk opening and the width of the opening available for the engine mount. The scan data, if exported as an STL file, could be sent directly to a 3D printer – though for this project the team is not printing the full body. Instead, subsets of the scan are being used for reverse engineering, where the data works as the basis for creative design elements to be printed and perhaps painted or plated.
To do so, the scanned data is be brought into a surfacing package such as Geomagic Design X or Innovmetric PolyWorks. Those software tools let users convert the STL mesh into an IGES surface, which can then be brought into a CAD package as the basis for a new solid model.
Not for the real build but as a fun example, here is a possible headlight-rim with the letters “Girl Gang Garage” cut out as a circular repeat pattern, that could be backlit with LEDS to customize the build. The design and dimensions are based on the maximum inscribed circle fitted by the GOM Inspect software inside the given opening. (In future blog posts, we’ll show examples of the CAD team’s actual 3D printing results.)
Scanning has many other purposes and capabilities. If CAD data were available for the actual vehicle, those files could be imported, overlaid on the captured data, and compared, alerting the user to deviations between intended and actual dimensions – a very common use of GOM Inspect software.
Next Steps
Every Thursday through Sunday, volunteer women come to Girl Gang Garage and learn to use cutting tools, welders, sanders and more, making daily progress toward the completed hybrid PV544. (All women are invited to come help and learn, at no cost – just sign up to get involved and get yourself to Phoenix.) Here are a few glimpses into the work as of early April – much more has been done but stay tuned for the next blog post as we show off elements of the S60 sedan, scan data being used for reference, and details of the design contest.
Views of the PV544 Volvo with work underway on a rear fender (also shown as scan data from the Tscan Hawk, with Bogi Lateiner in her Girl Gang Garage location). (Images courtesy PADT Inc.)
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on Stratasys printers and materials, contact us at info@padtinc.com.
Tracking time has challenged the human race for centuries, resulting in some of the finest mechanisms ever crafted. From sundials and hourglasses to pocket watches and atomic clocks, we have marked the passage of time with ever-increasing precision. Along the way, we became supremely skilled at creating the requisite gears and springs, as well as the machines to produce them. (If you have a deeper interest in measuring time, one must-read book is Longitude by Dava Sobel.)
This post, however, is about taking clock-making to a new dimension – three dimensions, in fact, using multiple 3D printers to generate not only the gears and structural components but even the watch-spring and winding-key, based on a mechanism called a Tourbillon. Invented around 1800 by Abraham-Louis Breguet, the Tourbillon concept compensates for the effects of gravity on delicate watch-springs when the watch is carried or laid down (varying its orientations), by employing multiple axes.
A traditionally made Tourbillon watch mechanism (watchgecko.com)
Depending on one’s donation amount, some or all of the intricate clock’s CAD files are downloadable. Recently Justin Baxter, PADT’s senior 3D Printing Service Engineer (with years of hobbyist clock-making under his belt), set out to reproduce the device with a twist. Why not take advantage of all the additive manufacturing systems in use by PADT’s Manufacturing Division, and print at least one component on each?
This approach spans the AM technologies of Fused Deposition Modeling (Stratasys FDM material extrusion), PolyJet (Stratasys material deposition), selective laser sintering (3D Systems SLS polymer powder bed fusion), direct metal laser sintering (EOS DMLS metal powder bed fusion), stereolithography (3D Systems and UnionTech vat SLA photopolymerization) and digital light processing (Stratasys Origin One DLP vat photopolymerization).
The Triple-Axis Tourbillon Mechanical Clock Design
Not all of the clock’s 230 components are 3D printed – metal screws, pins and ball bearings round out the assembly – but Justin is slowly printing all other parts spread across colors, materials and AM technologies. For starters, he has recreated the central first-axis mechanism called the Mini Mechanica; this subset serves well for new users to test out their own systems and parameters ensuring effective dimensional tolerances. The Mini Mechanica part files are also available as a separate free download.
First section of the Mechanist design of a 3D printed, three-axis Tourbillon mechanical clock, printed at PADT based on the downloaded files from MyMiniFactory. (Image courtesy PADT)
Justin’s Mini Mechanica includes the following parts made of ABS (acrylonitrile-butadiene-styrene), each 3D printed on one of our two Stratasys F370 FDM systems:
Part Name
01_Bottom Base
02_Upper_Base
03_Tourbillon_Lower_Cage
04_Tourbillon_Upper_Cage
05_Cage_Bridge
06_Cage_Spacer
07_Ratchet_Post
08_Winder
09_Mainspring
10_Core_Post
11_Impulse_Pin
12_Tourbillon_Ring_Gear
13_Hairspring
14_Balance_Wheel
15_Escape_Fork
16_Escape_Wheel
17_Washer
18_Display_Stand
When finished, here is how that subset will fit into the completed three-axis clock:
Three-axis Tourbillon clock designed for 3D printing by Mechanistic, with part files available by donation on MyMiniFactory (www.myminifactory.com) (MyMiniFactory)
Note: the fully printed clock operates on a 90 minute run-time if a steel spring is employed, and 20 minute run time with a 3D printed (FDM) version. (We’ve seen suggestions for adding a battery.)
As the part-builds progress across our other printers and materials, we’ll post an update. Here are a few more components in progress, including the decorative base on the left, which was printed in Nylon 12GS on our SLS powder-bed printer.
In-progress parts 3D printed for the Mechanica Tri-Axis Tourbillon Clock currently being reproduced at PADT. The decorative base at the left was printed in Nylon 12GS on our SLS system; the parts for the MiniMechanica (assembled at the top) and the remaining black and grey parts were printed in ABS and ASA on our Stratasys F370 FDM systems. (Image courtesy PADT Inc.)
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on Stratasys polymer printers and materialsand EOS metal printers, contact us at info@padtinc.com.
Just over a year ago, PADT, like most every other engineering company, shifted rapidly into minimal on-site-operations mode. As the PADT 3D Printing Application Engineer, I worked from home while requesting support from our manufacturing group for running benchmark parts on our Stratasys fused deposition modeling (FDM) filament and PolyJet resin printers. Whether those parts were created on the F370, F450, F900 or J55 printers, they spanned a wide range of part size, function and material. It was an interesting time, but software tools like GrabCAD Print made remote part set-up possible, and the on-site team kept everything running under some often-challenging conditions.
I’ve been back in the office for about a month, so I’m tending to tasks that were, out of necessity, put on a backburner while our company did high-importance projects such as printing a ton of PPE visor frames. Now it’s time to do some printer maintenance that got a little delayed beyond the recommended run-time schedule.
For our Stratasys J55 full-color PolyJet printer, while all the standard components were cleaned and checked after every print, we stretched the recommendation period for replacing the wiper blade, the roller-waste collector, and both filters in the compact ProAero Air Extractor that contributes to making this printer truly office-friendly. Now I’ve checked those off as done.
Bring in the Printer Maintenance Experts
Other steps should only be done by a professional from the Service Department at your reseller or from Stratasys. When they come on-site to perform Preventive Maintenance for your printer, do you know what goes into this, and the kind of tasks that keep your system humming along?
It’s similar to practicing good automotive ownership: checking the air in your tires, changing the oil every 5,000 miles or so, replacing brake pads before they’re so thin that you have to turn the rotors, etc. Some jobs you do monthly, some yearly and some on general principles to avoid future trouble which inevitably occurs during the critical stage of a project.
Here are some of the tasks our PADT service technician performs from the 12-month Preventive Maintenance Checklist for a Stratasys F450 industrial FDM printer:
With the printer powered off, clean the canister drives, gantry fans and electronics bay ventilation fans (kind of like cleaning out the ventilation area under the front of your refrigerator – which we all do regularly, right?) Also, inspect the head cable and heat shields, verify X-Y belt tensions, and replace the vacuum filter.
With the printer powered on, verify voltage levels, fan speeds and Z-Zero calibration, inspect the flicker brush assemblies and clean and lubricate the Z-axis leadscrew.
When the two-year point rolls around, these tasks are repeated plus another set is added, such as:
With the printer off: Replace the filament guide tubes, Kapton seals, X and Y bellows seals, oven lamps, air-pressure regulator diaphragm and all compressed-air system filter elements.
With the printer on: Adjust the air pressure and airflow, verify the oven blower operation and perform filament load-time tests.
And at the four-year mark, all of the above are completed plus such tasks as “replace the X and Y belts.” At every service appointment, too, the technician verifies that the current version of the printer control software has been installed, and that the user has the latest application software, whether Insight or GrabCAD Print. All in all, we’re talking more than 50 check points and tasks that keep the printer running smoothly.
High Expectations from Good Maintenance
I have to admit that when I get into my car, I expect the engine to idle smoothly, the air-conditioning to generate chilled-air, and my driveway to be free of oil spots. However, that expectation is only realistic if I or my mechanic has done due diligence with regular inspections and taken action when certain conditions show up. Checking for dirty spark plugs or a cracked distributor cap will maintain engine performance. If the serpentine belt is showing signs of wear, I’d better replace it rather than risk losing both power steering and air-conditioning on some far-off road in the desert on a beastly summer day. And worn rings, pistons or gaskets could all contribute to that oil leak.
And so it goes with 3D printers. First, the importance of avoiding down-time is huge for most manufacturers and factors into both production planning and a smooth workflow for printing prototypes. Second, if you’ve paid for a Stratasys-authorized Service Plan, you get guaranteed response time when something does go wrong (say you accidently melted filament into the print-head because you didn’t mount the tip correctly – life happens). Third, with a PM contract, a trained technician steps you through every aspect of the printer’s operation, inspection and cleaning whether done daily/weekly/monthly by a program engineer or by the system operator.
Stratasys offers three levels of contract service for almost all of its 3D printers, now covering the gamut from FDM and PolyJet to SLA, DLP, and the new Selective Absorptive Fusion (SAF, a polymer powder-bed fusion technology). Those levels are Sapphire, Emerald, and Diamond which can each be purchased for multi-year coverage.
Generally speaking, service offerings include:
On-site technical service
Spare parts
Priority service scheduling
Discounted user-training
Discounts on printer heads
Customers also win with hardware updates, optional backup printing services, predictable maintenance expenditures for easier budgeting, and more.
It’s not in my budget to buy a new car every year or even every couple of years, so regular, professional automotive inspection and maintenance is critical to me. It is to customers in the additive manufacturing world, too. So, to paraphrase that diamond-jewelry advertisement, “Now you have a friend in the 3D printer business: Stratasys.” Find out more about service contracts and the details of preventive maintenance by contacting 3DPSAL@PADTinc.com.
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on Stratasys printers and materials, contact us at info@padtinc.com.
The new combined offerings are being called #HandsOnMetrology. Someone must of let an engineer into the branding meeting because the new name is a perfect description of what the product line offers. Right now we are reselling three scanners and the outstanding software package that enables the unique advantages of each system:
When ZEISS and GOM joined forces, it was hard on our sales team here at PADT. We wanted to let our customers know about the significant advantages of the merger. After selling ZEISS Optical systems for many years, we knew that more and more customers wanted the flexibility of more handheld solutions along with laser scanning for larger objects. With the addition of the GOM line, we can now meet those needs.
You can learn more about these tools on our new #HandsOnMetrology page or by contacting PADT today. Remember, we are more than a reseller, we use these same tools in our consulting business, so we have real-world experience on how to apply and leverage this technology. You might say that PADT even has “hands on” experience with these tools.
Access the offical press release here or as a PDF here, or you can read it below.
Press Release:
Innovative GOM and ZEISS 3D Scanning Solutions Added to PADT Portfolio as it Joins the #HandsOnMetrology Digital Platform Global Network
PADT is Now Selling the Three Leading GOM and ZEISS Optical and Laser Scanning Systems Throughout the Mountain and Southwest States
“The HandsOnMetrology systems are the most precise and flexible scanners on the market,” said Ward Rand, co-founder and principal, PADT. “We are pleased to be expanding our product offerings, as well as providing scanning services to our customers. Specifically, the systems enhance our simulation services by allowing us to scan existing parts that can be simulated, or scan parts after testing for verification of simulation. It also supports our additive manufacturing activities by providing a simple-to-use and cost-effective way to reverse engineer older parts and inspect 3D Printed parts.”
The portfolio of HandsOnMetrology systems focuses on new to market hand-held measuring systems. The scanners are characterized by their precise measuring results and allow for mobile and flexible use around the shop floor. The industry-standard software GOM Inspect Suite is pre-installed on all three systems and supports users during inspections and analyses. It also walks users through the entire workflow from 3D scanning to the evaluation, including the inspection report.
PADT is selling the scanners and accompanying software across Arizona, California, Colorado, Idaho, Kansas, Nebraska, Nevada, New Mexico, Montana, Oklahoma, Texas, Utah, and Wyoming. The systems allow PADT and its customers to address a variety of 3D scanning processes including reverse engineering, art, architecture, inspection, quality, and control. The company is also providing support and training to help customers get real work done quickly and accurately.
“In addition to our ability to sell this innovative lineup of scanners, PADT and our customers will gain access to a network of resources through HandsOnMetrology,” said Jim Sanford, vice president, Sales and Support, PADT. “By teaming with these industry leaders, PADT can support our community of designers, technicians, engineers, scientists, and specialists with valuable knowledge to increase product quality, optimize processes and expand possibilities. It is the perfect complement to our long-term position as Ansys Elite, Stratasys Platinum and EOS Channel Partners.”
To learn more about PADT and its new lineup of #HandsOnMetrology 3D scanning systems and software, please visit www.padtinc.com.
About PADT
PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
About #HandsOnMetrology
#HandsOnMetrology is a new global 3D scanning network and provides a digital go-to for everything you always wanted to know about 3D scanning on the platform HandsOnMetrology.com. The platform is operated by GOM, a ZEISS company, that sets new standards in optical 3D metrology. From step-by-step setup instructions to more advanced tutorials and expert hacks: the platform is made for learning and for getting inspired. It gives users all the information they need to deliver 3D scanning excellence. HandsOnMetrology.com supports the community of designers, technicians, engineers, scientists and specialists with valuable knowledge to increase product quality, optimize processes and expand possibilities.
About GOM GmbH
GOM, a company of the ZEISS Group, specializes in industrial 3D coordinate measuring technology, 3D computed tomography and 3D testing. From product development to production and worldwide distribution, GOM offers machines and systems for manual and automated 3D digitizing, evaluation software, training and professional support from a single source. In industries such as automotive, aerospace, energy and consumer goods, more than 17,000 GOM system installations are in use internationally. At more than 60 locations and with more than 1,200 metrology specialists, GOM guarantees profound advice and first-class service. Since mid-2019, GOM has been a part of the ZEISS Group and has formed the Center of Excellence for optical metrology. With more than 31,000 employees in 50 countries and annual revenue totaling more than 6.4 billion euros, ZEISS is an internationally leading technology enterprise operating in the fields of optics and optoelectronics. (Status: September 30, 2019)
PADT’s model for over 27 years has been to become experts on the leading tool that engineers use, then become a reseller. We continue that model with our new partnership with EOS, the leader in Metal 3D Printing. We have been a user of several metal Additive Manufacturing solutions for some time, settling on EOS’ DMLS technology last year. We are now pleased to announce that that technical relationship has grown to include PADT as an EOS Distribution Partner for the Southwestern United States.
More details can be found in the press release below. You can see the official press release in PDF and HTML as well.
What does it mean for our customers? The same technology-driven win-win relationship you have come to count on for Ansys, Stratasys, and Flownex are now available if you need to add metal 3D Printing. And after your purchase, when you call for assistance you will talk to people that run the same machines you are.
Have questions? Why EOS or what machine would be best for you? More details on the metal systems can be found on our website. But the best way to learn more is to contact us at info@padtinc.com or 480.813.4884
If metal 3D Printing is part of how you make innovation work, PADT is ready to help.
PADT Named EOS Metal 3D Printing Distribution Partner Across the Southwest, Expanding its Established Additive Manufacturing Products Offering
Building on its Expertise in Metal 3D Printing Services and R&D, PADT Adds Metal Laser Powder Bed Fusion Systems to its Sales Portfolio
TEMPE, Ariz., April 13, 2021 ─ PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced it has been named Distribution Partner for EOS’s full lineup of industrial metal 3D printing systems. Founded in 1989, EOS is a leading technology provider for industrial additive manufacturing of metals and plastics. PADT will represent the company’s Direct Metal Laser Fusion (DMLS®) powder bed fusion systems across Arizona, California, Colorado, Idaho, New Mexico, Nevada, Texas, and Utah.
“PADT is experiencing explosive growth,” said Jim Sanford, Vice President, Sales & Support, PADT. “Our new partnership with EOS helps us serve our customers and expand their 3D printing options with this impressive lineup of systems. Metal materials are the next major frontier in 3D printing innovation and PADT is an early adopter. We continue to explore new ways to apply the technology to meet our customer’s evolving needs.”
EOS’ metal 3D printing platforms use proprietary DMLS technology that meters and deposits ultra-fine layers of metal powders and then melts each layer – as defined by a 3D CAD model – using high-powered lasers. The applications produced with DMLS are highly accurate, highly dense, and allow for incredible functionality at a cost that can be less than traditional manufacturing. DMLS printers are considered the industry standard for oil and gas components, consolidated and lighter-weight aerospace applications, and custom medical solutions such as guides and implants that improve patient outcomes.
PADT will sell EOS’ metal 3D printing systems, including the company’s small and medium systems, EOS M 100 and EOS M 290; and its large production platforms, EOS M 300 Series, EOS M 400, and EOS M 400-4. PADT has installed an EOS M 290 machine onsite to develop high-quality end-use metal products for customers and expand its ongoing research and development of metal 3D printing.
“As 3D printing technology has advanced, PADT has seen an increase primarily in the aerospace and defense industry’s use of 3D printing for end-use parts,” said Rey Chu, co-founder and principal, PADT. “Metal 3D printing provides many benefits over traditional manufacturing, including lighter, cost-effective parts made much faster and with greater design freedom. The EOS machines provide PADT’s entire range of customers with a wide variety of options to produce metal parts quickly and effectively. Those same advantages will benefit any industry that has a need for low volume production of complex metal parts.”
“PADT is a long-time leader in 3D printing systems and services since the early 1990s with a proven track record of identifying advanced manufacturing trends and helping customers integrate 3D printing innovation into their manufacturing operations,” said Andrew Snow, senior vice president at EOS North America. “We look forward to deepening our reach across the Southwest, a leading hub for aerospace and defense customers, through our partnership with PADT.”
To learn more about PADT and its new lineup of EOS metal 3D printing products and accessories, please visit www.padtinc.com.
About PADT
PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
About EOS
EOS is the world’s leading technology supplier in the field of industrial 3D printing of metals and polymers. Formed in 1989, the independent company is pioneer and innovator for comprehensive solutions in additive manufacturing. Its product portfolio of EOS systems, materials, and process parameters gives customers crucial competitive advantages in terms of product quality and the long-term economic sustainability of their manufacturing processes. Furthermore, customers benefit from deep technical expertise in global service, applications engineering and consultancy.
PADT’s long-standing relationship with Stratasys, the world leader in 3D Printing systems, continues to grow. The latest facet is our recent naming as a Stratasys Diamond Partner. We started this mutual journey as one of the first 3D Printing service providers to add Stratasys’ Fused Deposition Modeling. With that start as a customer we grew to become a reseller, then a supplier for support removal equipment, We also recently expanded our sales territory to include the state of Texas.
And now we are proud to be identified as a Diamond Partner, the top level for Stratasys channel partners. Please read the press release below to learn more about the details. You can also read the official HTML and PDF versions.
We could not have achieved this honor without two groups of people – our customers and our staff. PADT has the most amazing relationship with our 3D Printing users, who let us into their business to help them realize their additive manufacturing goals. And what those customers tell us is that our staff is amazing. From salespeople who have become trusted advisors, to our expert application engineers, to our service engineers who keep their machines running.
We can’t wait to see where the Stratasys + PADT journey takes us next.
The Southwest’s Leading Provider of 3D Printing Systems, Materials and Services, PADT, Named a Stratasys Diamond Partner
PADT has Served More Than 500 Customers With More Than 800 3D Printers Throughout Arizona, Colorado, New Mexico, Texas and Utah
TEMPE, Ariz., March 9, 2021 ─ PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced it has been named a Stratasys Diamond partner for its continued success selling the 3D printing manufacturer’s complete line of products and providing stellar support service. PADT becomes one of the few elite Stratasys resellers in the country to have achieved Diamond partner status.
“For more than 25 years, PADT has provided the highest level of 3D printing products, services and support to our customers across the Southwest,” said Jim Sanford, vice president, Sales & Support, PADT. “Earning the Stratasys Diamond partner designation is a result of the hard work of our team, and the continued respect of our customers.”
PADT became one of the first service providers in the country to offer fused deposition modeling (FDM) printing on Stratasys equipment in the late 1990s and has continued to expand its 3D printing capabilities as a service provider and reseller. The company built its customer base by providing outstanding 3D printing services and technical support across a wide variety of industries and organizations, from schools to startups, including some of the world’s largest aerospace organizations. To date, PADT has sold 883 printers to 506 customers across the Southwest.
PADT currently offers Stratasys’ complete portfolio of top-rated systems, accessories and materials, including full-color printing with PolyJet multi-material systems, robust and proven FDM manufacturing systems from desktop to those supporting advanced materials, and stereolithography for precision and finish.
“3D printing is a fast-growing industry that continues to expand its capabilities and quality year-over-year,” said Ward Rand, co-founder and principal, PADT. “We’re thankful for the strong partnership we’ve enjoyed with Stratasys, and with new technologies coming, we look forward to offering our customers even more choices to make 3D printing part of their everyday process to drive efficiency and cost-savings. This is especially true as we help our customers move from prototyping to creating tooling and production parts with Stratasys additive manufacturing solutions. 3D printing solutions from Stratasys are helping the world’s leading companies gain business agility and competitive advantage and PADT is proud to be a Diamond Partner.”
PADT now represents Stratasys in Arizona, Colorado, New Mexico, Texas, and Utah as an Elite Channel Partner at the Diamond level. To learn more about PADT and its 3D printing products and services, please visit www.padtinc.com.
About PADT
PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
The Sales and Support team at PADT is the group that most of PADT’s customers interface with. They sell world-leading products from Ansys, Stratasys, and Flownex and then provide award-winning support long after the initial purpose. The team has grown over the years and has plans for even more growth. To help make that happen, we are honored to have Jim Sanford join the PADT family as the Vice President of our Sales & Support team.
Many of our customers and partners know Jim from his time with industry leaders Siemens, MSC, Dassault Systems, and NextLabs, Inc. He brings that experience and his background as a mechanical engineer before he entered sales, to focus PADT on our next phase of growth. He also fit well in PADT’s culture of customer focused, technical driven sales and support.
Our customers have a choice of who they purchase their Ansys multiphysics simulation, Stratasys 3D Printers, and Flownex system simulation software from, and who delivers their frontline support. We know with Jim leading the team, even more companies will make the choice to be part of the PADT family.
The official press release has more details, and can be found at these links or in the test below.
Want to have a conversation about your Simulation or 3D Printing situation? Contact PADT now and one of our profesionals will be happy to help.
Ansys Elite Channel Partner and Stratasys DiamondChannel Partner, PADT Announces Jim Sanford as Vice President of Sales & Support
Sanford Brings a Wide Range of High-Profile Leadership Experience Across Technology and Aerospace and Defense Sectors to his New Position
TEMPE, Ariz., February 11, 2021 ─ PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced the addition of Jim Sanford as vice president of the company’s Sales & Support department. In his new position, Sanford is responsible for leading the increase of sales and customer support for a range of best-in-class simulation and additive manufacturing solutions. Sanford reports to Ward Rand, co-founder and principal, PADT.
“In the last few years, PADT has expanded across the Southwest, adding new expertise and technologies to our product and service offerings,” said Rand. “Jim is a valuable addition to the team and will be instrumental in sustaining PADT’s growth across the region. His leadership, experience, and knowledge of the industry will allow us to increase the pace of expansion and bring our solutions to serve new and existing customers in deeper and more impactful ways to their businesses.”
After a comprehensive search, Sanford proved to be the most experienced and capable leader to take on the vice president role. He will focus on providing visionary guidance, strategy, and tactical direction to the department. His responsibilities include refining the company’s sales team structure, recruiting, hiring, training, managing for profitable growth, and leading the support team to ensure an optimal customer experience for their use of Ansys, Stratasys, and Flownex products.
Prior to joining PADT, Sanford held business development and engineering positions in a diverse range of aerospace and defense, modeling and simulation, and software companies. His 30-year career span includes executive leadership roles at Siemens, MSC, and Dassault. Most recently he served as the VP for NextLabs Inc., a leading provider of policy-driven information risk management software for large enterprises, and the VP of Business Development for Long Range Services, where he was engaged in the development and testing of various classified items for the U.S. Department of Defense. He holds a bachelor’s degree in Mechanical Engineering from the University of Arizona, with emphasis in materials science and physics.
“PADT is a well-respected brand well-known for its product knowledge, customer-centric approach, and expertise,” said Sanford. “My career has been defined by my ability to take technology-focused companies to the next level of success, and I’m thrilled to join PADT and help continue its expansion by supporting highly innovative customers.”
PADT currently sells and supports the entire Ansys product line in Arizona, California, Colorado, Nevada, New Mexico, Texas, and Utah as an Ansys Elite Channel Partner. They also represent all Stratasys products in Arizona, Colorado, New Mexico, Texas, and Utah as a Diamond Channel Partner and are the North American distributor for Flownex.
PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.
For decades in the medical world, surgeons and their professional support teams have relied on X-rays, computed tomography (CT) scans and magnetic resonant imaging (MRI) data when performing their pre-surgical planning approach. These diagnostic tools have been literal lifesavers, yet the resolution and 2D perspective of these images can make it difficult to determine the full details of anatomical geometry. Subtle, critical abnormalities or hidden geometries can go unnoticed when viewing flat films and digital displays.
3D printed heart model produced by Phoenix Children’s Hospital. (Image courtesy Phoenix Children’s Hospital)
With the advent of 3D printing, many surgeons are now using 3D models for both surgical planning and patient communication. While cost is the primary hold-back, such models are seeing increased use. In addition, efforts are underway to quantify the benefits of reduced operating room time/expense and improved patient outcome; see Medical 3D Printing Registry (ACR/RSNA). Supporting this concept are the high-resolution, multi-material PolyJet 3D printers from Stratasys.
But how does the patient’s CT and MRI data become a unique 3D printed model you can hold in your hand? How do you segment out the areas of interest for a particular analysis or surgical model? This blog post describes the necessary steps in the workflow, who typically performs them, and the challenges being addressed to improve the process every step of the way.
Data Acquisition of Patient Anatomy
When we think of imaging throughout the decades, X-ray technology comes to mind. However, classic single 2D images on film cannot be used to drive 3D models because they are qualitative not quantitative. The main options that do work include the series of x-rays known as CT scans, MRI data, and to a lesser extent computed tomography angiography (CTA) and magnetic resonant angiography (MRA). Each approach has pros and cons and therefore must be matched to the proper anatomy and end use.
CT scans comprise a series of x-rays evenly spaced laterally across a particular body section, typically generating several hundred image files. These can be quickly acquired and offer high resolution, however, they do not do well displaying different types of soft tissue, and the process relies on extended exposure to a radiation source.
Sample multiple digital images generated as a CT scan is performed (Image courtesy nymphoenix/Shutterstock.com.)
Typical CT resolution is 500 microns in X and Y directions, and 1mm in Z. This is readily handled by Stratasys printers; for example, the print resolution of the J750 Digital Anatomy Printer is 42 microns in X, 84 microns in Y, and 14 to 27 microns layering in Z, which more than captures all possible scanned features.
Computed Tomography Angiography (CTA) involves the same equipment but uses a contrast agent. With this approach, brighter regions highlight areas with blood flow. This process is superior for showing blood vessels but does not differentiate tissue or bones well.
MRI data is based on a different technology where a strong magnetic field interacts with water in the body. This approach differentiates soft tissue and shows small blood vessels but is more expensive and not effective for capturing bone. Similarly, Magnetic Resonant Angiography (MRA) uses a contrast agent that can track small blood vessels which are important for identifying a stroke but cannot register tissue. MRI scans may also include distracting artifacts and offer poor regional contrast.
A final source of digital imaging data is Positron Emission Tomography (PET). Here, radioactive material is attached to a biologically active area such as cancer; the data obtained with sensors is useful but very local – it does not show surrounding tissue.
Segmentation: Conversion from DICOM to STL format
Whether generated by CT or MRI equipment, anatomic image data is stored in digital files in accordance with the Digital Imaging and Communications in Medicine (DICOM) standard. Two aspects of this standard are relevant to 3D printing medical models: DICOM files include patient-specific, HIPPA-protected information, and the data in the individual images must be merged and converted into a solid model, with the areas of interest defined and partitioned.
Various software packages and services are available that will convert DICOM data into an STL model file (standard format for 3D printer input) while stripping out the personal identifying information. (The latter must be done to comply with HIPPA regulations: never send a DICOM file directly to any service bureau.)
Segmentation involves partitioning a digital image into distinct sets of pixels, defining regions as organ, bone, blood vessel, tumor, etc., then grouping and combining those sub-sections into a 3D model saved as an STL file. Not only does this format offer more meaningful information than a stack of separate images, but it can then be exported for 3D printing.
Example of processed CT scans, combined into a multiple-view 3D visualization and saved as an STL file. (Image courtesy PADT Inc.)
The standard unit of measure for identifying and segmenting the different regions within the combined 3D series of CT scans is a Hounsfield unit. This is a dimensionless value, defined as tissue density/x-ray absorption; for reference, water = zero, a kidney =+40 and bone = +1000.
Human guidance is needed to set threshold Hounsfield levels and draw a perimeter to the area of interest. You can define groups with the same threshold level, cut out certain areas that are not needed (e.g., “mask” the lungs to focus on the spine), and use preset values that exist for common model types. Typically, a radiologist or trained biomedical engineer performs this task, since correctly identifying boundaries is a non-trivial judgement task.
A particularly challenging task is the workflow for printing blood vessels, as opposed to bones or organs. The output from CTA/MRA imaging is the blood pool, not the enclosing vessel. In this case, users need third-party software to create a shell of X thickness around the blood pool shape, then keep both model files (pool and vessel) to guide printing the vessel walls and their internal support structure (which, on the Stratasys J750 Digital Anatomy Printer, is soluble and dissolves out.)
So far, just a few medical segmentation software packages exist:
Materialise Mimics Innovation Suite is internationally known for its excellence in image analysis and allows you to write scripted routines for automating repeated aspects of the segmentation tasks. There are also tools for interpreting images with metal artifacts, designing support connections between parts, measuring specified features, and rendering a view of the resulting 3D model.
Synopsys Simpleware ScanIP is a 3D image segmentation, processing, and meshing platform that processes data from MRI, CT, and non-medical imaging systems. Simpleware ScanIP removes or reduces unwanted noise in the greyscale images, allows cropping to the area of interest, supports both automated and user-guided segmentation and measuring and includes API scripting. Modules are available for Cardio, Ortho, and Custom solutions.
Invesalius 3 is open-source software that can reconstruct CT and MRI data, producing 3D visualizations, image segmentation, and image measurements in both manual and semi-automated modes.
Embodi3D/Democratiz3D is an online service that lets you upload a series of CT scans, select a basic anatomy type (bone, detailed bone, dental, muscle, etc.), choose the free medium-to-low resolution or paid high resolution conversion service, and receive the link to an automatically generated STL file. (Users do not interact with the file to choose any masking, measuring, or cropping.) The website also offers downloadable 3D printable models and 3D printing services.
Note that these packages may or may not have some level of 510K FDA clearance for how the results of their processing can be used. Users would have to contact the vendors to learn the current status.
Setting up the STL file for printing
Most of the segmentation software packages give you options for selected resolution of the final model. As with all STL files, the greater the number of triangles, the finer the detail that is featured, but the model size may get too large for reasonable set-up in the printer’s software. You may also find that you still want to edit the model, either to do some hole repairs or smoothing, slice away a section to expose an interior view, or add mechanical struts/supports for delicate and/or heavy anatomy sections. Materialise Magics software will do all of this readily, otherwise, adding a package that can edit STL files or create/merge geometry onto an STL file will be useful.
Medical Modeling software workflow from CT scan to print, for typical Stratasys 3D printed model.
Whoever is setting the file up for printing needs to make a number of decisions based on experience. For Stratasys Connex3, J55, J8-series or J750 Digital Anatomy Printers, the process begins by bringing the file into GrabCAD Print and deciding on an optimized build orientation. Next, colors and materials are assigned, including transparent sections, percentages of transparent colors, and flexible/variable durometer materials, which can be for a single part or a multi-body model.
For the J750 Digital Anatomy Printer in particular, users can assign musculoskeletal, heart, vascular, and general anatomies to each model, then choose detailed, pre-assigned materials and properties to print models whose tactile response mimics actual biomechanical behavior, such as “osteoporotic bone.” (see Sidebar).
I tested out the free online Democratiz3D segmentation service offered by Embodi3D. Following their tutorial, I was able to convert my very own DICOM file folder of 267 CT images into files without patient ID information, generating a single STL output file. I chose the Bone/Detailed/Medium resolution option which ignored all the other visible anatomy then brought the resulting model into the free software Meshmixer to edit (crop) the STL. That let me zero in on a three-vertebrae section of my lower spine model and save it in the 3MF format.
Lastly, I opened the new 3MF file in GrabCAD Print, the versatile Stratasys printer set-up software that works with both FDM (filament) and PolyJet (UV-cured resin) printers. For the former case, I printed the model in ivory ASA on an F370 FDM printer, and for the latter, I was able to assign a creamy-grey color (Red248/Green248/Blue232) to give a bone-like appearance, printing the model on a J55 PolyJet office-environment printer.
GradCAD Print software set-up of 3MF vertebrae model, ready for printing in a user-defined bone color on a Stratasys J55 PolyJet full-color 3D printer. (Image courtesy PADT Inc.)
3D printed vertebrae parts created from CT scans: on left, ABS part from a Stratasys F370 FDM printer; on right, Vero rigid resin material from a Stratasys J55 PolyJet printer. (Image courtesy PADT Inc.)
Experience helps in producing accurately segmented parts, but more features, such as AI-enabled selections, and more online tutorials are helping grow the field of skilled image-processing health professionals. Clarkson College (Omaha, NE) also recently announced the first Medical 3D Printing Specialist Certificate program.
Reach out to PADT to learn more about medical modeling and Stratasys 3D printers.
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on Stratasys printers and materials, contact us at info@padtinc.com.
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Sidebar: J750 Digital Anatomy Printer
The Stratasys J750 Digital Anatomy Printer uses PolyJet resin 3D printing technology to create parts that mimic the look and biomechanical response of human tissue, organs and bones. Users select from a series of pre-programmed anatomies then the material composition is automatically generated along with accurate internal structures. Pliable heart regions allow practice with cutting, suturing and patching, while hollow vascular models support training with guide wires and catheters. General anatomy models can replicate encapsulated and non-encapsulated tumors, while bone structures can be created that are osteoporotic and/or include regions that support tapping, reaming and screw insertion.
Currently the Digital Anatomy Printer models present in the range of 80 to 110 Hounsfield Units. Higher value materials are under development which would help hospitals create phantoms for calibrating their CT systems.
Currently available Digital Anatomy Printer Model/Section Assignments:
In this episode your host and Co-Founder of PADT, Eric Miller is joined by Brent Stucker, the Director of Additive Manufacturing at Ansys to discuss the innovative capabilities of the Ansys additive suite of tools and it’s impact on the effectiveness of 3D printing for manufacturing and design.
If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!
PADT is currently partnering with Arizona State University’s 3DXResearch group on exploring bio-inspired geometries for 3D Printing. As part of that effort, one of our engineers involved in the project, Alex Grishin, PhD, was a co-author on several papers that have been published during this project.
Below is a brief summary from Alex of each article, along with links.
An Examination of the Low Strain Rate Sensitivity of Additively Manufactured Polymer, Composite and Metallic Honeycomb Structures
PADT participated in the research with the above title recently published in the open-access online journal MDPI ( https://www.mdpi.com/1996-1944/12/20/3455/htm ). This work was funded by the America Makes Program under a project titled “A Non-Empirical Predictive Model for Additively Manufactured Lattice Structures” and is based on research sponsored by the Air Force Research Laboratory under agreement number FA8650-12-2-7230.
Current ASU professor and former PADT employee Dhruv Bhate was the Lead Investigator and wrote the original proposal. Dhruv’s research interests involve bio-inspired design (the study of structures found in nature to help inform human design efforts) and additive manufacturing. Dhruv is particularly interested in the bulk properties of various lattice arrangements. While investigating the highly nonlinear force-deflection response of various additively manufactured honeycomb specimens under compression, Dhruv discovered that polymer and composite honeycombs showed extreme sensitivity to strain rates –showing peak responses substantially higher than theory predicts at various (low) strain rates. This paper explores and quantifies this behavior.
The paper investigates hexagonal honeycomb structures manufactured with four different additive manufacturing processes: one polymer (fused deposition modeling, or material extrusion with ABS), one composite (nylon and continuous carbon fiber extrusion) and two metallic (laser powder bed fusion of Inconel 718 and electron beam melting of Ti6Al4V). The strain rate sensitivities of the effective elastic moduli, and the peak loads for all four processes were compared. Results show significant sensitivity to strain rate in the polymer and composite process for both these metrics, and mild sensitivity for the metallic honeycombs for the peak load.
PADT contributed to this research by providing ANSYS simulations of these structures assuming viscoplastic material properties derived from solid dog-bone test specimens. PADT’s simulations helped provide Dhruv with a proposed mechanism to explain why INSTRON compression tests of the honeycomb structures showed higher peak responses (corresponding to classical ultimate stress) for these specimens than the solid specimens.
Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping and Interface
PADT participated in the NASA-funded research with the above title recently published in the open-access online journal MDPI (https://www.mdpi.com/2313-7673/5/4/59/htm ). This work was guided by former PADT engineer and current ASU Associate Professor Dhruv Bhate. Professor Bhate’s primary research interests are Bio-Inspired Design and Additive Manufacturing. It was only natural that he would secure a grant for this research from NASA’s Periodic Table of Life ( PeTaL) project. To quote from the website, “the primary objective…is to expand the domain of inquiry for human processes that seek to model those that are, were or could be found in nature…”
This paper focuses on the morphology of bee honeycombs found in nature –the goal being to identify key characteristics of their structure, which might inform structural performance in man-made designs incorporating similar lattice structures. To this end, the paper identifies three such characteristics: The honeycomb cell corner radius, the cell wall “coping” (a localized thickening of the cell wall at the mouth of each cell seen in a lateral cross-section), and the cell array “interface” (a zigzag pattern seen at the interface of two opposing, or “stacked” arrays).
Most of this work involved material testing and measuring dozens of natural honeycombs (most coming from various museums of natural history found in the United States) at ASU’s state-of-the-art facilities. PADT contributed substantially by verifying and guiding tests with simulation using the ANSYS suite of software.
A Comparison of Modeling Methods for Predicting the Elastic-Plastic Response of Additively Manufactured Honeycomb Structures
PADT participated in this research found in the reviewed article published in Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference.
The lead investigator was current ASU professor and former PADT employee Dhruv Bhate, whose research interests involve Bio-Inspired Design (the study of natural structures to help inform human design processes) and Additive Manufacturing. In this research, Dhruv investigates discrepancies between published (bulk) material properties for the Fused Deposition Modeling (FDM) of ABS honeycomb structures. The discrepancies arise as substantial differences between published material properties, such as Young’s Modulus and yield stress, and those determined experimentally from FDM dog-bone specimens of the same material (which he refers to as “member” properties).
PADT’s role in this research was crucial for demonstrating that the differences in base material characterization are greatly exacerbated in nonlinear compression simulations of the ABS honeycomb structures. PADT used both the manufacturer’s published properties, and the dog-bone data to show substantial differences in peak stress under the two assumptions.
I am so lucky in a zillion ways to be able to work from home while functioning in my position as a 3D Printing Application Engineer for PADT Inc., a Stratasys 3D printer reseller and engineering consulting/manufacturing company in Tempe Arizona.
Three things are making this possible:
1 – Awesome management and co-workers
2 – Great high-speed internet connection
3 – GrabCAD Print software, and more specifically, the GrabCAD Print phone app.
Of all the apps on my phone, next to my gmail account, this is the app I check most often, because it is so handy!
First off, I can instantly see the status of the nine PADT printers we have on our Tempe network; I can also check other networks and accounts in other locations for which I have permission. That means I know the status of printers I’m running or want to run, and can tell how long someone else’s job is going to take – a very useful bit of information when it comes to telling a customer or our sales group what printer is open for running a part.
– one print just finished on our Fused Deposition Modeling (FDM) Fortus400,
– my job is 43 percent complete on one of our FDM F370s, and
– another of my jobs has just begun on the second F370 system.
I can even see that a print got cancelled on our older F250; in this case, I was expecting that, but it’s good information in case I wasn’t. But there is so much more…
Say I want to confirm the file name of what’s running on that first F370, and get some data about its status. I click on that printer’s name and the app shows me this screen:
Now I see that the print has just gotten to layer 2 of 123 slices total, it started at 1:58pm and it will finish at 6:12pm this evening. It also displays the file name of the part and shows that I’m the owner.
If I slide the image of the printer to the left, I then get the camera view, since an F370 has a build-chamber camera that updates about every ten seconds. Because this print had just started, you can’t really see much beside the build plate (brightly lit at the top), but I can come back to that as often as I like to monitor a particularly challenging geometry – say, perhaps a tall thin part where I added some extra support structure.
At this point I can access several more windows. If I click Job Material Usage, I see
This information is useful if I need a reminder of how much model and support material this print will consume.
The next line offers the bigger picture: clicking through, I see how much material remains in each canister, for both the model and support; it also shows what, if any, material is loaded in the second set of bays. Stratasys printers with double bays will do an automatic hot-swap as needed – a nice feature over the weekend or in the middle of the night.
Here’s another possible status screen: a paused build, where I had planned ahead, inserting a Pause Build instruction in the GrabCAD job set-up. In this case, I wanted to stop the part and remove it, to create a sample piece that exposes the hexagram infill I chose for lightweighting. Another reason to pause and resume an FDM print is to add hardware such as a flat washer to reinforce a deep hole.
The GrabCAD Print App also sends me email alerts (with a chime on the phone) when the status of a print job changes, such as the message below telling me the job has indeed paused as planned:
(I don’t get notifications for other people’s jobs, so I don’t get inundated with messages.)
This real-time information lets me keep track of all my print jobs from my 3D Printing Command Center deep in the heart of suburban Phoenix. I can do 98% of what I need to remotely.
Of course, I depend on the engineers in PADT’s Manufacturing group – essential workers who’ve been in the office non-stop throughout this crazy 2020 work-year. They change filament, load clean trays, run calibrations, remove parts, and put finished prints in our Support Cleaning Apparatus tanks (a PADT-developed system spun off to Oryx and OEM’d to Stratasys since 2009.) That step dissolves the soluble support. (For several of the engineering filaments I run, the support is break-away, and my team takes care of that, too.)
The GrabCAD Print App is available as a free download from the Apple app store. And all of this is in addition to how you can view and interact with GrabCAD Print itself from any computer, setting up a part to print as you sit in one city then uploading the print-ready file to a system across the state or across the country.
Got any questions about the app? We’d love to answer them.
PADT Inc. is a globally recognized provider of Numerical Simulation, Product Development and 3D Printing products and services. For more information on Stratasys printers and materials, contact us at info@padtinc.com.
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