The Stratasys J750 Digital Anatomy printer truly brings the look and feel of medical models to life with unrivaled accuracy, realism and functionality. Whether used for surgeon training or to perform testing during device development, its models provide unmatched clinical versatility mimicking both the appearance and response of human tissue.
Bring medical models to life. The J750 Digital Anatomy Printer takes the J750 capabilities to the next level. Step up to the printer’s digital capabilities to create models with an incredible array of microstructures which not only look, but now feel and function like actual human tissue for true haptic feedback. All of this in a single print operation with minimal to no finishing steps like painting, sanding or assembly.
Join PADT’s 3D Printing & Support Application Engineer Pam Waterman for a discussion on the value of this innovative new technology, including:
– How it solves challenges facing medical device companies and hospitals
– More realistic, functional, and anatomically accurate modeling capabilities
– Quicker design and development, leading to reduced time-to-market
If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).
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The world of additive manufacturing, or 3D printing, is constantly evolving. The technology was invented less than 35 years ago yet has come a long way. What began as a unique, though limited, way to develop low-end prototypes, has exploded into a critical component of the product development and manufacturing process with the ability to produce end-use parts for critical applications in markets such as industrial and aerospace and defense.
To help our customers and the larger technology community stay abreast of the changing world of additive manufacturing, we launched a glossary of the most important terms in the industry that you can bookmark here for easy access. To make it easier to digest, we’re also starting a blog series outlining ten terms to know in different sub-categories.
For our first post in the series, here are the top ten terms
for Additive Manufacturing Processes that our experts think everyone
should know:
Any additive manufacturing process that uses a binder to
chemically bond powder where the binder is placed on the top layer of powder
through small jets, usually using inkjet technology. One of the seven standard
categories defined by ASTM International (www.ASTM.org) for additive
manufacturing processes.
A type of vat photopolymerization additive
manufacturing process where a projector under a transparent build
plate shines ultraviolet light onto the build layer, which
is against the transparent build plate. The part is then pulled
upward so that a new layer of liquid fills between the build
plate and the part, and the process is repeated. Digital light
synthesis is a continuous build process that does not create distinct layers.
A type of powder bed fusion additive manufacturing
process where a laser beam is used to melt powder material. The
beam is directed across the top layer of powder. The liquid material
solidifies to create the desired part. A new layer of powder is
placed on top, and the process is repeated. Also called laser powder bed
fusion, metal powder bed fusion, or direct metal laser sintering.
An additive manufacturing process where metal
powder is jetted, or wire is extruded from a CNC controlled three or
five-axis nozzle. The solid material is then melted by an energy source,
usually a laser or electron beam, such that the liquid metal
deposits onto the previous layers (or build plate) and then cools to a
solid. One of the ASTM defined standard categories for additive
manufacturing processes.
A type of material extrusion additive manufacturing process
where a continuous filament of thermoplastic material is fed into a heated
extruder and deposited on the current build layer. It is the trademarked name
used for systems manufactured by the process inventor, Stratasys. Fused
filament fabrication is the generic term.
A type of powder bed fusion additive
manufacturing process where a laser is used to melt material on
the top layer of a powder bed. Also called metal powder bed
fusion or direct laser melting. Most often used to melt metal powder
but is used with plastics as with selective laser sintering.
A type of direct energy deposition additive
manufacturing process where a powder is directed into a
high-energy laser beam and melted before it is deposited on
the build layer. Also called laser powder forming.
Any additive manufacturing process where build
or support material is jetted through multiple small nozzles whose
position is computer controlled to lay down material to create a layer.
One of the ASTM defined standard categories for additive
manufacturing processes.
A type of vat photopolymerization additive
manufacturing where a laser is used to draw a path on the
current layer, converting the liquid polymer into a solid. Stereolithography
was the first commercially available additive manufacturing process.
A class of additive manufacturing processes that utilizes
the hardening of a photopolymer with ultraviolet light. A vat of liquid is
filled with liquid photopolymer resin, and ultraviolet light is either traced
on the build surface or projected on it. Stereolithography is the most common
form of vat photopolymerization. The build layer can be on the top of the vat
of liquid or the bottom. One of the ASTM defined standard categories for
additive manufacturing processes.
We hope this new blog series will help to firm up your
knowledge of the ever-evolving world of additive manufacturing. For a list of
all of the key terms and definitions in the additive manufacturing world,
please visit our new glossary page at https://www.3dprinting-glossary.com/.
The glossary allows you to search by terms or download a PDF of the glossary in
its entirety to use as a reference guide.
Subscribe to the
PADT blog or check back soon for the next installment in our series of “Top Ten
Terms to Know in Additive Manufacturing.” We also welcome your feedback or
questions. Just drop us a line at here.
Advatech Pacific, a Phoenix-based aerospace and defense contractor founded in 1995, works to change the way engineering is conducted for the better by incorporating innovative technologies into its customer’s workflow. Based on the success of previous projects, Advatech is a strong proponent of using high-end simulation software such as Ansys to identify and evaluate the fine details of massive multi-body mechanical systems, whether through simple static analyses or tightly-coupled multiphysics computations.
Implementing additive manufacturing as an additional way to improve system design presented opportunities to cut back on tooling costs and reduce lead time for several candidate turbine-engine parts. Doing so would also alleviate the challenge of reproducing complex castings, a problem made increasingly difficult by the fact that many of the original casting providers are no longer in business.
Join PADT’s Lead Mechanical Engineer Doug Oatis, and Advatech Pacific’s Engineering Manager Matt Humrick for a discussion on Ansys tools with regards to additive manufacturing & topology optimization, and how Advatech Pacific was able to use them to drastically improve the efficiency of their design and manufacturing process.
If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).
You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!
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Click the link below to download the solution guide and discover five ways the Stratasys J55 can help you save time and money during the product development process.
From perfecting products to applying concepts learned in the classroom, Stratasys can help you realize any number of design ideas. The new J55 introduces a rotating print platform for outstanding surface finish and printing quality, and features multimaterial capabilities and material configurations for both industrial and mechanical design.
The Stratasys J55 3D Printer is a huge leap forward for accessible, full color 3D printing and allows designers to have multiple iterations of a prototype ready and at their fingertips throughout every phase of the design process.
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Click the link below to download the product brochure and learn how this innovative new machine is revolutionizing the world of additive manufacturing.
In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Pam Waterman and Robert McCathren for a discussion on how Ansys Granta can be used to help optimize hardware selection for additive manufacturing. The Senvol Database details 1,000 AM machines and more than 850 compatible materials. Using this tool within Granta Selector, you can search and compare materials based on properties, type, or compatible machines.
If you would like to learn more about the Ansys tool and it’s applications for additive, check out our webinar on the topic here: https://bit.ly/2SAZN8G
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!
Example of full color part with mapped image, created from a 3MF file-format brought into GrabCAD Print and set up to print on a Stratasys PolyJet 3D printer. (Image courtesy GrabCAD)
What is the 3MF format? How does it differ from the standard
STL format? And what can you do with it, especially if your 3D printers run
GrabCAD Print software from Stratasys?
For most designers, engineers and users involved in 3D printing, regardless of the 3D CAD software you use, you save (convert) your model to print as an STL format file. A lot has been written about it, including a PADT post from back in 2012 – and STL-wise, things really haven’t changed. This format approximates the native CAD solid model as a closed surface comprising small triangles of various shapes and sizes. STL has been the standard since the AM industry began, and although different CAD packages use different algorithms to create the mesh, for the most part, it’s worked pretty well.
A Sample STL File Segment
However, an STL file is simply a large text file listing the
Cartesian coordinates for each vertex of the thousands of triangles, along with
info on the normal direction:
A modest number of large triangles produces relatively small
files but doesn’t do a good job of reproducing curves (think highly faceted
surfaces); conversely, big files of many small triangles produce much smoother
transitions but can take a long time to process in slicing software.
And, perhaps the biggest negative is that an STL file cannot
include any other information: desired color, desired material, transparency,
internal density gradient, internal fine structure or more.
What is 3MF?
In early 2015, Microsoft and a number of other major
corporations including Autodesk, Dassault Systèmes, HP, Shapeways and SLM
Group created a consortium to address these issues. They decided to overhaul a
little-used file format called the 3D Modeling Format (3MF), to make it support
highly detailed 3D model information and be more useful for 3D printing and related
processes.
This ongoing consortium project defines 3MF as “a set of
conventions for using XML to describe the appearance and structure of 3D models
for the purpose of manufacturing (3D printing).”
In developer language, 3MF is a standard package or data that
follows a core specification and may
include some task-specific extensions.
In user terms, a 3MF file contains some or all of the
following information in ASCII format:
Metadata about part name, creator and date
Information on the mesh of triangles (yes, it still creates and uses these, but does it better for a number of reasons, one of which is that it cannot create non-manifold edges (i.e., triangles that share endpoints with more than one triangle, which confuses the printer))
Color information (throughout the complete part body or in sub-sections)
Ways to define multiple materials combined as a composite
Texture information – what it is and where to place it
Ways to assign different materials to different sections of a part
Ways to duplicate information from one section of a part to another section, to save memory
Slicing instructions
Without getting into the nitty gritty, here are just two
examples of XML code lines from 3MF metadata sections:
Meaning, information about the part number and the part
color rides along with the vertex coordinates! For a deep-dive into the coding
schema, including a helpful glossary, see the 3MF
github site; to learn how 3MF compares to STL, OBJ, AMF, STEP and other
formats, check out the consortium’s About Us
page.
Exporting 3MF Files
Now, how about using all of this? Where to start? Many 3D
CAD software packages now let you save solid models as 3MF files (check out
your “Save As” drop-down menu to verify), but again, they can vary as to what
information is being saved. For example, a SolidWorks 3MF file can generate
data on color and material but does not yet support transparency.
Here are all the options that you see in SolidWorks when you
click the arrow next to “Save As”:
“Save As” window in SolidWorks 2019, where step number one is to select “.3mf” format. (Image courtesy PADT)
You can select “.3mf” but don’t Save yet. First, click on the “Options” button that shows up below the Save as File Type line, opening this window:
Second step in SolidWorks for saving a file in 3MF format: check off “include materials” and “include appearance.” (Image courtesy PADT)
You need to check the boxes for “Include Materials” and
“Include Appearances” to ensure that all that great information you specified
in the solid model gets written to the converted file. A good, short tutorial
can be found here.
Another interesting aspect of 3MF files is that they are
zipped internally, and therefore smaller than STL files. Look at the difference
in file size between the two formats when this ASA Omega Clip part is saved
both ways:
The 3MF-saved file size is just 13% the size of the standard
STL file, which may be significant for file manipulation; for files with a lot
of detail such as texture information, the difference won’t be as great, but
you can still expect to save 30 to 50%.
Working with 3MF files in GrabCAD Print
Okay, so CAD programs export files in 3MF format. The other
half of the story addresses the question: how does a 3D printer import and use
a 3MF file? Developers of 3D printing systems follow these same consortium specifications
to define how their software will set up a 3MF file to print. Some slicers and
equipment already act upon some of the expanded build information, while others
may accept the file but still treat it the same as an STL (no additional
functions enabled so it ignores the extra data). What matters is whether the
system is itself capable of printing with multiple materials or depositing
material in a way that adds color, texture, transparency or a variation in
internal geometry.
GrabCAD Print (GCP),
the cloud-connected 3D Printer interface for today’s Stratasys printers – both FDM
and PolyJet – has always supported STL and native CAD file import. However, in
GCP v.1.40, released in March 2020, GrabCAD has added support for 3MF files. For
files created by SolidWorks software, this adds the ability to specify face
colors, body colors and textures and send all that data in one file to a
PolyJet multi-material, multi-color 3D printer. (Stratasys FDM printers accept
3MF geometry and assembly structure information.)
For a great tutorial about setting up SolidWorks models with
applied appearances and sending their 3MF files to GrabCAD Print, check out these
step-by-step
directions from Shuvom Ghose.
Example of setting up a textured part in SolidWorks, then saving the file in 3MF format and importing it into GrabCAD Print, for printing on a full-color Stratasys PolyJet printer. (Image courtesy GrabCAD)
At PADT, we’re starting to learn the nuances of working with 3MF files and will be sharing more examples soon. In the meantime, we suggest you download your own free copy of GrabCAD Print to check out the new capabilities, then email or call us to learn more.
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.
There are hundreds of industrial AM machines and materials. New products come to market weekly, and picking the best option for a manufacturing or research project is a tough call. A wrong direction can be costly. This is where Ansys Granta and the Senvol Database come in handy.
The Senvol Database details 1,000 AM machines and more than 850 compatible materials. Using this tool within Granta Selector, you can search and compare materials based on properties, type, or compatible machines. Identify and compare machines based on supported processes, manufacturer, required part size, cost, or compatible materials (and their properties). Quickly focus on the most likely routes to achieve project goals, save time and get new ideas as you research AM options.
JoinPADT’s Application Engineer Robert McCathren for an overview of Ganta Material Selector, along with its importance and applications for those working with or interested in additive manufacturing.
If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).
You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!
In this episode your host and Co-Founder of PADT, Eric Miller is joined by 3D Printing Applications Engineer Pamela Waterman and Advatech Pacific’s Engineering Manager Matt Humrick for a discussion on real world applications for topology optimization, and it’s value when it comes to creating parts though additive manufacturing.
If you would like to learn more about this topic and what Advatech Pacific is doing, you can download our case study covering these topics here: https://bit.ly/38Bqu2b
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!
(Edited 3 August 2020 to reflect GrabCAD Print V1.44)
You haven’t really lived in the world of 3D printing until
you’ve had a part fail spectacularly due to open faces, self-intersecting faces
or inverted normals. Your part ends up looking more like modern art than
technical part. Or perhaps the design you have in mind has great geometry but
you wish that some parts could have regions that are dense and strong while
other regions would work with minimal infill.
In Part
One of this blog post about GrabCAD
Print software, we covered the basics of setting up and printing a part;
now we’ll look at several of the advanced features that save you set-up time
and result in better parts.
Behind the Scenes Repairs
Stratasys GrabCAD Print software, available as a free download, is crafted for users setting up solid models for 3D printing on Stratasys FDM and PolyJet printers. Once you’ve started using it, you’ll find one of its many useful advanced features is the automated STL file-repair option.
Imported STL file, with GrabCAD Print ready to automatically repair errors. PADT image.
Most people still create solid models in CAD software then convert
the file to the industry-standard STL format before opening it in a given 3D
printer’s own set-up software. Every CAD package works a little differently to
generate an STL file, and once in a while the geometry just doesn’t get
perfectly meshed. Triangles may overlap, triangles may end up very long and
very skinny, or the vector that signals “point in” or “point out” can get
reversed.
Traditionally, the 3D printer set-up program reacts to these
situations by doing one of two things: it prints exactly what you tell it to
print (producing weird holes and shifted layers) or it simply refuses to print
at all. Both situations are due to tiny errors in the conversion of a solid CAD
model to a tessellated surface.
GrabCAD Print, however, gives your file a once-over and
immediately flags sections of the model in need of repair. You can see a
color-coded representation of all the problem areas, choose to view just some
or all, and then click on Automatic Repair. No hand-editing, no counting layers
and identifying sections where the problems reside – just a click of the
virtual button and all the problem regions are identified, repaired and ready
for the next processing steps.
CAD vs. STL: Do So Much More with CAD
GrabCAD Print also uniquely allows users to bring in their models in the original CAD file-format (from SolidWorks, Autodesk, PTC, Siemens, etc.) or neutral formats, with no need to first convert it to STL. For FDM users, this means GrabCAD recognizes actual CAD bodies, faces, and features, letting you make build-modifications directly in the print set-up stage that previously would have required layer-by-layer slice editing, or couldn’t have been done at all.
For example, with a little planning ahead, you can bring in a multi-body CAD model (i.e., an assembly), assemble and group the parts, then direct GrabCAD to apply different parameters to each body. This way you can reinforce some areas at full density then change the infill pattern, layout, and density in other regions where full strength is unnecessary.
Here’s an example of a SolidWorks model intended for
printing with a solid lower base but lighter weight (saving material) in the
upper sections. It’s a holder for Post-It® notes, comprising three individual
parts – lower base, upper base and upper slot – combined and saved as an
assembly.
Sample multi-body part ready to bring into GrabCAD Advanced FDM. Image PADT.
Here was my workflow:
1 – I brought the SolidWorks assembly into GrabCAD, assembled and grouped all the bodies, selected an F370 Stratasys FDM printer, chose Print Settings of acrylonitrile butadiene styrene (ABS) and 0.010 inches layer height, and oriented the part.
2 -To ensure strength in the lower base, I selected just that section (you can do this either in the model tree or on the part itself) and opened the Model Settings menu at the right. Under Body, I chose Solid Infill.
3 – Next I selected the upper base, chose Hexagram, and changed the Infill Density to 60%.
4 – Lastly, I selected the upper slot section, chose Sparse, and changed the Infill Density to 35%.
5 – With all three sections defined, I clicked on Slice
Preview, sliced the model and used the slider bar on the left to step through
each section’s toolpath. For the screenshots, I turned off showing Support
Material; the yellow bits indicate where seams start (another parameter that
can be edited).
Here is each section highlighted, with screenshots of the
parameter choices and how the part infill looks when sliced:
Upper base set up in GrabCAD to print as Hexagram pattern, 60% infill; sliced toolpath shown at right. Image PADT.
Upper slot section set up in GrabCAD to print as Sparse pattern, 35% infill; sliced toolpath shown at right. Image PADT.
So that you can really see the differences, I printed the part four times, stopping as the infill got partway through each section, then letting the final part print to completion. Here are the three partial sections, plus my final part:
Lower base (solid), upper base (hexagram) and first part of upper slot (sparse), done as partial prints. Image PADT.
Completed note-holder set up in GrabCAD Print using advanced infill features, weighted toward the bottom but light-weighted internally. Image PADT.
Automated Hole Sizing Simplifies Adding Inserts
But like the old advertisements say, “But wait – there’s
more!” Do you use heat-set inserts a lot to create secure connections between
3D printed parts and metal hardware? Planning ahead for the right hole size,
especially if you have different design groups involved and fasteners may not
yet be decided, this is the feature for you.
Sample part set up for easy insert additions, using advanced, automated hole-resizing features in GrabCAD Print. Image PADT.
In your CAD part model, draw a hole that is centered where you know the insert will go, give it a nominal diameter and use Cut/Extrude so that the hole is at least the depth of your longest candidate insert. Save the file in regular CAD format, not STL. Next bring your part into GrabCAD Print and go to Model Settings in the right-hand menu.
This time, click on Face (not Body) and Select the inner cylindrical wall of your hole. Several options will become active, including Apply Insert. When you check that box, a new drop-down will appear, giving you the choice of adding a heat-set insert, a helicoil insert or creating a custom size. Below that you select either Inch or Metric, and for either, the appropriate list of standard insert sizes appears.
Automatic hole-resizing in GrabCAD Print, for a specific, standard heat-set insert. Image PADT.
Choose the insert you want, click Update in the upper middle of the GrabCAD screen, and you’ll see the hole-size immediately changed (larger or smaller as needed). The new diameter will match the required oversized dimensions for the correct (melted into place) part-fit. You can even do this in a sidewall! (For tips on putting inserts into FDM parts, particularly with a soldering iron, see Adding Inserts to 3D Printed Parts: Hardware Tips.)
Note that this way, you can print the overall part with a sparse infill, yet reinforce the area around the insert to create just the right mass to make a solid connection. The Sliced view will show the extra contours added around each hole.
Sliced view showing insert holes with reinforced walls, done in GrabCAD Print. Image PADT.
Manufacturing notes automatically created in GrabCAD Print when insert holes are resized. Image PADT.
To document the selected choices for whoever will be doing
the insert assembly, GrabCAD also generates a numbered, manufacturing-footnote that
lists each insert’s size; this information can be exported as a PDF file that
includes a separate close-up image of each insert’s location.
GrabCAD Print keeps adding very useful functions. Download it for free and try
it out with template versions of the various Stratasys 3D printers, then email
or call us to learn more.
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.
3DPrinting-Glossary.com Covers Everything from Machines and Materials to Pre- and Post-Processing Terms
After searching the internet for a resource you can’t find, have you ever sat at your desk and said to yourself “I wish someone would take the time to create this. I could really use it.” Here at PADT, we have been saying that for many years about the need for a comprehensive reference on the terms used in Additive Manufacturing. Then we realized that the only way to get it done was to roll up our sleeves and do it ourselves. And so we did.
This free online resource contains over 250 terms with definitions for each one. We write each definition and reviewed it amongst our team of long term users of Additive Manufacturing. After over 25 years in the business, we should know the difference between direct laser melting and selective laser sintering. And even if we are off a little, it is a start and we encourage the community to send us corrections, recommendations, and especially new terms to add to this compendium.
Check it out and let us know what you think. More details are below in the official Press Release, which you can also find in PDF and HTML.
And do not hesitate to contact PADT for any of your Additive Manufacturing, Product Development, or Simulation needs. The same expertise that went into creating this resource is applied to every project we work on and every product we sell.
3D
Printing Glossary Now Available from PADT Provides Most Comprehensive Online
Resource for Additive Manufacturing Terminology
3DPrinting-Glossary.com Covers Everything from
Machines and Materials to Pre- and Post-Processing Terms
TEMPE, Ariz., March 3, 2020 ─ PADT, a globally recognized provider of numerical
simulation, product development, and 3D printing products and services, today announced
the launch of the most comprehensive online Glossary of industry terms relevant
to additive manufacturing. The new site, www.3dprinting-glossary.com, includes more than 250 definitions in nine
different categories.
“In addition to being an outstanding partner to our customers, PADT strives to be a trusted advisor on all things additive manufacturing,” said Eric Miller, co-founder and principal, PADT. “Our goal for the glossary is to help educate the community on the evolving terminology in our industry and serve as a critical resource for students and professionals seeking 3D printing knowledge and clarification.”
The company
has been a provider of additive manufacturing services since 1994. They are
also a Stratasys Platinum Partner that has sold and supported Stratasys
equipment in the Southwest for over fifteen years. Many of their employees are
recognized and award-winning experts in the AM community.
The creation
of PADT’s 3D Printing Glossary was the result of a companywide effort to gather
and define the terms used in the industry daily. The user-friendly website
allows visitors to search for terms directly or by category. PADT will continue
to support and update the glossary as the industry grows and innovates.
The nine glossary
categories include:
Additive Manufacturing Processes
Build Characteristics
General
Manufacturing Term
Material
Post-Processing
Pre-Processing
Product Definition
System Characteristic
Since founding
PADT in 1994, the company’s leadership has made a great effort to become more
than just a reseller or service provider.
They want to be a resource to the community. In addition to investing in
entrepreneurs, serving on technology boards and committees, and speaking at
industry events, PADT donates a great deal of money, time and resources to
STEM-focused educational initiatives. The 3D Printing Glossary is another
resource that PADT has created for the benefit of students as well as up and coming
professionals in the engineering and manufacturing industry.
PADT is also
asking the community to contribute to this effort If users notice a term is
missing, disagree with the definition, or have more to add to the definition,
they ask that readers email additions or changes to info@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.
In this episode your host and Co-Founder of PADT, Eric Miller is joined by Lead Mechanical Engineer Doug Oatis for a discussion on the latest advancements in simulation for additive manufacturing and topology optimization in ANSYS 2020 R1.
If you would like to learn more about what this release is capable of, check out our webinar on the topic here:
https://www.brighttalk.com/webcast/15747/384528
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!
ANSYS offers a complete simulation workflow for additive manufacturing (AM) that allows you to transition your R&D efforts for metal additive manufacturing into a successful manufacturing operation. This best-in-class solution for additive manufacturing enables simulation at every step in your AM process. It will help you optimize material configurations and machine and parts setup before you begin to print. As a result, you’ll greatly reduce — and potentially eliminate — the physical process of trial-and- error testing.
ANSYS additive solutions continue to evolve at a rapid pace. A variety of new enhancements and features come as part of ANSYS 2020 R1, including the ability to work with EOS printers, using the inherent strain approach in ANSYS Workbench Additive, and new materials in ANSYS Additive Print and Science.
Join PADT’s Lead Mechanical Engineer Doug Oatis for an exploration of the ANSYS tools that help to optimize additive manufacturing, and what new capabilities are available for them when upgrading to ANSYS 2020 R1. This presentation includes updates regarding:
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Where are you on your New Year’s resolutions? They often
include words such as “simplify,” “organize” and “streamline.” They can be timely
reminders to rethink how you do things in both your personal and professional
lives, so why not rethink the software you use in 3D Printing?
Preparing a CAD solid model or an STL file to print on a 3D
printer requires using set-up software that is typically unique to each
printer’s manufacturer. For Flashforge equipment, you use FlashPrint, for
Makerbot systems you use MakerBot Print, for Formlabs printers you use PreForm,
and so on.
GrabCAD Print software for setting up STL or CAD files to print on Stratasys 3D printers (main screen). Image courtesy PADT.
For printers from industrial 3D printing company Stratasys, the go-to software is GrabCAD Print (along with GrabCAD Print
Mobile), developed for setting up both fused deposition modeling (FDM) and PolyJet technologies in
new and efficient ways. Often just called GrabCAD, this versatile software
package lets you organize and control prints assigned to one of more than 30
printer models, so the steps you learn for one printer transfer directly over
to working with other models.
If you’ve previously used Stratasys Catalyst (on Dimension
and uPrint printers), you’ll find similarities with GrabCAD, as well as some enhanced
functionality. If you’re accustomed to the fine details of Stratasys Insight,
you’ll see that GrabCAD provides similar capabilities in a streamlined
interface, plus powerful new features made possible only by the direct import
of native CAD files. Additionally, you
can access Insight within GrabCAD, combining the best of both traditional and
next-generation possibilities.
Simple by Default, Powerful by Choice
GrabCAD lets users select simplified default settings throughout,
with more sophisticated options available at every turn. Here are the general
steps for print-file preparation, done on your desktop, laptop or mobile device:
1 – Add Models: Click-and-drag files or open them from
File Explorer. All standard CAD formats are supported, including SolidWorks, Autodesk,
Siemens and PTC, as well as STL. You can also bring in assemblies of parts and multi-body
models, choosing whether to print them assembled or not. (Later we’ll also talk
about what you can do with a CAD file that you can’t do with an STL.)
2 – Select Printer: Choose from a drop-down menu to
find whatever printer(s) is networked to your computer. You can also experiment
using templates for printers you don’t yet own, in order to compare build
volumes and print times.
3 – Orient/Rotate/Scale Model: Icons along the right
panel guide you through placing your model or models on the build platform,
letting you rotate them around each axis, choose a face to orient as desired,
and scale the part up or down. You can also right-click to copy and paste
multiple models, then edit each one separately, move them around, and delete
them as desired.
4 – Tray Settings: This icon leads to the menu with
choices such as available materials, slice height options, build style (normal
or draft), and more; always targeted to the selected printer. These choices
apply to all the parts on the tray or build sheet.
5 – Model Settings: Here’s where you choose infill
style, infill density (via slider bar), infill angle, and body thickness (also
known as shell thickness) per part. Each part can have different choices.
6 – Support Settings: These all have defaults, so you
don’t even have to consider them if you don’t have special needs (but it’s
where, for example, you would change the self-supporting angle).
7 – Show Slice Preview: Clicking this icon slices the
model and gives you the choice to view layers/tool paths individually, watch a
video animation, or even set a Z-height pause if you plan on changing filament
color or adding embedded hardware.
8 – Print: You’re ready to hit the Print button,
sending the prepared file to the printer’s queue.
Scheduling Your Print, and Tracking Print Progress
A clock-like icon on the left-side GrabCAD panel (the second
one down, or third if you’ve activated Advanced FDM features) switches the view
to the Scheduler. In this mode, you can see a day/time tracking bar for every
printer on the network. All prints are queued in the order sent, and the
visuals make it easy to see when one will finish and another start (assuming
human intervention for machine set-up and part removal, of course).
Scheduling panel in GrabCAD Print, showing status of files printing on multiple 3D printers. Image courtesy PADT.
If you click on the bar representing a part being built, a
new panel slides in from the right with detailed information about material
type, support type, start time, expected finish time and total material used
(cubic inches or grams). For printers with an on-board camera, you can even get
an updated snapshot of the part as it’s building in the chamber.
Below the Scheduler icon is the History button. This is a
great tool for creating weekly, monthly or yearly reports of printer run-time
and material consumption, again for each printer on the network. Within a given
build, you’ll even see the files names of the individual parts within that job.
Separately, if you’re not operating the software offline (an
option that some companies require), you can enable GrabCAD Print Reports. This
function generates detailed graphs and summaries covering printer utilization
and overall material use across multiple printers and time periods – very
powerful information for groups that need to track efficiencies and
expenditures.
And That’s Just the Beginning
Once you decide to experiment with these settings, you begin to see the power of GrabCAD Print for FDM systems. We haven’t even touched on the automated repairs for STL files, PolyJet’s possibilities for colors, transparency and blended materials, or the options for setting up a CAD model so that sub-sections print with different properties.
For example, you’ll see how planning ahead allows you to bring in a multi-body CAD model and have GrabCAD identify and reinforce some areas at full density, while changing the infill pattern, layout, and density in other regions. GrabCAD recognizes actual CAD bodies and faces, letting you make build-modifications that previously would have required layer-by-layer slice editing, or couldn’t have been done at all.
Stay tuned for our next blog post, GrabCAD Print Software, Part Two: Simplify Set-ups, Save Time, and Do
Cool Stuff You Hadn’t Even Considered, and reach out to us to learn more
about downloading and using GrabCAD Print.
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.
Taking risks attempting to capture design intent at the end of the process requires a lot of post-processing (coloring, assemblies, a mix of technologies, etc.) – when its too time consuming, expensive and late to make changes or correct errors. Stratasys PolyJet 3D printing technology is developed to elevate designs by realizing ideas more quickly and more accurately and taking color copies to the next level.
By putting realistic models in a designer’s hands earlier in the process, companies can promote better decisions and a superior final product. Now, with the Stratasys J8 Series, the same is true for prototypes. This tried and tested technology simplifies the entire design process, streamlining workflows so you can spend more time on what matters –creating, refining, and designing the best product possible.
PADT is excited to introduce the new StratasysJ826 3D printer
Based on J850 technology, the J826 supplies the same end-to-end solution for the design process and ultra-realistic simulation at a lower price point. Better communicate design intent and drive more confident results with prototypes that realistically portray an array of design alternatives.
The Stratasys J826 3D Printer is able to deliver realism, shorter time to market, and streamlined application thanks to a variety of unique attributes that set it apart from most other Polyjet printers:
High Quality – The J826 can accurately print smaller features at a layer thickness of 14µm to 27µm. As part of the J8 series of printers it is also capable of printing in ultra-realistic Pantone validated colors.
Speed & Productivity – Three printing speed modes (high speed, high quality & high mix) allows the J826 to always operate at the most efficient speed for each print. It can also avoid unnecessary down-time associate with material changeovers thanks to it’s built-in material cabinet and workstation.
Easy to Use – A smooth workflow with the J826 comes from simple integration with the CAD format of your choice, as well as a removable tray for easy clean up, and automated support creation and removal.
Are you ready to learn how the new Stratasys J826 provides the same quality and accuracy as other J8 series printers at a lower cost?
Provide the requested information via the form linked below and one of PADT’s additive experts will reach out to share more on what makes this new offering so exciting for the enterprise design world.
