How to Simplify Aircraft Certification – Stratasys Webinar

The aerospace industry’s adoption of additive manufacturing is growing and predicted to revolutionize the manufacturing process. However, to meet stringent FAA and EASA requirements, AM-developed aerospace products must be certified that they can achieve the robust performance levels provided by traditional manufacturing methods. Current certification processes are complex and variable, and thus obstruct AM adoption in aerospace.

Thanks to a newly released aerospace package released by Stratasys for their Fortus 900mc printer and ULTEM 9085 resin, Aerospace Organizations are now able to simplify the aviation certification process for their manufactured parts.

Join PADT’s 3D Printing General Manager, Norman Stucker for a live webinar that will introduce you to the new Stratasys aerospace package that removes the complexity from FAA and EASA certification.

By attending this webinar, you will learn:

  • How Stratasys can help get more parts certified for flight quicker and easier.
  • The benefits of Aerospace Organizations using the Fortus 900mc and ULTEM 9085 resin
  • And much more!

Don’t miss your chance to attend this upcoming event,
click below to secure your spot today!

 

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Quick Tips for Stratasys’ new Nylon 12CF Material

One of the newest materials available for the Stratasys Fortus 450 users (other machines could have this capability at a later date) is the Nylon 12CF. Nylon 12CF is a Carbon Fiber filled Nylon 12 filament thermoplastic. The carbon fiber is chopped fibers that are 150 microns long. This is Stratasys’ highest strength and stiffness to weight ratio for any of their materials to date as shown below. 
Often times, when Stratasys is getting close to releasing a new material, they will allow certain users to be a beta test site. One beta user was Ashley Guy who is the owner of Utah Trikes, which is located in Payson, Utah. He is having so much success with this material that he is making production parts with it. Watch this video to hear more from Ashley and to see some of his 3D printed parts.

Talking with Ashley, he has helped us with understanding some of the tips and tricks to get better results from printing with this material. One change that he highly recommends is to adjust the air gap between raster’s to -.004”. This will force more material between the raster’s so there won’t be as many noticeable air gaps. Here is a visual representation of the air gap difference using Stratasys software Insight:

The end goal at Utah Trikes is to produce production parts with this material, so by adjusting the air gap, the appearance of the parts look close to injection mold quality after the parts have been run through a tumbler. Some key things that I really like about this material is that the support material is soluble and easily removed using PADT’s own support cleaning apparatus (SCA Tank) that aid with the support removal. After the support has been removed, they are placed in a tumbling machine to smooth the surfaces of the part with different media within the tumbling machine. Any post process drilling or installing of helicoil inserts or adding bushings to the part is done manually.

Jerry Feldmiller of Orbital ATK, who also did a beta test of this material at his site in Chandler, Arizona, mentions these 3 tips:

  1. Nylon12 CF defaults to “Use model material for Support”. 90% of the time I uncheck this option.
  2. I use stabilizing walls and large thin parts to anchor the part to the build sheet and prevent peal up.
  3. Use seam control set to Align to Nearest.

Jerry also supplied his Nylon 12CF Tensile Test that he performed for this new material as shown below. He mentions that the Tensile Strength is 8-15 ksi depending on X-Y orientation.
~5 ksi in Z-axis, slightly lower than expected.

This part is used to clamp a rubber tube which replace the old ball valve design at ATK. Ball valves are easily contaminated and have to be replaced. After two design iterations, the tool is functioning.

Jerry also follows a guide that Stratasys offers for running this material. If you would like a copy of this guide, please email me your info and I will send it to you. My email is James.barker@padtinc.com

Now onto Stratasys and the pointers that they have for this material. First, make sure the orientation of the part is built in its strongest orientation. Nylon materials have the best layer-to-layer bond when comparing them against the other thermoplastics that Stratasys offers.

Whenever you print with the Nylon materials (Nylon 6, 12, and 12CF), it is advised to print the sacrificial tower so that any loose strands of material are collected in the sacrificial tower instead of being seen on the 3D printed part. You also want to make sure that these materials are all stored in a cool and dry area. Moisture is the filaments worst enemy, so by storing the material properly, this will help tremendously with quality builds.

It is also recommended for parts larger than 3 inches in height to swap the support material for model material when possible. Since the support material has a different shrink factor than the model material, it is advised to print with model material where permitted. This will also speed your build time up as the machine will not have to switch back and forth between model and support material. We have seen some customers shave 5+ hours off 20 hour builds by doing this.

This best practice paper is the quick tips and tricks for this Nylon 12CF material from our users of this material. The Stratasys guide goes into a little more detail on other recommendations when printing with this material that I would like to email to you. Please email me with your info.

Let us know if this material is of interest to you and if you would like us to print a sample part for testing purposes.

Silicon Desert Insider: How close are we to 3-D Printing human organs?

Being able to grow your own replacement organ is one of those things, like flying cars, that we have been waiting a long time for.  The combination of stem cells and 3D Printing may be what we need to get that new liver on order.  In “How close are we to 3-D Printing human organs?” I go over where we are with this technology and what is needed to take those final steps.

Press Release: PADT and Stratasys Announce Lockheed Martin Additive Manufacturing Laboratory at Metropolitan State University in Denver

PADT-Press-Release-IconPADT and Stratasys have worked with Lockheed Martin to establish a new Additive Manufacturing Laboratory at Metropolitan State University in downtown Denver.  The Lockheed Martin Additive Manufacturing Laboratory is the first-of-its-kind facility in Colorado. It is focused on giving students and industry access to the equipment and faculty needed to develop the next generation of manufacturing tooling, based on the use of 3D printing to make the tooling.

This is PADT’s third successful contribution to the creation of Academia + Industry + Equipment Manufacturer lab, the others being at ASU Polytechnic focused on characterization of 3D Printed parts and at Mesa Community College, focused on training the needed technicians and engineers for running and maintaining additive manufacturing systems. These types of efforts show the commitment from Stratasys, industrial partners, and PADT to making sure that the academic side of new manufacturing technology is being addressed and is working with industry.

We reported on the grand opening of the facility here,and are very pleased to be able to announce the official partnership for the Laboratory.  Great partners make all the difference.

Official copies of the press release can be found in HTML and PDF.

Press Release:

PADT and Stratasys Announce First-of-its-Kind Additive Manufacturing Lab in Colorado, Located at Metropolitan State University of Denver

Lockheed Martin Additive Manufacturing Laboratory helps students and engineers spur design and creation of composite tooling applications to reduce manufacturing lead times and streamline costs

TEMPE, Ariz. and Minneapolis, MN – August 28, 2017 ─ Phoenix Analysis and Design Technologies (PADT) today announced the company is teaming with Stratasys Ltd. (Nasdaq: SSYS), a global leader in applied additive technology solutions, to unveil a first-of-its-kind additive manufacturing lab in Colorado – located at the Metropolitan State University of Denver. Expected to open later this fall, the Lockheed Martin Additive Manufacturing Laboratory is unique to the state, dedicated to advance use of 3D printing for creation of composite tooling applications addressing complex design and manufacturing requirements. Empowering next-generation manufacturing, 3D printing allows designers and engineers to improve efficiency and lead times while minimizing costs.

At the centerpiece of this lab are additive technology solutions from Stratasys, enabling students and engineers to speed production and streamline efficiencies with 3D printed, custom tooling solutions addressing even the most complex designs and shapes.  Backed by the Stratasys Fortus 900mc Production 3D Printer, the environment is funded through a grant from Lockheed Martin Space Systems – and now becomes one of the few located in Colorado and the only one at a higher-education institution in the Rocky Mountain region.

Building the Lockheed Martin Additive Manufacturing Laboratory at MSU Denver is a major development in the progression of additive manufacturing tooling applications,” said Rey Chu, Principal and Co-Founder, Manufacturing Technologies at PADT, Inc.The expertise and dedication of Stratasys and PADT – combined with the generosity of Lockheed Martin and vision for advanced workforce development from MSU Denver – will help propel our industry far beyond where it is today.

“We’re excited to work with Lockheed Martin to propel creation of highly innovative, additive manufacturing curriculum at MSU Denver. Both students and local businesses now have access to leading 3D printing solutions for development of composite structures – enabling manufacturers to save time, money, and solve even their most unique design challenges,” said Tim Schniepp, Director of Composite Solutions at Stratasys. “We have no doubt the lab will quickly become a cornerstone of additive manufacturing innovation across the State of Colorado.”

 Initially deployed at MSU Denver, the additive manufacturing curriculum will later become available for use by other academic institutions across the country. Additionally, PADT will work with MSU Denver, Lockheed Martin and other users to build a Fortus 900mc Users Group within the Rocky Mountain region.

Supporting Quotes

Brian Kaplun, Manager, Additive Manufacturing at Lockheed Martin Space Systems: “Lockheed Martin believes this first-of-its-kind laboratory at MSU Denver can shape the future of space. We’ve built 3D-printed parts that traveled 1.7 billion miles to Jupiter, and we look forward to developing a workforce that understands how to use this technology for future flight hardware, tooling and other advanced manufacturing applications.”

Robert Park, Director, Advanced Manufacturing Sciences Institute at Metro State University of Denver: “MSU Denver is fortunate to have such great partners who support our passion for nurturing young minds to shape the future of the additive manufacturing industry. We’re also excited to work with Stratasys and PADT on progressing the industry beyond its current scope.”

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, 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 Lockheed Martin Space Systems

Headquartered in Bethesda, Maryland, Lockheed Martin is a global security and aerospace company that employs approximately 97,000 people worldwide and is principally engaged in the research, design, development, manufacture, integration and sustainment of advanced technology systems, products and services.

About Metropolitan State University of Denver
MSU Denver is a leader in educating Coloradans through university programs particularly relevant to the state’s economy and the demands of today’s employers. With the highest number of ethnically diverse students among the state’s four-year colleges, MSU Denver offers 67 bachelor and five master degrees in accounting, business, health administration, teaching and social work. Nearly 20,000 students are currently enrolled at MSU Denver, and 75 percent of the University’s 88,000 graduates have remained in Colorado as valuable members of the state’s workforce. More information can be found at www.msudenver.edu.

About Stratasys

Stratasys (NASDAQ: SSYS) is a global leader in applied additive technology solutions for industries including Aerospace, Automotive, Healthcare, Consumer Products and Education. For nearly 30 years, a deep and ongoing focus on customers’ business requirements has fueled purposeful innovations—1,200 granted and pending additive technology patents to date—that create new value across product lifecycle processes, from design prototypes to manufacturing tools and final production parts. The Stratasys 3D printing ecosystem of solutions and expertise—advanced materials; software with voxel level control; precise, repeatable and reliable FDM and PolyJet 3D printers; application-based expert services; on-demand parts and industry-defining partnerships—works to ensure seamless integration into each customer’s evolving workflow. Fulfilling the real-world potential of additive, Stratasys delivers breakthrough industry-specific applications that accelerate business processes, optimize value chains and drive business performance improvements for thousands of future-ready leaders around the world.

Corporate Headquarters: Minneapolis, Minnesota and Rehovot, Israel.

Online at: www.stratasys.com  http://blog.stratasys.com and LinkedIn.

Stratasys, Fortus, and FDM are registered trademarks, and the Stratasys signet is a trademark of Stratasys Ltd. and or its subsidiaries or affiliates. All other trademarks belong to their respective owners.

# # #

PADT Media Contact
Alec RobertsonTechTHiNQ on behalf of PADT
585.281.6399
alec.robertson@techthinq.com
PADT Contact
Eric Miller
PADT, Inc.
Principal & Co-Owner
480.813.4884
eric.miller@padtinc.com
Stratasys Media Contact
Craig Librett
Stratasys
Principal & Co-Owner
518.424.2497
craig.librett@stratasys.com

 

Silicon Desert Insider: What’s so exciting about metal 3-D printing anyway?

The ability to take a model of some object on a computer and make a physical copy with one machine, 3-D Printing or Additive Manufacturing, has been around for more than twenty-five years.  Recently, the bug noise in 3D Printing has been around metal 3D Printing.  It is a big deal, and in “What’s so exciting about metal 3-D printing anyway?” I explain why engineers are so head-over-heals for this new capability.

Introducing the Stratasys J750 – Webinar

Introducing the Stratasys J750 – Webinar

August 30th, 2017 – 11:00 AM – 12:00 PM MST

The Stratasys J750 3D printer delivers unavailed aesthetic performance including true, full-color capability with the texture mapping and color gradients. Create prototypes that look, feel and operate like finished products, without the need for painting or assembly, thanks to the Stratasys J750’s wide range of material properties.

With this, students can easily experience both the prototyping and testing stages of the manufacturing process, helping to prepare them for what they will experience once they enter the workforce. The high quality materials available with the J750 also allow for the creation of highly intricate and realistic models, perfect for helping medical students with research.

The wide color spectrum, combined with the fine-finish, multi-material capability, let’s the Stratasys J750 produce parts with an incredible array of characteristics. Prototypes that need to look, feel and function like future products are possible in a single print operation, with minimal to no finishing steps, like painting, sanding or assembly.

With such an innovative machine comes a variety of user applications, such as:

  • Image Rapid Prototyping
  • Concept Models
  • Medical Models
  • Jigs & Fixtures
  • Colored Textures

Join PADT’s Sales executive Jeff Nichols and 3D Printing Application Engineer James Barker from 11:00 AM – 12:00 PM MST AZ for an in depth look at how the Stratasys J750 stacks up against it’s competition, and how it’s various attributes help to make it the perfect fit for institutions such as yours!

 

Don’t miss this unique opportunity to bring the future of manufacturing into your classroom or workplace, secure your spot today!

  

DustRam: A Great Example of Using 3D Printing for Durable Production Parts

Nothing makes us happier here at PADT than seeing a customer be successful with technology we worked with them on. When Jack King of DustRam came to us for a prototype for a part on his dust free tile removal product it was just the start of a fantastic journey that showed off the power of 3D Printing.  After a few iterations Jack was able to replace his expensive and long lead metal mouthpiece with a plastic one that he could manufacture on demand in his own shop using his Stratasys 3D Printer.

It was such a great story that two publications were interested and wrote far better writeups than I could.

The first is interesting because it is an industry trade magazine for people in the floor installation business. Their perspective is refreshing for those of us who live in the engineering world, getting more into the practical application of the product:

http://digital.bnpmedia.com/publication/?i=422744#{“issue_id”:422744,”page”:52}

This was preceded by a fantastic article in Additive Manufacturing magazine that gets more into the technical side:

http://www.additivemanufacturing.media/articles/3d-printed-device-proves-rugged-enough-for-dust-free-tile-removal-

If you want to learn more about how you can use additive manufacturing to produce yout production hardware, contact us today.

 

Webinar: Additive Manufacturing & Simulation Driven Design, A Competitive Edge in Aerospace

PADT recently hosted the Aerospace & Defence Form, Arizona Chapter for a talk and a tour. The talk was on “Additive Manufacturing & Simulation Driven Design, A Competitive Edge in Aerospace” and it was very well received.  So well in fact, that we decided it would be good to go ahead and record it and share it. So here it is:

Aerospace engineering has changed in the past decades and the tools and process that are used need to change as well. In this presentation we talk about how Simulation and 3D Printing can be used across the product development process to gain a competitive advantage.  In this webinar PADT shares our experience in apply both critical technologies to aerospace. We talk about what has changed in the industry and why Simulation and Additive Manufacturing are so important to meeting the new challenges. We then go through five trends in each industry and keys to being successful with each trend.

If you are looking to implement 3D Printing (Additive Manufacturing) or any type of simulation for Aerospace, please contact us (info@padtinc.com) so we can work to understand your needs and help you find the right solutions.

 

Announcement: Affordable Metal 3D Printing from Desktop Metal Added to PADT Portfolio

PADT is pleased to announce that it has partnered with Desktop Metal to resell its office-friendly and affordable metal 3D Printing solution. The partnership will also allow PADT to integrate this exciting new technology into its 3D Printer maintenance and part printing services. Desktop Metal’s new system is unique to the industry because it is a complete solution with a patented anti-sintering material that enables easily removed supports and the creation of complete assemblies. With the proprietary sintering furnace the DM Studio System delivers accurate parts quickly.  PADT will be representing this new solution in Arizona, Colorado, New Mexico, and Utah.

“We are very excited to fill this gap in our product offering,” said Rey Chu, co-owner and director of manufacturing technology at PADT. “It enables us to serve customers who need stronger properties than plastic additive manufacturing systems can offer, but who don’t need a direct laser melting solution. We researched our options and watched the development of many different products. We knew Desktop Metal had the right solution when we learned that it had developed a complete package that is easy to use.”

The DM Studio System™ is based on the Metal Injection Molding (MIM) process and will start shipping this September. It is the first office-friendly platform for metal 3D printing and is considerably less expensive than existing technology. The Studio System will be sold as a package for $120,000. This includes the metal 3D printer, debinder, and microwave-enhanced sintering furnace.

As a leader in additive manufacturing for more than 20 years, PADT is a resource for customers who need 3D Printing as a service, or who need their own systems in-house. The DM Studio System™ will compliment the complete line of Stratasys FDM and Polyjet systems that the PADT resells as well as direct laser melting systems from our partner Concept Laser. Our company’s expertise with fused deposition modeling, sintering, and MIM also make us uniquely qualified to represent this solution.

“Our team is looking forward to getting this technology in front of customers,” said PADT’s Manager of Hardware Sales, Mario Vargas. “Metal 3D Printing is something our customers have wanted to add, but they could not find a turn-key solution for prototyping with various metal materials. Desktop Metal leveraged its expertise in metallurgy and software to deliver a complete system that can be run in an office environment. This is very compelling for many of our customers across industries.”

In the coming months, PADT will be setting up seminars and contacting customers across the Southwest to help educate the user community on the unique value proposition of the DM Studio System™. Anyone interested in learning more can reach out to info@padtinc.com or call 480.813.4884, technical experts are available to explain and answer any questions.

Save the date!

To show off this exciting technology we will be having putting on a DesktopMetal Studio System Road Show in August. Register now!

To learn more right now you can:

Phoenix Business Journal: Five 3-D printing breakthroughs everyone needs to know about

The world of 3-D printing is changing fast. New materials are announced and new systems are proposed almost every month. And as with any fast-growing technology, there is a lot of hype. When something is announced it will get a lot of press and attention, but what do you really need to know to follow the industry? In “Five 3-D printing breakthroughs everyone needs to know about” I take a look at the changes that should have the most impact on product development.

Aerospace Summit, Additive Manufacturing Peer Group, and Industry-Education Partnership – A Three Event, Three State Hat Trick

Sometimes everything happens at once.  This June 22nd was one of those days.  Three key events were scheduled for the same time in three different states and we needed to be at all of them. So everyone stepped up and pulled it off, and hopefully some of you reading this were at one of these fantastic events.  Combined they are a great example of PADT’s commitment to the local technology ecosystem, showing how we create true win-win partnerships across organizations and geographies.   Since the beginning we wanted to be more than just a re-seller or just consultants, and this Thursday was a chance to show our commitment to doing just that.

Albuquerque: New Mexico Technology Council 3D Printing Peer Group Kickoff

Everyone talks about how they thing we should all work together, but there never seems to be someone who is willing to pull it all together. That is how the additive manufacturing committee in New Mexico was until the New Mexico Technology Council (NMTC) stepped up to host a peer group around 3D Printing.  Even though it was a record 103f in Albuquerque, 35 brave 3D Printing enthusiasts ventured out into the heat and joined us at Rio Bravo Brewing to get the ball rolling on creating a cooperative community.  We started with an introduction from NMTC, followed by an overview of what we want to achieve with the group. Our goals are:

  1. Create stronger cooperation between companies, schools, and individuals involved in 3D Printing in New Mexico
  2. Foster cooperation between organizations to increase the benefits of 3D Printing to New Mexico
  3. Make a contribution to New Mexico STEM education in the area of 3D Printing

To make this happen we will meet once a quarter, be guided by a steering committee, and grow our broad membership.  Anyone with any involvement in Additive Manufacturing in the state is welcome to join in person or just be part of the on-line discussion.

Then came the best part, where we went around the room and shared our names, orginization, and what we did in the world of 3D Printing.  What a fantastic group.  From a K-12 educator to key researchers at the labs, we had every industry and interest representing. What a great start.

Here are the slides from that part of the presentation:

NMTC-PADT-3D-Printing-Peer-Group-2017_06_22

Once that was done PADT’s Rey Chu gave a presentation where it went over the most important developments in Additive Manufacturing over the last year or so.  He talked about the three new technologies that are making an impact, new materials, and what is happening business wise.  Check out his slides to learn more:

NMTC-PADT-New-3D-Printing-2017_06_22

After a question and answer period we had some great conversations in small groups, which was the most valuable part.

If you want to learn more, please reach out to info@padtinc.com and we will add you to the email list where we will plan and execute future activities.  We are also looking for people to be on the steering committee and locations for our next couple of meetings. Share this with as many people as you can in New Mexico so that next event can be even better!

Denver: MSU Advance Manufacturing & Engineering Sciences Building Opening

Meanwhile, in Denver it was raining.  In spite of that,  supporters of educating the next generation of manufacturers and engineers gathered for the opening of the Advanced Manufacturing and Engineering Sciences Building at Metropolitan State University.  This 142,000 sqft multi-disciplinary facility is located in the heart of downtown Denver and will house classes, labs, and local companies.  PADT was there to not only celebrate the whole facility, but we were especially excited about the new 3D Printing lab that is being funded by a $1 million gift from Lockheed Martin.  A nice new Stratasys Fortus 900 is the centerpiece of the facility.  It will be a while before the lab itself is done, so watch for an invite to the grand opening.  While we wait we are working with MSU, Lockheed Martin, Stratasys, and others to put a plan together to develop the curriculum for future classes and making sure that the engineers needed for this technology are available for the expected explosion of use of this technology.

Stratasys and PADT are proud to be partners of this fantastic effort along with many key companies in Colorado.  If you want to learn more about how we can help you build partnerships between industry and academia, please reach out to info@padtinc.com or give us a call.

Phoenix:  2017 Aerospace, Aviation, Defense + Manufacturing Conference

The 113f high in Phoenix really didn’t stop anyone from coming to the AADM conference. This annual event was at ASU SkySong in Phoenix and is sponsored by the AZ Tech Council, AZ Commerce Authority, and RevAZ.  PADT was proud to not only be a sponsor, but also have a booth, participate in the advanced manufacturing panel discussion, and do a short partner presentation about what we do for our Aerospace and Defense Customers.

Here is Rob’s presentation on PADT:

PADT-AeroConf-AZTC-2017

We had great conversations at our booth with existing customers, partners, and a few people that were new to us.  This is always one of the best events of the summer, and we look forward to next year.

If you want to know more about how PADT can help you in your Aerospace, Defense, and Manufacturing efforts, reach out and contact us.

3D Printing Example: CEI Awards – Using color, multiple methods, and clever CAD

One of the fun things I get to do is design and print cool things to share what you can do with 3D Printing.  This has extended to making awards for organizations that PADT supports like the Arizona Technology Council, The Arizona SciTech Festival, and AZBio.  Recently our favorite incubator asked us to design a custom award for their first Impact and Innovation Celebration. The request was to incorporate the CEI logo:

Taking a 2D image and making it 3D can be a lot of fun, and in this case it showcased some cool things you can do with 3D CAD and then 3D Printing.  There were some special steps needed to get this one done so I thought I’d share them.

The basic concept was to take the initials, CEI, and create a block that can serve as base. Then extrude the orange line-circle geometry as the key visual object.  But the thing that sets the logo apart from most, is the use of the succulent plant, an agave I think, in the logo.  So we definitely need a 3D agave on there.  The last element needed was the actual award part, where the name and award being given could be listed.

To get started I needed to get the logo into the CAD system I use, SolidEdge. Usually I convert a PDF into DXF in Adobe Illustrator. I then imported this into sketch planes. But in this case I only had a bitmap (PNG)  Fortunately you can paste that into a sketch plan as well, then just draw on top of it.  So I made three planes: Front facing and one rotated 45 deg and another -45 about the Z axis.  I then pasted the logo on to each of these centering the bottom center of the E on the global axis. This allows me to extrude and cut on each plan while keeping everything aligned

The base was made by extruding the initials from the +45/-56 planes and doing a Boolean intersect, This gives the letters from two views while creating a “3D-ness” That stands out.  The circle-line was then extruded on the front plane to cover the block created by the intersection.  It needed a “foundation” as well as a way to hold the letters together, so I just made a simple base.

That left the agave.  I thought about modeling it but nah… too much work.  So I went online and found a bunch of plants that people have made for video games and rendering.  Cool except the format was not STL, what we need for 3D Printing. So I downloaded some crazy rendering format.  Then I used a free online tool (thank you google, sorry I didn’t write down the one I used) that converts between 3D graphics files.  That took it to STL where I could read it into Meshlab, the open source tool for playing with this type of data. As usually with models made for graphics ,there was a lot of extra data and coordinate systems didn’t really translate right.  No problem, Meshlab makes it easy to select and delete objects.  I also scaled it from gigantic to the size I needed for the award.  Next step was to save that as STL and import that into SolidEdge so I could view it and position it properly on the award.

Last was the award part itself.  I played with a couple of ideas and just came up with a simple plaque that we could 3D print words on. i made it white and the “holder” blue to stand out. Then printed the award name and winner in bright colors using the text extrusion feature in SolidEdge.  When I need to get fancy, I’ll do the words and often a logo in Illustrator, export as DXF, then import as a sketch for extrusion. But in this case a nice simple Bold Arial font worked great.

So it was done, and I have to say looked pretty good.  So I asked our experts on 3D Printing if they had any suggestions.  Their one comment was “this is really cool, but its going to be expensive to print as one part.” Duh, I should have paid more attention in my own seminar on design for 3D Printing.  I had tall thin objects and bulky objects and they were all combined.  Lots of unneeded supports and flat surfaces at non-vertical or horizontal angles in the printer.  Bad stuff.

The solution was to design the parts so they could be printed separately and easily assembled.  The resulted in an STL for the base, for the circle-line, the frame, the agave, and the award plaque with simple features that would allow us to quickly glue it all together.  We also decided to print the base on FDM because it needed to be white and used the bulk of the material, and therefore cost. The rest was printed on a Stratasys Polyjet printer in color.

One more change worth noting was how to connect the crazy shapes of the agave needed some simple interface to the circle-line part.  So I created a simple cylinder that intersected the base of the agave.  In the printer we were able to combine the STL of the cylinder and the agave with two different colors.  A cylindrical cut in the orange part made assembly easy.

The results came out pretty nice, and the winners seemed to really like them.

The great thing about 3D Printing is the restraints it removes on making things.  You still have to plan it out to align with what the printers do well, but that doesn’t take a lot of effort and the results are great

.

 

Figure it Out: Guest spot on podcast – 3D Printing, automation, AI, and the comming robot wars

I was honored to be asked to join Santari Minor and George Grombacher for episode 31 of their podcast: Figure it Out.  It was wide ranging and fun conversation that flowed across so many different and interesting topics, it was hard to stop.  We covered 3D printing, automation, artificial intelligence and the future of work. Made me think. Take a listen and maybe it will make you think.

You can listen at most podcast services, here are two locations:

Podbean  –  http://figureitout.podbean.com/e/figure-it-out-31-eric-miller/

Itunes: https://itunes.apple.com/us/podcast/figure-it-out-31-eric-miller/id1190137632?i=1000386591054&mt=2

Google Play: https://play.google.com/music/m/Dhl7gsnwxma46ug7bzg6dd3a6tm?t=Figure_it_Out_31_Eric_Miller-Figure_it_Out 

Enjoy and hopefully it will start your own conversation.

 

 

 

Upgrade to the future of 3D printing – Stratasys F 123 Webinar

Take the Next Step!

Upgrade to the future of 3D Printing

Performance so good, you won’t believe it’s so easy to use!
The Stratasys F123 3D Printer Series demands less knowledge and experience, while meeting even the most advanced rapid prototyping expectations and needs, helping to make it the perfect machine for the classroom. This Series excels at all stages of the design prototyping process, from draft-concept iterations – to complex design verification – to high-quality functional prototypes.
Enhanced 3D printing capabilities of the F123 series include: 
  • New user interface
  • Remote print monitoring
  • Built-in camera
  • Auto calibration
  • Improved software experience with GrabCAD Print
  • Easy material change out
  • Auto material changeover

Join PADT’s Application Engineer James Barker and Sales Executive Jeff Nichols for a webinar that will provide an in depth look at all three machines that make up the all new F123 3D Printer Series (F170, F270, & F370).

Additive Manufacturing: 3D Printing a Metal Shift Knob for Faster Cooling

When Nathan Huber moved to Arizona from Colorado to join PADT he learned a lot, and one of the things he learned fast was that the inside of cars get very hot in the summer here.  In fact, the shift knob on his car was untouchable in July.  This coincided with his learning more about metal 3D Printing and an idea occurred, what about 3D Printing a metal shift knob designed to cool off faster, and that looked cool.  Oh, and use ANSYS to drive the design.

He blogged about it before (here and here), and Additive Manufacturing online picked up the story and added to it on their blog post “3D Printing a Metal Shift Knob for Faster Cooling”  Check it out, they did a nice job of explaining what we did and how Nathan used several of our tools like ANSYS Mechanical and our Concept Laser metal system to realize the design.