TEST SLIDE Is this text readable in the back? Are the corner dots - - PowerPoint PPT Presentation

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TEST SLIDE

• Is this text readable in the back?
• Are the corner dots visible?

ITERATING FASTER WITH A 3D PRINTER

More of a 3d printing overview

SLIDES WILL BE ON MY BLOG

https://sphereinabox.wordpress.com/

Q'S FOR AUDIENCE

Have you watched a 3d printer work? Can you handle millimeters?

SB STARTUP WEEKEND TROPHIES 2014

I made these

VIRTUAL REALITY DISPLAY USING IPAD MINI

My first 3d printing based project Completed before the delivery for the Oculus Rift

Another dumb project of mine The ratchet locks the screen in place so the motor can be turned off.

Santa Barbara Hackerspace is a Non-Profit to help educate the community and help them build stuff. Members can use the space, wifi and tools including 2 FDM 3d printers, laser cutter, electronics bench and more. We’re open to everyone on Saturday afternoons after 2PM so stop by and see what we’re working on or ask us questions.

ZAR PLOTTER

Early Prototype

Notice the motors hose clamped down to a board.

ZAR PLOTTER DRAWING BANNER

RANDY SZARZYNSKI

“SUBTRACTIVE MANUFACTURING”

Make a part by removing (subtracting) material

Nobody calls it that.

SUBTRACTIVE

ShopBot Desktop at Crash Space in Culver City

This part shows up later

ADDITIVE MANUFACTURING

Build up part by adding material

Video is time lapse of Zortrax M200 print starting

CAN'T MILL THIS

Herringbone planetary gear skateboard wheels

http://www.thingiverse.com/thing:151216 Yes I know these are a dumb idea.

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UV SENSITIVE RESIN PRINTING

• Selectively cure layers of resin, using laser or DLP

projector

Little RP Form Labs … many more

ENTRY LEVEL RESIN PRINTER KITS $800 INCLUDING THE PROJECTOR

LittleRP

[pre-release machine shown] [projector not shown]

Super high detail Limited build volume Expensive material ($90/liter or more)

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SLS (LASER SINTERING)

• On each layer, spread a new layer of powder, and

selectively melt it with laser or heat.

• Various materials and costs:
• Nylon is cheaper, machine costs [lots]
• Metals like titanium are possible but machines

would cost over $500,000

Video introduction to nylon SLS printer https://www.youtube.com/watch?v=wD9-QEo-qDk The patent covering this is about to, or just expired so things are going to get fun here.

SLS INTRODUCTION

Clip by Solid Concepts

Video clip from Solid Concepts (now Stratasys) https://www.youtube.com/watch?v=9E5MfBAV_tA

SLS RESULTS

Raw (grainy) or Sanded
 (Shapeways Strong and Flexible)

https://www.shapeways.com/materials/strong-and-flexible-plastic Layers are .12mm SLS patents have started expiring so others will start making these machines

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NO "STANDARD" METAL PRINTING PROCESS

• Do lost-wax casting from resin, plastic, or jet process

print

• Glue metal powder together, move into bed of sand,

then use as mold

• Laser welding then post-machining
• Standard welding then post-machining

[Glued metal powder casting process video] https://www.youtube.com/watch?v=i6Px6RSL9Ac Also additive laser welding https://www.youtube.com/watch?v=yKnlmfuMSgo

FUSED DEPOSITION MODELING (FDM) / FUSED FILAMENT FABRICATION (FFF)

Draw part by drawing lines of plastic layer by layer

FDM is a Stratasys trademark

WHY ARE 3D PRINTERS A POPULAR THING NOW?

… answered in future slides

REPRAP PROJECT

Make a machine that replicates itself when supplied raw materials

OPEN SOURCE

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TYPICAL OPEN SOURCE LICENSE

• You can use this and create derivatives as long as:
• You make the source files available for others to

build on.

• And your derivative works are also available under

the terms of this license

Paraphrased GPL “Available” means “include them with your copy” or “have a process to get them for the cost of media and postage”

FEBRUARY 2008 DARWIN

First model to replicate it’s major parts

http://reprap.org/wiki/Darwin University of Bath (England)

OCTOBER 2009 MENDEL

MAKERBOT CUPCAKE

April 2009 Photo by Bre Pettis (Founder

• f MakerBot)

Wow this thing is terrible. Repeating wobble due to riding on Z threaded rods which aren’t straight. Motors VERY loud because current/voltage is wrong. Extruder calibration is nearly impossible because it’s driving a DC motor without an encoder. Later models had a stepper driven extruder. You can yell over one. Here’s the SB hackerspace’s printing https://www.youtube.com/watch?v=bN6HSEdB3co Photo by Bre Pettis CC-BY 2.0 https://www.flickr.com/photos/bre/3458247336/

MAKERBOT REPLICATOR

January 2012

http://www.makerbot.com/blog/2012/01/09/introducing-the-makerbot-replicator

MAKERBOT REPLICATOR 2

September 2012 End of open source updates from MakerBot, likely in response to clones.

https://en.wikipedia.org/wiki/File:MakerBot_Replicator_2.jpg

NOW

Hey look, a MakerBot clone.

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CONSUMER FDM/FFF MATERIALS

• PLA
• ABS
• PET variants
• Nylon

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CONSUMER FANCY FDM/FFF MATERIALS

• Co-Polyester-based plastics
• Flexible Urethane based plastic (Ninjaflex)
• PLA with metal powder (Bronze, Copper, Iron,

Stainless)

http://www.ninjaflex3d.com http://www.proto-pasta.com

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EXOTIC FDM/FFF MATERIALS

• These require higher temperature nozzle, and a

controlled temperature chamber.

• Polycarbonate (Print 300°C in 100°C chamber)
• PEEK (About 350°C nozzle in 100°C chamber)

HEATED BED

Lulzbot TAZ 5 printing HIPS on 110°C bed

WITHOUT SUPPORT MATERIAL

This is one of our most successful makerbot cupcake prints. Yes I know it looks terrible.

SUPPORT MATERIAL (REMOVABLE)

Support removed in left photo, sitting behind part. Lower right photo shows interior of object is hollow.

SUPPORT MATERIAL (DISSOLVABLE)

PLA dissolves PLA caustic soda in ultrasonic water bath HIPS: Dissolve HIPS with Limonene PVA: Dissolve PVA in water

Pictured: HIPS (White) support ABS (Black) print material Print is the comet the Rosetta space probe landed on.

Create a plaster mold around the original 3d printed part, with vent and pour inlet Burn/melt out printed material Pour in molten metal When cool, brake plaster to get part. Then trim spout+vents and polish. This perfectly replicated our print defects.

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TYPICAL PRINTING WORKFLOW

• Design in a computer, export STL file
• Load STL file in "Slicer" to generate g-code.

Choose options like layer height, fill density, and support material.

• Send g-code to printer to print file.

CAD or whatever Export STL Load into Slicer and nearly instantly get result

OPTIONS

Only really need two of these

Support material on/off is about the only setting I change If I’m switching between printing strong parts and ones that look good, I may change shell thickness and layer height

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DESIGN APPROACHES

• Solidworks, OnShape or other solid modeling

packages

• Sculpting
• 3d Scanning

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DESIGN CONSTRAINTS

• Solids
• Thin features
• Thin walls
• Overhangs

Shapeways description pages do a good job of describing each of these but I don’t want to read you the material pages for a full hour. https://www.shapeways.com/materials/?li=nav

OVERHANGS

Nice beard

NON-MANIFOLD

Usually the opposite of “Watertight”

http://www.thingiverse.com/thing:40262 I expect this was intended for video games where the inside of the car didn’t need to be solid.

CURA (SLICER) TRIES ITS BEST

CURA X-RAY PREVIEW

Highlights problems in red

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TOLERANCES (CHEAP FDM/ FFF MACHINES)

• Small holes tend to be 0.4mm too small in

diameter.

• Outer shapes tend to be 0.2mm too large
• Layer heights of 0.1-0.3mm are typical

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FDM LIMITATIONS

• Temperature for printed part. PLA gets soft at

65°C (149°F)

• Strength and durability isn’t as good as molded or

metal

• Parts weaker between layers then along their

length

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PRINTING SPEED

• Typical speed of moving print head is

30mm-80mm/sec (70-190 inches per minute)

• Typical layer height 0.1mm-0.3mm
• A part 4 inches long, 2 inches wide, and 1 inch tall

may print in 2-6 hours.

PRINTING FASTER

Increasing federate has limits: Melting plastic

Under extrusion (from https://ultimaker.com/en/community/5586-can-your-um2-printer-achieve-10mm3-s-test-it-here )

MOVING FASTER IS HARD

Mechanics can only look nice moving so fast

INFILL DENSITY

To reduce print time and required materials, objects are not printed solid.

I’m told stratasys doesn’t let you adjust this :-(

PRINTING FASTER

There are heaters/nozzles for extruding plastic at a higher volume for thicker layers

e3d volcano http://e3d-online.com/Volcano/Volcano-Eruption-Pack-175

Don’t need to print EVERYTHING if you have other tools. Laser cut reel holder Mixed Laser/plastic VESA mount for tablet

"WIRE" PRINT

https://www.youtube.com/watch?v=Ea4V7kb2VsY

PRINTED PARTS ARE NOT FOR EVERYTHING

Don’t try this.

BRAKE CALIPERS PRESS HARD

The gray part was also 3d printed

Both lime and gray parts are 3d printed. The car was not moved while these “brake pads” were installed.

ZORTRAX M200

$1990 200x200x180mm build volume Slow but good prints

https://zortrax.com/printers/zortrax-m200/

LULZBOT TAZ 5

$2200 295x725x250mm build volume Fully open source machine, prints well

https://www.lulzbot.com/store/printers/lulzbot-taz-5

"REQUEST A QUOTE"

Hobbyists need not apply

Screenshot is http://www.purpleplatypus.com/stratasys-3d-printers/

STRATASYS MOJO

MOJO

Approximately $5000 Soluble support by default $250/kilogram spools of plastic and support 127x127x127mm build volume

Spools are probably $200/44 cubic inches The comparison $250/kilogram compares to reputable consumer suppliers selling ABS or PLA for $30/kilogram

UPRINT SE PLUS

$22,000 Machine 203x152x152mm build volume Soluble Support by default

http://www.purpleplatypus.com/stratasys-3d-printers/uprintse/ price from http://www.hanselman.com/blog/3DPrinterShootout600PrintrbotVs20000UPrintSEPlus.aspx

SHAPEWAYS

Most approachable 3d print service

AUTOMATED INSTANT QUOTE

Strong & Flexible Nylon round trip time is about 2 weeks

WEB BASED ERROR DISPLAY

There are some edges highlighted in yellow for being where the part is too thin

LOTS OF MATERIALS

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PRINTING SERVICES

• Shapeways http://shapeways.com
• i.materialise https://i.materialise.com
• Stratasys Direct https://www.stratasysdirect.com/
• 3d Systems: http://www.3dsystems.com/quickparts

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MORE LOCAL, POTENTIALLY FASTER TURN AROUND

• I haven’t tried these but:
• Go Engineer has office in SB, offers FDM printing services http://

www.goengineer.com/3d-printers-2/

• Stratasys Direct (formerly Solid Concepts) has office in Valencia https://

www.stratasysdirect.com

• Steve Bond Design in Camarillo FDM http://stevebonddesign.com/3d-services.html
• Hollywood http://www.hollywood3dprinting.com/3d-printing-overview/ FDM, SLA

resin or wax (detail)

• Gardena http://www.sbmolds.com/3d_printing.html Resin or FDM

“Request a quote” means “not in my hobbyist budget” so I haven't tried any of these

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MORE

• Los Angeles, http://3drp.com range of materials from resin to metal
• Los Angeles http://www.3d-cam.com/index.html resin-based materials

that act like plastics

• Los Angeles http://www.3dwaxprinting.com for jewelry masters
• Los Angeles http://www.guruprinters.com/3D-Printing.html full color

gypsum (not durable)

• Irvine http://www.purpleplatypus.com/3d-printing/ Resin (polyjet) or

FDM

BONUS SLIDES

3D SCANNING

PARALLAX FROM LINE LASER ($3000 NEXTENGINE)

more links, photos, videos on http://www.eevblog.com/forum/reviews/3d-scanner-the-nextengine-2020i-my-latest-purchase/

PHOTOGRAMMETRY ($180 PHOTOSCAN, “FREE” 123D CATCH)

phtoscan: http://www.agisoft.com 123d catch: http://www.123dapp.com/catch Image above from 123d catch video, doesn't show software in use but shows how to arrange photos: https://www.youtube.com/watch?v=7TfXXJxDsXw

STRUCTURE SENSOR ($380)

Reconstruct the world using a Primesense “Depth Camera”

http://structure.io Picture is screenshot of scanning using Skanect from http://structure.io/getstarted/first-use

3D SCANNING PREP

Get rid of glossy parts of what you intend to scan

Unscented might be better. http://www.amazon.com/Gold-Bond-Spray-Powder-Fresh/dp/B00B4CYRHA/

REMOVE EXTRA SCANNED MATERIAL

source: http://www.nasa.gov/sites/default/files/files/3DScannerTutorial.pdf

FILL HOLES

WHY STEPPER MOTORS IN 2016?

(MakerBot Mini)

… because they’re cheap These are the one-of prices on http://robotdigg.com

GOING VERTICAL

3D PRINTED VUVUZELA

3d Printed Vuvuzela for if you missed during the 2010 South Africa World Cup