Chris Anderson & Doug Angus-Lee talking 3D Printers at Canada 3.0

At the Canada 3.0 Conference last week there were two 3D printer experts in attendance, Chris Anderson and me. Both of us are passionate about the ability of 3D printers to create real world objects and both of us where featured in this article published by the CBC.

Anderson’s keynote speech was excellent. He focused on the democratization of manufacturing and how average people can now accomplish what only the biggest companies once could, the manufacturing of things. Like the internet allowed all of us to become publishers the 3D printer will allow all of us to become manufacturers.

Anderson is right on with this. We are at the beginning of the next industrial revolution as manufacturing becomes accessible to the masses. However, Chris’ talk focused on home applications for 3D printing like printing toys for his kids.

What we showed in the Javelin booth is very different; commercial quality equipment from Stratasys that our clients use to grow their business. Javelin’s clients are businesses; engineering firms, product designers, dental labs, hospitals, universities, architects, etc. They need tools to help them design more creatively, get projects to completion faster and control their costs. Home based printers in the under $3,000 price category are great for doll house furniture but they just aren’t accurate or dependable enough for our clients.

At our booth we were demonstrated our entry-level, commercial quality, 3D printer The Mojo which currently sells for $9,900. So what is the difference between a $10,000 3D printer and a $3,000 hobbyist/home one?

The Mojo is a commercial quality machine that makes parts accurately and dependably. Hobbyist, or home, 3D printers require a lot of fine tuning on an ongoing basis and cannot match the accuracy of more expensive models. If you plan to print doll house furniture or you like to “tinker” a hobbyist printer may be for you. If your business relies on being able to accurately model parts for form, fit or functional testing and you need to be able to make parts when you need them a commercial quality printer is the way to go.

Let me tell you two stories that illustrate this point.

First 3D Printed part from our Mojo

Story #1 - I recently met with a client who bought a hobbyist 3D printer for about $3,000. In 3 months they had been able to make a few good parts but it took a lot of attempts to get each one and there had been many abandoned prints along the way

Story #2 – At Javelin we recently received our first Mojo printer. We took it out of the box and set it up in about an hour and 15 minutes (watch this blog for an unboxing video soon). We printed our first part in about 30 minutes and it was perfect – see the Javelin name plate on the right. In two weeks we have printed about a dozen parts and every one has been perfect. No fine tuning, no tinkering, no failed or bad prints; just good and accurate parts.

In short if you are a hobbyist and you want to experiment, take a serious look at the hobbyist printers. If you need your 3D printer to consistently make reliable and accurate parts, then talk to us. We can help.

Doug Angus-Lee is Rapid Prototype and Additive Manufacturing Product Specialist at Javelin Technologies.  Doug can be reached at doug.angus-lee@javelin-tech.com or by phone at 905-815-1906 x214.

Twitter @DougAngusLee      LinkedIn http://ca.linkedin.com/in/douganguslee/

SolidWorks ScanTo3D is a utility available in SolidWorks Premium which allows a user to open scan data from any 3D scanner in the form of a mesh or point cloud file. This data can then be converted into a Surface or a Solid Model. If you wanted to do exactly the reverse of this operation, the only option would be to save the file out as an STL file but there is little control that a user has over the point distribution and the resolution of the STL file.

Here is a nice trick that allows you to save the data as a point cloud file from a SolidWorks Model. You will need to have SolidWorks Premium to complete this operation.

1. Create a new Static Study in SolidWorks Simulation
2. Mesh the model with the desired resolution
3. Right-Click on the Mesh in the feature manager and choose probe
4. Choose Selected Entities
5. Turn on the Filter Face from the filter toolbar
6. Click on a face and then click CTRL+A to select all faces
7. Hit update on the Probe property page
8. Uncheck show element number but keep the Show X,Y,Z location
9. Hit Save as CSV

The CSV file that is created has all the X,Y,Z data like a point cloud file and can be used as a point cloud file

See the attached video to see step-by-step guide how to create the point cloud file

Part 1 Javelin Tech TV Trebuchet Challenge

If you’ve been watching Javelin Tech TV then you know that Scott Lidgey and I are planning to design and build a trebuchet and we encourage you to get involved too.  Watch today’s episode of Javelin Tech TV to see Scott’s initial design and how he uses the weldments feature of SolidWorks to create the frame.

If you want to build your own trebuchet here are the parameters we are using.  Let us know how you’re doing either by commenting on our blog entries or send us a note to javelintv@javelin-tech.com and include some video of your chucking things.

The Rules

Here are the parameters we used to design our trebuchet.  I encourage you to build and fire your own trebuchet using these same parameters and send us the results (video would be great).  Beat us if you can (evil laugh).

As a part of their design process, many of our customers need to prototype parts. Form / fit testing, concept modeling, dimensional verification, marketing surveys, ergonomic studies, rapid tooling, jigs and fixtures, etc. are common needs that can be fulfilled with a good prototype.

For those who don’t have a 3D printer in their facilities, Javelin provides 3D printing services supported by the Stratasys Connex 500, or by the Stratasys Objet 30 Pro 3D printers. Rigid plastics, elastomeric, clear, translucent and speciality materials can be used to prototype parts for companies or individuals who need to bring their ideas to life: consumer goods, industrial products, customized parts can come to life directly from your CAD files or from 3D data captured with a 3D scanner.

The process is really simple, just contact us, submit your file (STL, SolidWorks, STEP, IGES or Parasolid) with a description of the requirements of your part and we will get back to you with a quote and a suggestion of the material that best suit your needs.

3D printed multi material part. Text block uses Tango Plus, the main body uses Vero White.

Many people are curious about how to include text elements (or other components) in a 3D printed multi material part. In my last post I described the features of a multi material sample with 10 different materials on it. Coincidentially, I needed to include some text blocks in the body of the sample in order to identify each one of the materials. As we have a Connex 3D printer, the only 3D printing solution able to use 2 materials to build multi material prototypes, I was able to achieve this objective.

In order to emboss text blocks with a different material of the base part, you need to follow this procedure:

1. Model the recess feature (extruded cut) in the base part.
2. Model the text block as a separtate part. Make sure that the dimensions of the letters are exactly the same of the extruded cut in the base part.
3. Create an assembly and position the text exaclty within the recess of the base part.
4. Export the assembly as an STL file. Make sure to UNCHECK the option “Save all components of an assembly in a single file”.
5. In Objet Studio, import all the STL files you just exported in SolidWorks. Make sure to CHECK the “Assembly” option.
6. Select one part at a time, and assign the materials according to your requirements.
7. You can use the “Automatic Placement” option in Objet Studio.
8. You can now save the tray or send the job to print.

You are done, now you have text embossed into a body, with a different material in the same part.

Multi material sample part made out of Vero White and Tango +

The Connex line of Stratasys 3D printers is the only 3D printing solution able to use two materials at the same time, and obtain a new one by combining these two base materials. To demonstrate this unique capability I modeled a sample part with 10 different digital materials on it. By using Vero White and Tango Plus materials I was able to print a sample part with 8 digital materials and 2 base materials:

• Vero White: Rigid opaque.
• Tango +: Flexible (Shore 27) and trasnparent.
• DM9740: Flexible (Shore 40) and translucent.
• DM9750: Flexible (Shore 50) and translucent.
• DM9760: Flexible (Shore 60) and translucent.
• DM9770: Flexible (Shore 70) and translucent.
• DM9785: Semi flexible (Shore 85) and opaque.
• DM9795: Semi flexible (Shore 95) and opaque.
• DM8430 Polypropylene like
• DM8425 Polypropylene like

As you can see, it is not only about obtaining more materials, but also different physical properties and applications for simulating over coated parts such as automotive gaskets, protective sealings and more.

This is just a quick tip on how to reduce the noise coming from the pressure unit for the smaller Objet Waterjet.  The water pressure used to clean the support material from the printed parts is generated by a pressure washer type unit.  This device is quite loud so I decided to try to find a way to make it quieter.

Read More »

Stratasys FDM sample kit

After several years of dealing with 3D printed parts from Objet (now Stratasys) we are very familiar with the appearance and features of Polyjet parts. Now, with an enhanced rapid prototyping portfolio due to the Objet / Stratasys merger we are getting to know the benefits and properties of the FDM (Fused Deposition Modeling) parts.

A few days ago we received the Dimension sample case, with very interesting parts that show the strengths and applications of parts printed in a Stratasys Dimension machine. After carefully observing, manipulating and analyzing the parts I would like to summarize some of the key points of these models:

• Strong and durable parts.
• Colour variety (up to 9 available colours).
• Fully functional models.
• The parts can be drilled, tapped, painted, sanded and even metal coated.
• Perfect for snap fit testing due to the nature of the material (real ABS).
• Great dimensional stability.

With this enhanced portfolio, Javelin will be able to cover most of the rapid prototyping requirements of our customers. Now we have the missing piece of the puzzle.

Recently Javelin Technologies was asked to present recently Golden Horseshoe Manufacturing Network – Innovation Breakfast held at the Ron Joyce Centre, part of the the DeGroote School of Business at McMaster University.  The event, sponsored by Ontario Centres of Excellence, brought together business owners, educators, financial partners and other stakeholders who want to see the Ontario economy grow.

photo by Dave Gurggen http://www.gruggenphotography.com/

We talked about 3D printers, the history, the technology and the capabilities, but, mostly we talked about the value of 3D printing as a tool for innovation.

As part of the design process, 3D printing encourages more creativity and allow decisions to made more quickly.  There are lots of examples of companies reducing their design cycles by more than 50% by implementing in-house rapid prototyping solutions.  These companies have a competitive advantage and benefit by getting products to market months earlier.

As 3D printing matures, it is also having a profound impact on manufacturing and this impact will continue to grow and help to re-shore manufacturing jobs.  By removing the expensive labour component from complex manufacturing, 3D printing allows parts to be made locally for the same cost as in China or other inexpensive labour markets.  This is already happening for custom manufacturing jobs and low run production, and as the technology develops, larger volumes will start to make sense.

Recently the Gartner Group released a report focused on the huge impact 3D printing is likely to have on the economy.  In that report they specify that “early adopters of 3D printing technology could gain an innovation advantage over rivals“.

The time for innovation is now.  Canadian companies need to innovate more creatively and quicker than their competitors here and abroad.  It is by innovating that we will grow our economy and create jobs. Who’s with me?

Doug Angus-Lee is Rapid Prototype and Additive Manufacturing Product Specialist at Javelin Technologies.  If you have an idea for The Buildup or want more information about our product and service offerings contact Doug at doug.angus-lee@javelin-tech.com or by phone at 905-815-1906 x214.

Twitter @DougAngusLee      LinkedIn http://ca.linkedin.com/in/douganguslee/

The typical source content for a 3D printer is an STL file, it comes from two main sources, a new design modeled with 3D CAD software or 3D digital information captured from a real part using a 3D scanner.

Here at Javelin we tried an alternative method – convert a 2D photo into 3D printable material! To achieve this SolidWorks Certified Expert Dr. Irfan Zardadkhhan wrote a program in C++ that reads a PGM (Pixel Gray Map) file and translates the data into an X, Y, Z table. In the table, X and Y represent the location of the point and Z represents height, which equates to the gray intensity value of a pixel (when 0 is black and 255 is white).

Once the XYZ file is generated as a plain ASCII file, using the ScanTo3D SolidWorks Add-in product  the file is converted into a surface. Then SolidWorks modeling tools are used to finish the 3D model data.

The model is then generated using a Stratasys Objet 30 3D printer and the results are amazing. As you can see in the images the printed part contains a textured 3D face, the depth of the surface blocks provides the detail; and when you hold the part in front of a light source the original picture will show through.