Last week I showed you how to use the new Intersect tool for simplifying your model by filling its internal cavities.

Today let’s consider the situation where you need to fill the external cavities from the Mr. Smiley model with discrete solid bodies in order to 3D print the end result with a bi-material printer from the Objet Connex family.

This video proposes two different solutions for this challenge. Can you think of more?

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.

As a result of the Stratasys / Objet merger, Javelin now offers a broader 3D Printing portfolio. The Polyjet line of products is now complemented with FDM (Fused Deposition Modeling) 3D printing systems from Stratasys. With this enhanced portfolio, Javelin is now able to cover most rapid prototyping requirements.

Dimension and uPrint SE 3D printers from Stratasys.

We just received a sample kit from Stratasys, with very good plastic parts that show the benefits and strengths of the FDM technology:

• Strong and durable parts.
• Great for functional testing.
• Perfectly suitable for real life use.
• Available in 9 bright colors.
• Made out of real ABS plastic.
• Suitable for post processes such as sanding, drilling, taping, gluing, painting and metal coating.

With 3D printers starting at just $9,900, Javelin is now able to provide professional grade 3D printing solutions to designers, engineers, teachers, in fact anyone that needs to take their ideas from concept to reality.

I have written several blogs about printing parts from 3D CAD models, but I still have not talked about capturing 3D data from the real world in order to reproduce it with a 3D printer.

A 3D model printed with a Stratasys/Objet 3D Printer from 123D Catch data.

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3D Printed Speaker Wall Mount with lock.

In previous posts I wrote about the recommended clearances and tolerances for modeling parts intended to be Printed in 3D with an Objet machine. In order to verify these recommendations I have modeled a wall mount for a small speaker consumer product, consisting of an assembly of two interacting components joined by an internal rail (this part can’t be manufactured using a conventional method), and a lock with 15 degree tilt constrains. My design intent is to:

• Print the product in a single job with no assembly required.
• Create moving parts that have a tight fit.

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Objet and Stratasys officially announced their merger today, December 3, 2012, resulting in the creation of a $3 billion multi-solution company. Stratasys now carries a broad portfolio of digital manufacturing and rapid prototyping solutions, including FDM, Polyjet, and Drop On Demand technologies. The new company will trade on the NASDAQ stock exchange as Stratasys Ltd (SSYS). Read the Objet Stratasys Merger press release for more information.

Want to take your iPhone picture taking to the next level? Now you can! Olloclip has created the ultimate 3-in-one lens system for your iPhone that fits in your pocket. Product design in most recent years has been impacted tremendously by 3D printing, and Olloclip’s camera lenses are no different. Whether it’s wide angle, fish eye or a macro picture view, this development in camera phone technology has been made possible by Objet 3D Printing.

Please join Chong Pak of Olloclip and Objet Geometries as they discuss product design within the iPhone era and how 3D printing can help engineers design, create and ultimately bring products to life faster.

What you will Learn:

• Olloclip and their fast hitting iPhone accessory
• 3D printing and the design process
• Objet’s multi-platform capabilities

Webcast: Olloclip Advances iPhone Camera Capabilities with 3D Printing
Date: Tuesday, December 4th, 2012
Time: 2:00pm to 3:00pm EST

Register Now! https://www2.gotomeeting.com/register/488568634

Digital mold in place in the support plates.

Objet is continuously developing new materials. One of the materials that they recently launched was the ABS like (RGD5160-DM). A unique digital material that combines the best of its components: toughness, heat resistance and flexibility. If you add those great features to a 3D printer able to deliver smooth surfaces and high detail, you are in front of a new world of applications.

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3D printed samples to test tolerances in an static assembly

I already wrote about the recommended tolerances when prototyping moving assemblies in a single print. What happens when you need to test static applications that require tight interaction between parts?

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