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.

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.

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.

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.

Read More »

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.

Read More »

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

Some great news from Objet this week!  Objet has just announced that they are now accepting waste resin generated by the Desktop, Eden and Connex printers.

Previously we could return only the used resin cartridges to Objet and we had to find our own solution for the waste.

Here is a link to the Objet website where you can find more information on this: Objet Recycle Program or contact Objet at: SupportUS@objet.com

For shipping the waste to Objet they recommend you place the waste container into a heavy plastic bag such as ULINE #S-14698BL and then place that into a heavy cardboard box, ULINE numbers S-4603 (Large frame machine), S-15048 (Mediium frame machine), S-4591 (Small frame machine, 2 waste containers per box).  Tie the heavy plastic bag shut with a zip tie such as ULINE #S-5071.

The waste and used cartridges go to the same address:

 Refer to section 14 of the MSDS sheets included with every resin shipment for specific shipping instructions and material classifications.