Door handles made easy
Manual
i.materialise stainless steel door handles v1.1
Contents Introduction - 3
Introduction
Design Kit - 5 Tips and Tricks - 10
2
3D Printing - 15
Design by PeLi Design
i.materialise is a 3D printing service for everybody with an eye for design and a head full of ideas. We want you to focus on the creation of designs –made by you– that add value to people’s lives, while we do the manufacturing.
Design by PeLi Design
Door handles? Really?
3
Yes… 3D printed door handles! Personalize your door handles and welcome people into your sense of style at the same time they enter your house. Inspired by PeLi Design’s groundbreaking door handles, we’ve created a design kit allowing you to create 3D printed stainless steel door handles of your own. These unique door handles are sure to impress any visitor, and with this kit, we ensure that you get the design that suites you best…your own. Design by PeLi Design
There’s something special about physically holding a design you’ve spent so many hours on.
Introduction
We want to be the power behind your design.
How does it work?
90
m
It’s simple.
m
5
2 rosettes with 4 screws for attaching the rosettes,
2 handles with 2 fixation screws for the handles,
a locking mechanism with the connection box and 4 screws
a small installation guide.
4
m m 0
es
14
m olu v g
din
il bu
4x
ite
m s
2x
4x
ka ge
55mm
We ‘ll offer you the following items: (from left to right)
Introduction
m
pa c
m m 5
35mm
We offer you a building volume with fixed dimensions for your handles 10 and rosettes. With our design kit you can prepare your file for production. m
Content Design kit
On the website, you can select the software program you want to design in. In these files you’ll find the different layers with aids, and guides that will help you with make your design printable.
Open the design kit in your 3D modeling program and you will find:
A reference door and lock
You can chose from the following file types:
Bounding boxes for one rosette and one door handle
An example set of door handles with handles, rosettes, a fixation screw, and rosette screws
A star shaft that needs to be subtracted from the lever
Elements which remain in the model: the fixation screw
References for the rosette screws
A guide of tolerances for a Teflon ring on the lever and rosette
5
Google SketchUp
Rhino
.skp
.3dm
3ds Max
.3ds
Wavefront
.obj
TIP
Once you’ve selected and downloaded the kit, you can get started. but it’s best to read through the manual to get to know the do’s and don’ts. example of set
Introduction
Download the Design kit
m
Step 1 - Size handle and rosette Example
Bounding box handle m
10
m
m
35mm
m 5m
m
5
To help you design your door handle set, we have added an example in one of the layers. You use it as a template or just a reference. The choice is yours. The example also serves a checklist to see what needs to be included when uploading the file to our 3D print lab.
mm
0 14
Design Kit
6
90
55mm
For a fixed price we offer you a so called bounding box. This means that your design has to fit inside of this box. So it’s good to start looking at this size when starting to design in order to avoid having to rescale your design afterwards.
For your ease we have split up the bounding box of the rosette and the lever. A box of 55mm x 10mm x 55m is the maximum you can use for one rosettes. For the handle the maximal size would be 140mm x 90mm x 35mm.
90
m
m
35mm
TIP
Designing within the bounding boxes is obligatory since non conform sizes will be rejected. Please pay attention to this
In the kit we have also included a standard size door and locking mechanism, to making it easier to get an idea of how your design would look in the end. You’ll find them in the layer called “reference door & lock”’.
Step 2 -Shaft lever The second step is all about making sure your doorhandle can fit on to the locking system. This means that you need to substract the star shaped volume that we provide in the design kit
Star Shape The reason we want you to use a star shape is that it allows you to use the doorhandle for both of the standards on the market.
The first standard has a neutral position with a horizontal square shaped hole.
Subtracted volume Make sure that the star shaped volume is in the correct position when you subtract it from your design, and that your handle has a wall thickness of at least 3mm at least around this shaft. You can find the star shaped box in the “boolean difference‘‘ layer
With the star shape subtracted the box shaped shaft can be slid on for the 2 standards, as you can see.
In the the second standard this square hole is turned by 45 degrees.
Also, for the second standard, the lever can be slid on without any problems.
This is the option that we will ship in our package.
This flexibiltiy is the main reason this type of shape is used.
Design Kit
7
If you already have a locking system in place, you can check which standard you have. But in principle, this doesn’t change anything on your design. The star shaped hole in the handle will allow both options to be used. This means if you move or want the doorhandle on a different door, this should be possible.
Step 3 - Screws The next step is forseeing a fixation for the lever. This screw needs to be inserted to attach the handle to the connector box that will be inserted in the lock. Since this is a screw, holes need to be made and a thread needs to be created. Due to the technology used and the strength needed, it is better to create the hole and thread after the level is built. Therefore, the only thing you need to ensure in your 3D file is that there is enough space for the screw to be inserted after printing. If you keep enough wall thickness of minimum of 3mm around this cylinder so the hole and thread can be made without any problems. You can find the cylinder in the “keep in model”’ layer.
fixation screw
8 Rosette screws In order to attach the rossettes to the door, you need to foresee holes for the screws in both sides of the rossettes. Depending on your choice, the screws can be positioned either horizontally or vertically.
Design Kit
Handle screw
Step 4 - Tolerances
In the layer called “tolerances�you can see what size the component should be.
9 teflon ring
Design Kit
The final step before uploading is making sure that the lever and rosette have good tolerances in order to ensure the handle works without any issues. When putting your set of doorhandles together we will insert a teflon ring between the handle and the rosette. Therefore, it’s important to leave enough room between the 2 components.
Step 5 - Checklist Wall thickness
Check the general design rules of Stainless steel on our webpage.
Minimum
3mm
Go over the following items to verify whether your design is ready for uploading.
90
m
10
10
m
m
35mm
m 5m
m
55mm
5
14
0
mm
Check the wall thicknesses. For your door handles you should have a minimum of 3mm. Only then, a part will be strong and durable enough to be used as a door handle.
Building volume
Content upload
Make sure your design fits inside the building volumes. If your model is too big, rescale it, but make sure you don’t lose too much wall thickness by doing so. Also, make sure that the dimensions of the star shaped shaft are correct. If you rescale the design, it’s preferable that you redo the boolean difference of your lever with the star shaped volume.
Delete the references before uploading. Keep the fixation screw in your model, and make sure to subtract the star shaped shaft.
Ergonomics Try to imagine the use of your door handle. In everyday use, ergonomics are important.
Check the example layer to see what we expect you to upload.
Design Kit
Design guide
Step 6 - Upload Upload In order to have your design recognized as a door handle set you need to upload it via the door handles page. Once you have selected your file and pressed open, your file will be upload to our 3D print lab.
When the upload is completed, a preview will be generated. This way you can see if the upload was done correctly.
11
Material The material will automatically be selected since we only offer the door handles set in Stainless Steel. It is not possible to choose another material.
Color You can now select the color you want your door handle set to be. Note that the entire set has to be the same color..
Checkout If you are happy with everything, you can complete the order by pressing the checkout button.
Design Kit
Preview
12
Stainless steel
Texture
Models made in stainless steel are printed in stainless steel powder that is infused with bronze.
Due to the building process, which adds material layer by layer, lines will be visible on your door handle. Some of the lines will be polished away by tumbling.
Stainless steel is the cheapest form of metal printing, very strong, and suitable for very large objects like doorhandles.
If an area of your model is inaccessible during the tumbling process, because it is a recess or is covered, it will be dark black in color. Check the stainless steel page on our website for more information, design guides, and images.
Colors There are three options when selecting a color in stainless steel. Check our Flickr for more examples
Old Silver
Wheat Pewter
Medieval Pewter
Design by PeLi Design
Tips & Tricks
Tips and tricks
Example: Doorhandle by PeLi Design
Design by PeLi Design
13
5 When the model is uploaded on the i.materialise website, PeLi proceeds through the necessary steps and orders his model. PeLi receives his 3D printed door handles in the mail. They look awesome, and are exactly what he wanted!
2 Peli uses the different layers and references to adjust his design to the building volume, places the screws, subtracts the star shaped shaft and uses the tolerances provided.
3 Once he is happy with the model, he presses the upload button. and selects his 3ds file. His file is quite big, so he visits other websites while waiting for the upload. The progress bar keeps him updated on the status of the upload.
4 Once the model is uploaded, he selects the color of his choice - Old Silver- and confirms his order.
Tips & Tricks
1 PeLi has designed a set of door handles and would like to have a real life model of it. He downloads the i.materialise door handle kit.
3D printing technology by How Pro Metal technology works
3 The process is repeated until every layer is printed and the part is complete and ready to be removed.
14 1 A 3D CAD file is imported into the system software. The software slices the file into thin cross-sectional slices, which are fed to the 3D printer.
2 The printer creates the model one layer at a time by spreading a layer of metal powder and inkjet printing a binder in the crosssection of the part.
3D Printing
Ex One technology works by creating a 3D physical model directly from digital data, layer by layer, turning concepts and ideas into real, physical 3D models that you can hold, examine, and evaluate.
Forming Process
3D printing technology by
Print functional parts in hours directly from CAD. Metal parts are built in a layered fashion. Each layer is comprised of two materials added sequentially: Powdered Metal
Bound Metal
15
1 Print
2 New Layer
Binder is selectively dispensed using inkjet printing technology.
The build platform is lowered by a set increment..
5 Finishing
4 Repeat
3 Spread
Unbound metal is removed. Metal parts are thermally processed..
Steps 1-3 are repeated, until the part is built.
A new layer of powdered metal is spread.
The printhead selectively dispenses the resin in to the powdered metal. This temporarly builds the part until it can be sintered to the specified density.
3D Printing
recoater applies the powdered metal on the build platform.
Enjoy your 3D printed door handles ▪▪