Report & Reflection Rapid Prototyping

DBB222 RAPID PROTOTYPING

Manon Barendse s119828 Rachel van Berlo s118985 Koen Scheltenaar s137536 Roy Gevers s106744 March 2015

prologue Rapid Pro Fair - 3D Scan arm

For the Module DB222, Rapid Prototyping, we have gone through a design process in which we have been introduced to multiple Rapid Prototyping manufacturing techniques. We have (re)designed a non-functional product, using the 3D-printer, the Milling machine and the Laser cutter. To be able to use these techniques, we have acquired CAD-skills, mostly Solid Works.

We learned by doing (‘trial and error’): exploring, thinking and creating were often present in one and the same activity. In this report we will take you along all the stages of our process.

Next to the somewhat more practical side of this module, we have done additional research about the effects of Rapid Prototyping becoming a dominant manufacturing technique on Industrial Design, production and society. We have been to the Rapid Pro fair, in which we have deliberately asked experts about their view on the position of Rapid Prototyping in different contexts. We will share some of the interesting insights with you in our personal reflections, as well as in the chapter about the Rapid Pro fair.

Lastly, we have had the opportunity to make a silicon mold for a small object to learn how easy – and fun - it is to work with this technique. Silicon molding ‘opens up’ a range of new material choices, and therefore new prototype qualities. Very invigorating!

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INDEX Prologue - 1 Design case 4 - 28 Scanning 6 - 10 From Scan to Mesh 11 - 14 3D-make exploration 15 - 16 4 body designs 17 - 24 Final design 25 - 26 mechanical connection 27 cost calculation 28

Silicon Molding 29 - 30 Rapid Pro Fair 31- 34 Task division 35 Reflections 36 - 42 3

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THE WOODPECKER

3d-SCANNING

We initiated the module by choosing a context in which we could explore the various techniques at hand. Since we all had a preference and interest in scanning an existing object, we decided this would form the basis for our module work.

For the lesser spotted woodpecker, which we will further address to as ‘the bird’ we explored various 3D-scanners. The challenge was to find the optimum between a high quality scan, and a manageable size to further work with.

The object of our choice was a stuffed ‘lesser spotted woodpecker’ (kleine bonte specht).

The beautiful bird is only rarely seen in nature, let alone seen from up close.

The scanning devices that we tried: The Sense Hand Scanner The NextEngine 3D laser scanner FaroArm CMM (coordinate measuring machine) scanner These scanners all promised a very different fidelity. Where on the one hand, the sense is a user friendly consumer product, the FaroArm is used to verify product quality by performing 3D inspection.

Sense Hand Scanner

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the stuffed lesser spotted woodpecker

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3D-SCANNING

3d-SCANNING

the NextEngingeScan

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FaroArm Scan at the Rapid Pro Fair

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3D-SCANNING While scanning, it proved to be very difficult to fully scan a complex object such as our bird.

Although a bit unexpected, even the FaroArm was not able to catch all the feathers of the bird. What also complicated the scan was how the bird is mounted to the wood piece. With this knowledge, we can conclude that we chose a very complex starting point and that 3D-scanning techniques are still in a developing phase.

We continued working with the scan from the Sense Hand Scanner. However this scan had the least details, it’s surface was most completed.

Sense scan, 3 views

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from scan to mesh 0. Get rid of the ‘noise’ (in this case the piece of ‘wood’).

The choice for the scan to adjust was based on the fact that it had (coincidentally) scanned the body of the bird and the wood separately (two bodies in one scan) and the body of the bird was closed (no holes).

To be able to work in it with Solid Works, we had to transform the mesh into a body consisting out of surfaces. We have done this in Solid Works by activating the Scanto3D add-in and open our mesh as MESH file. This last thing is very important, because when opening the file as STL, Solid Works will only show the mesh as graphic (which is not adjustable to surfaces).

After carefully selecting and deleting the ‘wood-body’, the transformation of the bird could start!

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from scan to mesh 1. Surface struggle

2. Filling the errors

Using the Surface Wizard, Solid Works could calculate the total amount of surfaces that could be created out of the mesh. By adjusting the Surface Detail slide, this amount could be increased or decreased. The challenge was to have a good balance between the amount, size and (self-intersection) errors.

With ‘Surface fill’, the error holes could be filled with square shapes surface patches.

Sometimes more surfaces had to be deleted to make a smoother fill – DeleteFaces made this possible. In total, there were 13 ‘errors’ that had to be filled.

Before the creation of the surface body, Solid Works will ask if it would solve the errors within the body. By declining this, the program made the surface body with some holes in it (where the errors were), but this situation provided us more control about the end result. ... Sometimes Solid Works ‘solves’ problems in an unusual way, what sometimes makes it only worse.

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from scan to mesh 3. Making a Solid Mesh To connect every surface to each other, Surface Knit could be used. It combines one or more adjacent non-intersecting (luckily we fixed all these errors!) surfaces together. Within this tool, there was also the possibility to form a solid body, merge entities together and to set the Gap Control. This was the moment that our bird would change from a surface shell to a solid mesh – and ready to be adjusted!

from scan to mesh 4. Making of the egg with the surface of the bird on it.

To make a smooth connection between the stomach/belly and the body of the bird, we liked to have the same relief on sides that they touch each other (but then negative and positive of course).

To do so, we have made a ellipse shaped surface extrude from the sketch plane right through all of the bird’s body. After, the two bodies have been Combined, what resulted in a rough body with an ellipse contour.

By doing the same trick with this rough body – adding another body and combine – we could make one side smooth and round, while the other side could remain the relief. The last addition to the belly was a flat cut at the round side to be able to lay it down or hang it up.

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combining techniques

3D-MAKE EXPLORATION

The main requirement for the module was to combine two rapid pro techniques. Furthermore, we wanted to be able to develop ourselves individually. From the scan we decided to create four individual bodies, which enabled us to create our own designs.

By creating a 3D-make lasercut model, we explored yet another technique and program and were able to reflect upon the scan in real life. We found that the scan had not caught the birds belly appropriately. We therefore decided to create a second universal ‘belly’ . The belly will be created using a different technique, namely milling. By choosing a neutral wood piece as belly, we create an aesthetic contrast between the universal piece and allow ourselves the freedom to explore a wide variety of techniques, colors and materials individually.

3D-make model

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roy - body design

the boeing bird.

In this module, there was no societal changing design case, which was a great thing, because it could potentially interfere with purely learning about the opportunities and limitations of rapid prototyping and manufacturing materials and techniques. This also meant it was a great opportunity to do something weird and fun, like 3D scanning a dead bird to experience and learn about the limitations of current scanning techniques.

To stay in agreement with aforementioned weirdness and fun, I also gave the bird a little jetpack, which in turn sparked my interest in creating very small moving parts so that they can be 3D printed, hence the propeller in the back of the jetpack, which takes into account tolerances (every gap is 0.2 or bigger) and makes sure support material is easily removed through strategically placed holes and notches, that either stay out of sight or add to the overall aesthetic of the jetpacking bird.

After this, it was important for me to refresh my Solidworks skills, so I could help the rest of my team with their efforts, so I started to manipulate the surface of the complex bird scan, giving it a more streamlined beak and pilot goggles.

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manon - body design

The swirl bird - two little worms together make a bird.

0. Sketching

2. Make a swirl

tach these part to the two worms.

It is pretty difficult to make a design and planning to make in Solid Works, when you don’t know all the (im)possibilities of the program.

So what I have done is to sit together with a friend who has a lot of Solid Works knowledge to discuss what design would be realistic and full of learning moments.

To make the twist with the Surface Sweep feature, I had to sketch a line that would go vertically through the middle of the bird (path), and a horizontal line (profile).

6. Only swirling to the top

In the end we came up with a design in which we would twist a surface sweep through the length of the bird. This would theoretically result in two little birds that could be swirled into each other, forming a bird.

1. Surfaces – Planes; a different way of working

3. Through the bird After defining these lines as path and profile, the Surface Sweep will create a surface feature.

4. Making of the worms The two worms are still attached to each other; I used a Thickened Cut to split them. This cut is the space between the two worms and cannot be smaller than 0.02 mm (3D Printer requirements).

To sketch from planes and surfaces is a real change of sketch mindset. It asks for another approach of building/constructing objects. The 5. Tale/Feather problems Swirl design showed me quite well what the The only challenge left was that two little parts basics of this approach are. of the tail were ‘swept of’ the main bodies.

Jasper has helped me to make use of 3D Sketching, Surface fill and Surface Loft to at19

Having done all of this, I could send the bird as an STL file to Jasper and the 3D printer. We printed it three times as small to save time and costs.

The advantage of having a physical model is (logically) that you can try out if it works and if the real model also catches/reflects the character of the digital CAD-model. I found out that (also quite logically) one of the worms could only twist upwards, because otherwise it would break parts of the tail.

7. Mechanism To have a final version, we only have to add a construction mechanism to connect belly and bird.

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koen - body design

the bone bird .

For my personal design I decided for combining silicone casting and 3D printing. With 3D printing a bone structure will be printed. The bone structure will then be casted in Silicone resin to make a fully transparent body. It could be possible to 3D print the whole bird but there is currently no full transparent material available at the university for the 3D printer.

Costs would also be higher to fully print the bird with a 3D printer. The mould for casting the silicone will be made by milling the bird out of wood.

When starting to make the skeleton however I quickly noticed it was quite difficult to decide how to make something yourself, not following tutorials. There are always multiple ways to make something and a lot of tools to use.

Solidworks really requires some kind of ‘’3D thinking’’ that you can only train by practicing a lot.

Before starting to make the skeleton in Solidworks I decided to do multiple tutorials because I did not have any experience with Solidworks at all. In the end I made all introduction tutorials, all basic tutorials and 2 advanced tutorials about 3D sketching. This helped me get a basic understanding of all basic tools.

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Sketching the basic skeleton was not very difficult but it took me a while to make the skeleton look a bit organic. To achieve an organic look I ended up using the bend tool a lot, bending and twisting the bone structure of the bird.

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rachel - body design

the NAY SAYING BIRD

For my personal design, I made a ‘nay saying’ bird, which can rotate it’s head 360 degrees. I was able to calculate the space needed in the joint to let the head rotate freely. Furthermore I restricted all the degrees of rotation except for the rotation around the y-axis with a shape closed fastening in the body. With regular rapid-prototyping techniques, such an application is not possible, however with 3D-printing it is. To actually print the bird, I also included a small pipe that leads to the head to be able to clean the excess material.

To come to this design, I have explored various solidworks tutorials which especially focused on solid modeling. As a future exploration I appreciate the aesthetic of the varanoi grid. However this is aesthetically very interesting, it does not have a function and is quite a ‘shallow’ application.

cut through view mechanism

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final design We have chosen the swirl bird as final design to rapid protype because we collectively found that it is an aesthetically pleasing design and additionally it has a unique shape that can only be created with the 3D Printer.

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mechanical connetcion Our prototype will consist of two parts that can connect to each other. This means glue and a ‘’regular’’ press fit connection is not possible.

As explained by the assignor of the module, F. Delbressine, a lot of ID students often opt for press fit fastening while there is also another type of fastening that can be very useful. This type of fastening is fastened by force instead of form. A special characteristic of this type of fastening is that it needs a force that secures the connection. If this force disappears the parts can be taken apart.

cost calculation Another advantage of force closed fastening is that it is less sensitive for errors and tolerances. If one of the materials in a shape confined fastening expands or shrinks even only a little bit the connection won’t be optimal anymore. In the second image above, the three little dots on the green oval help make sure the oval will make a connection with the blue shape on least three points (3 points in case of a 3d shape). A disadvantage of the force closed fastening is that a force has to be provided. This can however be done by something as simple as gravity, magnets, or a small spring.

Because our prototype will be made from different materials and it has to be easy to take apart the choice for a force closed fastening has been made. For this connection we make use of magnets and the specific shape of the belly of our bird.

Costs Although we as students can use all facility’s (within reasonable use) for free, the making of our prototype would normally cost money.

To get a general idea about how much rapid prototyping costs we estimate the costs for making our prototype below.

The Objet 3D printer is a very high tech machine requiring expensive materials to print.

The CNC machine does not necessarily require very expensive materials but in itself is a complicated, expensive machine.

3d printing costs:

A regular press fit, shape confined fastening.

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A force closed fastening.

The total material cost will result in 143.36 US dollar, which is 136.37 euro with the current exchange rates (19/03/15).

Next to material costs the 3d printer will have to run for 9 hours and 55 minutes to make our prototype. Based on information provided by Chet Bangaru an advanced 3D printer machine like the Objet 350 costs 150 per hour. 150 euro’s are only the raw costs without much room for profits because the machine is very expensive. This adds up to 1487,50 euros for our prototype.

Total costs for the 3d printing, material costs and running costs included will add up to For the base material 285 grams of RDG525 is 1623,87 euros. needed which costs 1292 dollar for 3.6Kilos. In addition to this, 316 grams of support material Milling costs is needed which costs 468 dollar for 3.6 Kilos.

For milling the mill has to run for a total of 51 minutes to make our prototype. The material These prices are based on two order forms will not cost much, this can just be regular found online wood as long as its dry and not too hard. Our (http://files.goengineer.com/Stratasys/Objet_ prototype is small, for 30 euro’s we can defiConsumables_Order_Form_PDF.pdf , nitely find a suitable piece of wood. http://www.capinc.com/wp-content/uploads/2013/05/Objet-consumables-order-form. See for example: pdf ).

http://www.eiken-balken.com/ and http://www. eikenhoutbestellen.nl/sokkels.html.

Chet mentioned that usage of a CNC machine easily costs 80 euro’s per hour. Online it was difficult to find exact numbers on company websites because all prices were inquiry based.

Somebody on a forum mentioned that a common startup fee for a 3d mill is 100 euros while the price per milling hour is about 100 euro’s.

This is roughly in line with Chet’s estimation.

When going with the prices proposed by Chet our prototype will add up to 68 euro’s for our prototype.

Total costs for milling, material and running costs included will add up to 98 euros.

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silicon casting

silicon casting

Compared to injection moulding silicone casting is much and much cheaper in low order sizes. This is due to the fact that a mould for injection moulding is very expensive Silicone casting results in really high end look- (â‚Ź10.000+). Even for small simple prototypes.

Another advantage of silicone casting is that ing prototypes that are quite strong as well.

Silicone casting is great for making prototypes a prototype does not have to have tapered edges. While a mould for injection moulding is from order sizes of one till 20. More is possible but generally speaking a silicone mould made from metal, a silicone mould is flexible can only be used around 20 times. After this a and can thus be manipulated to free a casted new mould has to be made. Different materials prototype without tapered edges. The advanfor the end product can be used, from colour- tage of injection moulding is the fact that it becomes much more economical to use with ful rubbers to hard plastics. Making a silicone larger batch sizes. casted prototype usually takes a few days because of the (curing) processes that take place in the process of creating the mould and A disadvantage of silicone casting is that final cast. making a good mould can be quite difficult.

Replicating objects is simple but for creating an entirely new object you have to be creative by using for example clay, foam, or other rapid prototyping techniques like 3D printing, laser cutting or milling.

Silicone casting was a rapid prototyping technique explained and demonstrated during the module by Chet Bangaru.

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rapid pro fair On Wednesday, we went to the RapidPro in Veldhoven, where we visited some lectures from people from industrial backgrounds and home professional backgrounds. We also saw amazing things on the exhibitions, where new and existing applications for rapid prototyping ranged from healthcare, to automotive all the way to art.

Our main goal was to find an exhibitor who would demonstrate their 3D scanner with our stuffed woodpecker, and give us a copy of that scan we could use as a starting point for our further design efforts. There were some interesting 3D scanners available and exhibitors kind enough to scan the bird (most notably the people from FARO) but we quickly learned that scanning complex things, like feathered creatures, with the current and next generations of scanners is still a problem. We were shown, however, that work is being done in that field.

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rapid pro fair So in the end, we didn’t leave with a usable CAD file of a scanned bird, but we did left with knowledge about the status quo of 3D scanning and its use for rapid prototyping: where it is now being used to scan for instance the monocoque of a race car for measuring purposes, in the future, it can be used to replicate existing things using rapid prototyping and manufacturing.

ARBURG Plastic Freeforming - Daniel Hamburger This was the first lecture of the day and the first one I attended. To me, this industrial presentation sounded like a glorified sales pitch aimed at the business representatives in the audience. The plastic freeforming machine that was presented was interesting because it showed that there are many ways to approach additive manufacturing, and that the end of possibilities is far away. This particular technique was new to me, because it uses a process similar to injection molding, but instead of using a mold, it drops little droplets on a platform, making it much like some 3D printing techniques in that it can use many sorts of granulates to make one-off products quite cheaply.

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rapid pro fair How 3D printing can disrupt supply chains Bram de Zwart (3D Hubs) The speaker compared the fast disappearance of physical books and music (CD’s) in favor for digital versions to 3D printing taking over traditional manufacturing. As a lover of old books and traces of use in products and designs, I don’t agree that the disappearance of books, music and other things is a good thing.

The emergence of 3D printing (and other rapid prototyping techniques) on the other hand is a good thing. The speaker showed how things are produced today and told us that roughly 30% of manufactured goods are never sold.

On top of that, they are produced far away and have to travel a lot, which adds to the price and takes a toll on the environment.

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rapid pro fair With the techniques 3D printing network he showed, manufacturing is close by, quick and on demand, which is a great improvement. 3D Hubs, with their big network of people with a 3D printer at home, is taking steps to make sure everyone can get cheap products in small batches. This presentation left me somewhat worried about the quality of the things printed on people’s 3D printers, but the CEO of Atum3D, who also gave a presentation, reassured me, because he showed that a lot of work is being done to make rapidly manufactured products as trustworthy as the things we buy and use now.

Van Prototyping naar functioneel 3D printen Tristram Budel (Atum3D) The Atum 3D printers use Direct Light Processing (DLP) printing, which is the oldest standard for 3D printing and therefore the most developed one. It is also quite fast in comparison to other techniques. Their machines are open source and modular, so they can be altered to fit customers requirements. This is in line with a future where rapid prototyping gets used by many people to create their own highly customizable and one-off products.

More and more, rapid prototyped products get treated as consumer goods, so they need to withstand more rigorous testing. Material properties get analyzed, so that things like hardness, strength and wear can be predicted and guaranteed for different materials and rapid manufacturing techniques. This is another good step to making rapid prototyping a viable way to let the user make their own every-day products, cutting out many costly and environmentally unfriendly manufacturing steps.

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TASK DIVISION TEAM Roy 3D- scanning Body - belly connection Rapid Pro Fair summary Detailing bird

Koen 3D- scanning Calculation of costs Silicon mold summary Renders Mechanical Connections

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REFLECTION ROY Manon 3D- scanning Create workable mesh from scan Final design to be printed body Body-belly connection

Rachel 3D- scanning Scanning summary Flatten belly Report – lay-out

Before this module, I’ve always had a distaste for using rapid prototyping manufacturing techniques in the design process. My process benefits from hands-on prototyping, where trial and especially error lead to interesting new ideas and insights, so I dislike simply sending a CAD file to someone else or a machine, to do all the work. In short: I like making my own mistakes and learning from them right away, and I always felt many rapid prototyping machines kept me from doing so. A downside of not using these techniques, is that I could never really form an educated opinion against the use rapid prototyping in a design end. This is why I chose this module in the first place.

In this module, I learned when to use rapid prototyping and when not to use it. I now know that for me, the limitations of CAD software and the lack of real-time feedback on opportunities and errors (for the inexperienced user, it is difficult to see what will work before it comes out of the machine) make rapid prototyping not a viable idea generation tool and I would therefore still hesitate to use it in my process. However, at the end of an iteration, when an aesthetically pleasing and

realistically functioning prototype is needed, I certainly see the many benefits of rapid prototyping over toiling away in the workshop.

Furthermore, I now recognize the impact rapid prototyping techniques like 3D printing in a world where individually customizable, oneoff products are needed in third-world countries and wanted in the first-world. (respective examples being cheap prosthetic limbs and Fairphone 3d printed smartphone covers.) So instead of designing with rapid prototyping, I see interesting opportunities to design for rapid prototyping, where throughout the design process, the designer considers the way the product is manufactured, so that it can be easily and cheaply printed and/or customized by the user.

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REFLECTION MANON Within this Module (DB222) we got the opportunity to taste and try Rapid Prototyping for a whole week. We have gone through a design process in which we have been introduced to multiple Rapid Prototyping manufacturing techniques, and the accompanying software.

In other words, in my design process I perceive Rapid Prototyping as a tool for ‘fast track’ concept creation and validation.

To be able to do this creation and validation, it is crucial to understand the nature of the different CAD-programs. The available input I have joined this module to learn more about and the preferred output define heavily what kind of program should be used. For example, the possibilities of prototyping within our dewe made the decision to work with an organic partment and to gain a sense of understandbody (Woodpecker), a 3D hand scanner and ing regarding the role of Rapid Prototyping in the whole field of Industrial Design (and socie- Solid Works, what did not work out very well ty). Lastly, I would like to experience and learn because the features of all three combined how there different techniques could influence were a total mismatch. It is impossible to learn all CAD-programs, so next time I will have to my design practice and therefore my identity. make a choice, I will consult an expert and ask Overall, this module felt like some kind of if the program can do what I want. surprise box for me; a box that revealed how many different making possibilities I have in Personally, I have love/hate relationship with my design process. I believe that the more the fact that CAD and most of the Rapid Protoknowledge I have about these possibilities, typing techniques increasingly take in a bigger the bigger the change is that my prototypes role in design processes. As I have menare appropriate: fitting in or adapted to the tioned before, I love the fact that it provides context I envision. Because the result of the opportunities to do fast track high fidelity (proRapid Prototyping techniques look most of totype) testing. On the other hand, it requires the time quite realistic, it is the perfect tool to quickly create intermediate prototypes to test to sit behind a desk ‘excluded’ from the rest of interactions and functions of my concept (with the world – for me one of the less inspirational activities I can think of. the user).

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Rapid Prototyping will bring my concept faster into the world/in the context, but it also means that I have to spend less time within the world/ out of the context. For me, the perfect balance within my design practice will be conceptualizing in the real context, being able to quickly make it in CAD, use the Rapid Prototyping techniques and validate them. In this way, I don’t see CAD as an shaping process but more as an activity to digitalize (and of course realize) my concept.

Nevertheless, to optimally make use of Solid Works in its most efficient way, I have to remain practicing Solid Works on a regular basis until I have reached the top of the learning curve.

Building within CAD does have influence on a design, because it introduces (im)possibilities for manufacturing. I think it is has value when a designer has an understanding of the relationship between her concept and the manufacturing possibilities because it helps to remain control over the characteristics (in shape, appearance and function) of the concept – also in production. Within this module, working with Solid Works has already taught me how to think differently about shapes and constructions.

I envision for Rapid Prototyping is the biggest opportunity of Rapid Prototyping in creating shapes that could never be realized in traditional machines. This will enable designers and industries to innovate in concept (customizability), form and production.

This customizability will have huge effects on society. Not only sustainability and economic wise (I am thinking about things as plastic waste and CO2 pollution), but also on a personal level. For example 3D hope (http:// www.3dhope.com/) makes customizable 3D printed limbs for children that are actually affordable. During our 3D-scan session we have noticed that a lot can be improved in scanning, but if this is already possible, I can’t wait to see what the future will bring (… and what role I can play in it).

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REFLECTION KOEN For me the rapid prototyping module was a very instructive module. Before the module I felt like I knew much too little about production processes. In addition to this I had no experience at all with software like Solidworks while experience with solid works is often asked for in a lot of vacancies for industrial designers.

The module did not force us to create a specific concept but allowed us to experiment with all kind of production processes. During the week we explored all common higher end rapid prototyping techniques; silicon casting, lasercutting, milling, 3d printing and Solidworks. 3D printing is still heavily in development; this quickly becomes apparent when you visit a fair like RapidPro.

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The Rapid Pro Fair

Concerning me as a designer

Our visit to the RapidPro fair made me realise how new 3d printing actually is as a technique.

The term 3D printing does not sound new anymore but there is actually still an enormous amount of development going on in the area of 3D printing. Prices of the cutting edge machines are very high and the materials they use are not cheap either. In addition to this, there are multiple manufacturers who promise cutting edge performance but neglect to tell what their machines cannot do. Arburg for example is developing a 3D printing machine that can use regular granular plastics that only cost 2-3 euro per kilo. The machine seemed to be perfect until the audience asked some critical questions. It then quickly became clear the machine was not as flexible about material choices as presented. The same was the case with the 3D scanners; most of the scanners were not fool proof and had a lot of trouble with scanning the feathers of our stuffed woodpecker. For us as designers this means you have be very wary and try not to succumb to every sales pitch.

To me the most interesting at the fair was the presentation of 3D hubs (https://www.3dhubs. com/). One of the founders told how he started the company and how the vision of 3D hubs contributed to the rapid growth of the company. The goal of 3D hubs is to create one big network of 3D printers that can be addressed to everyone who does not have an own 3D printer. The network is now made up of 13656 3D printers, which means there is always a 3D printer near. With a network of 3D printers this big, 3D hubs is able to disrupt current manufacturing processes.

In the future companies could decide to make a product as soon as there is a demand, instead of offshoring production of 10.000 products to China and hoping they will sell after they are made. I believe that this kind of production will be entirely possible if 3D printing keeps developing as rapidly as it does.

Eliminating shipping costs, eliminating unnecessarily high stocks and enabling customisation of every product. All while being more environmentally friendly. 3D printing really is a promising technique that can change the world.

Right now, and possibly even more in the future, rapid prototyping will allow me as a designer to quickly make low and high-end prototypes. Allowing me to do user tests or just allowing me to experience the product hands on. During the module I learned the advantages and weaknesses of four common rapid prototyping techniques; silicone casting, milling, lasercutting and 3D printing. Right now rapid prototyping is still quite expensive for me as a student. Luckily new innovations like the BoXZY (https://www.kickstarter.com/ projects/boxzy/boxzy-rapid-change-fablabmill-laser-engraver-3d-p) are making rapid prototyping increasingly more practical and affordable. At the moment rapid prototyping already allows for disruptive business models like 3d Hubs is proving.

Concluding I can say this module allowed me to get a better understanding of regular manufacturing processes, rapid prototyping processes and how I can use them in my work.

Working in Solidworks was new for me but I am confident that I can use it for my projects if I keep practising, which I will definitely do.

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REFLECTION RACHEL In the past I have particularly focused on what only is the beginning of a design process, from idea to prototyped concept. Although I am still novice in Solidworks the more skilled I become, the more I will be able to prolong my influence on the eventual product. Solidworks is quite a technical program and proved to be most valuable to create a ‘set’ sketch in I have learned that for a designer various techniques are available to create high fidelity 3D. Whereas you do have to make a creative prototypes considerably fast. In respect to my consensus, you are able to deliver realistic knowledge of the existing techniques and ma- and technical requirements to the engineers. terials before I entered this module, I felt quite Through Solidworks one can have a more vallimited. In many of my prototypes, I recognized uable discussion with the engineers who will enable and produce your concept. Solidworks the typical materials and techniques that are for me is an embodiment of the dialogue beavailable in the architecture workplace. tween concept and product This realization offered an intrinsic reflection By learning Solidworks, I have discovered an entirely new way of communicating my ideas. on what kind of designer I am and want to be.

I think I am a very conceptual and explorative I think that the techniques that were offered interaction designer. I have not yet found a are especially valuable to prototype existing way to implement my concepts in the socieconcepts. The limitations of the 3D-scanning, ty of tomorrow, rather in the society of a few printing and milling (still) lie in the fact that years from now. reflection in action on for instance the interaction is almost impossible. Working behind a computer in combination with the time needed to create and print the model leave little space for explorations.

I enrolled for this module to invest in my design vocabulary by exploring various rapid pro techniques. By reinforcing the dialogue between analyzing and synthesizing, as a designer I can strengthen both conceptualizing and communicating my ideas.

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At the Rapid Pro fair I encountered a company called PEZY. PEZY is a design studio that rapid prototypes concepts for various companies.

This means that they are positioned on the very beginning of the design process and constantly invest in the dialogue between concept and product. For me this company is an example of how I could contribute as a designer to the society on a shorter term. I have the freedom to explore concepts and can challenge myself to implement them in realistic current-day products.

3D-printing For me 3D printing is a technology that embodies a paradigm shift. However it is very clear to see that it’s still in a development stage, it offers a societal relevant change in terms of production processes. However at first, I was skeptical regarding the positive environmental consequences of the rather chemical plastics that can now be printed, I can see that the consequences of 3D printing in the future can be enormous. As 3D-hubs sketched very bluntly at the fair, it is almost ridiculous how we are currently producing our common-day products. It was quite an eye-opener to see the entire production and logistic chain behind a single plastic bowl and the vastness of its polluting effect.

3D-printing will reduce waste, storage, transportation and pollution dramatically.

3D printing also can be implemented in the current paradigm of production, whereas it is a great way to create rapid prototypes to eliminate any major flaws in the design of for instance an injection mold.

For me as a rather conceptual designer, these new materials and techniques will open up an entirely new dialogue between form (material), function and interaction. Interactions can be explored with the new techniques that were never available before which might prove to be extremely enriching.

In regard to the effect 3D printers can have in developing countries, I am still dubious. This technology will offer the very poorest people to print what are currently very costly products, however we must not forget that the current production paradigm provides an income for these exact same people.

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