TCT Europe 23.2 by TCT Magazine

APRIL 2015 www.tctmagazine.com

A NEW ERA OF MANUFACTURING 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

APRIL 2015

ISSN 1751-0333

EDITORIAL GROUP EDITOR

James Woodcock james@rapidnews.com ASSOCIATE EDITOR

Daniel O’Connor daniel.oconnor@rapidnews.com EDITORIAL ASSISTANT

Laura Griffiths laura.griffiths@rapidnews.com NEWSDESK

+44 (0) 1244 680222 REGULAR CONTRIBUTORS

Todd Grimm tgrimm@tagrimm.com

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Carol Hardy carol@rapidnews.com NEW BUSINESS DEVELOPMENT

Jonathan Priest jonathan.priest@rapidnews.com

PRODUCTION Sam Hamlyn Tracey Roberts

MANAGEMENT C.O.O. / PUBLISHER

Duncan Wood C.E.O.

Mark Blezard

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The shrinking world

he inaugural TCT Asia + Personalize took place in Shanghai this March and surpassed even our expectations. As relative newcomers to the Chinese market (which is why our fabulous local partners, VNU Exhibitions Asia, were so important) we’d read conflicting reports in our research. Was the wider Asia market really 10 years behind the West? Or is it true that behind closed doors research beyond the dreams of Western science is underway? Probably somewhere between the two, which is to say exactly where we are, is the answer. Roughly. Certainly the knowledge, ambition and money are all in place for the local Chinese market to really push on with additive technologies at all levels. The TCT Inspired Minds education initiative, generously supported by TierTime and G. P. Tromans Associates proved that the next generation of talented designers, engineers and artists is there and familiar with 3D technologies. On the show floor companies familiar to anyone in the US and Europe were side-by-side with

organisations rarely — to date — seen beyond their home market. Given the size of the home market, that’s hardly surprising but we are already seeing Chinese companies become exporters of both existing and new technologies in the space. It’s a fascinating time in a fascinating market and the roughly 9,000 attendees were keen to see everything from aerospace components to a 3D printed wedding dress. In this issue you can find out more of the tools that are being used and being exported by China, read Dan O’Connor’s interview with splashmaking Carbon3D, read Laura’s indepth report on colour 3D printing and hear more from me with a travelogue from the desert.

On the show floor companies familiar to anyone in the US and Europe were side-by-side with organisations rarely — to date — seen beyond their home market.

Keep on creating,

Jim Woodcock Group Editor & Conference Director

For a new era of manufacturing Applying over 40 years of cross-sector engineering Renishaw’s new metal powder bed fusion additive manufacturing system for industrial production features increased emphasis on automation and reduced operator interaction. Find out more at www.renishaw.com/additive

www.renishaw.com Renishaw's EVO project Strip ad TCT 0315.indd 1

20/03/2015 12:14:16 APRIL 2015 www.tctmagazine.com 05

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

FROM THE EDITOR

LEAD NEWS

GETTING HANDS ON IN A NEW ERA OF MANUFACTURING

Our cover story for this issue comes from the Renishaw stable; the British manufacturing firm talk the challenges of early adoption and the solutions they are finding through building partnerships.

FEATURES

NEWS

A roundup of all the latest news from the last month, for more on each of the story visit www.tctmagazine.com

TCT ASIA CONFERENCE REVIEW The first TCT Asia Summit featured a stellar speaking line-up from both east and west; Jim Woodcock reviews the simultaneously translated sessions.

TCT ASIA AND INSPIRED MINDS A look at the inaugural TCT Asia show floor, the Inspired Minds Competition and its eventual winner, who travelled over 2,000km just to take part.

FORMNEXT POWERED BY TCT

TCT joins forces with Mesago Messe Frankfurt to run what is sure to be the foremost additive technologies event in Mainland Europe.

IF IT AIN’T BROKE… REMANUFACTURE IT

Laura speaks to DM3D’s Chief Operating Officer to see how the company uses Direct Metal Deposition Technology to refurbish expensive parts.

PUTTING AN HISTORIC WATERFRONT TO WORK ONCE AGAIN Jim travelled to Autodesk Pier 9 to see how the industry titan are reviving San Franciso’s defunct waterfront.

MATERIALISE WORLD CONFERENCE

The Belgian company are celebrating their 25th anniversary with the Materialise World Conference in Brussels.

INTERVIEW WITH OMER KRIEGER

YOU WINSUN, YOU WIN SOME

At TCT Asia Dan took a closer look at the 3D printing construction company, who printed 10 homes in 24 hours in 2014.

Laura speaks to Materialise Senior Business Development Manager Dave Flynn on streamlining the AM process.

AMUG PREVIEW

This April sees one of the industry’s favourite events descend on the Jacksonville Hyatt Regency; we take a look at what’s coming up at the 2015 Additive Manufacturing Users Group.

COLOUR: 3D PRINTING’S GREY AREA

55 65

An in depth look at the hot topic of colour in 3D printing featuring players from Adobe, Faberdashery, IPF, Shapeways, Mcor and Spectrom.

RAPID 2015

Like Materialise the RAPID event in Long Beach, California is celebrating its 25th anniversary this year with its biggest ever show.

CARBON 3D

Dan takes a look at the newest company making waves in the 3D printing industry and asks if this is 3D printing’s judgement day?

CENTRAL SCANNING

Dan goes through the doors at one of Europe’s finest 3D scanning companies and takes a look at some of their more unusual case studies.

RESTORING THE BEAUTY TO A VINTAGE PORSCHE

As part of our reverse engineering focus we take a look at how 3D technologies are being put to use in the restoration of classic vehicles.

A report from the University of Exeter’s CALM facility on an event that brought thought leaders of the technology together in order to discuss this key industry requirement. processes too.

The newly appointed General Manager of Stratasys Asia Pacific and Japan talks to Laura on why Asia is 3D Printing’s fastest growing market.

EVERY MACHINE IS AN ISLAND

THE FUTURE OF POLYMERIC AM: HIGH TEMPERATURE

3D PRINTED GUIDES

The University of Sheffield have succeeded in using a 3D printed guide to help damaged nerves.

REGULARS

05 66 74

FROM THE EDITORS DESK GUEST COLUMN TODD GRIMM COLUMN

APRIL 2015 www.tctmagazine.com

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

CONTENTS

TCT | APRIL 2015 EDITION

LEAD NEWS: RENISHAW

GETTING HANDS ON

IN A NEW ERA OF MANUFACTURING

RIGHT: The fingers of fate

WOR DS : R O B I N W E S T O N , R E N I S HAW

Last time Renishaw put pen to paper for our annual spot on the front cover of TCT we were fresh from the reveal of the Empire MX6-R, the world’s first 3D printed metal bike frame and we’re still reeling from the astonishing global coverage on social media and in the specialist cycling and 3D print trade press. It’s now recorded in the Guinness World Records and still turns heads wherever it goes, especially those of young children who we are aiming to inspire to become the next generation of engineers.

APRIL 2015 www.tctmagazine.com

’d like to say it was all planned with precision and that we had a media strategy in place to profile the activities around the bike but initially that’s some way from the truth; and so it goes with AM in general. The scale and pace of media and market interest in AM is relentless and the industry still has some way to go before the day-to-day reality of AM catches up with the sometimes ridiculously high levels of expectations created by the general media, and it has to be said some within the industry itself. It is clear to me and other serious heads within the industry that we are still a way from AM being accepted as a standard production tool in the manufacturing armoury. Most current users and innovators in AM would be seen very much as ‘early adopters’, prepared to take calculated risks to get in early and capitalise on the potential opportunities and competitive advantages that could be offered by this ‘new’ technology. THE CHALLENGES OF EARLY ADOPTION Being first into any new technology involves a range of challenges; from funding the investment with the uncertainties over payback, through to finding the necessary skilled staff to help deliver on that investment. The key for most businesses is however, a full up-front understanding of those areas of uncertainty so that they can be fully managed through careful mitigation strategies. With metal additive manufacturing the barriers to entry can be high and unlike for example an investment in five-axis machine tools, most manufacturers simply do not have any experience of the core technology on which to base their calculations and implementation strategy. Key issues that we also see, and which are completely understandable given the limited availability of skilled people within the sector, is the need for manufacturers to acquire a better

understanding of which of their components are truly suitable for AM, and a willingness to design specifically for the AM process, rather than expect that additively manufacturing an existing design will magically bring all the benefits of the process. SO WHAT IS THE ANSWER TO THESE VARIOUS CHALLENGES? Knowledge about metal based additive manufacturing isn’t widely available through traditional channels, although some universities and colleges are now taking up this mantle. Skills are generally in short supply on the open labour market and, like it or not, many of those with the required skills have been trained by system vendors or current system users. This is an unsustainable labour ecosystem and will not support the growth and adoption of AM technologies at even a fraction of the predicted market growth forecasts. Part of Renishaw’s responsibility, and that of other suppliers in the sector, is to foster these skills in our own staff and share the knowledge with our current and potential new users. This isn’t something new to us as we have been sharing our applications expertise with our various customer groups for many years with all of our measurement products, whether used for machine tools, co-ordinate measuring machines, motion control or even brain surgery. We recognise that for organisations to consider AM as part of their product development and manufacturing strategies they must own and understand their own processes. The initial steps to achieving this usually mean gaining access to the technology and evaluating the true potential of AM, before making their first purchase. This can be done in a number of ways already - through collaboration with some of the institutes operating the technology, possibly via a



RIGHT: Cranio-facial placement guides

funded project with other organisations, or alternatively by engaging with a service provider to get parts made. Both are valid and each has its pluses and minuses. At Renishaw we have a clear goal of offering opportunities to experience our technology prior to purchase and also to gain an understanding of the wider considerations of ownership. Delivering this effectively is requiring a large investment to create a global network of Additive Manufacturing Solutions Centres, including a UK centre which will be housed within our new 90,000 sq ft site (9,000 m²) in Stone, Staffordshire, UK. Last August the UK’s Deputy Prime Minister, Nick Clegg, also announced that we will be opening a centre at our large facility in Pune, India, recognising the large potential for AM in this growth market. These new centres will provide a working space where new and current users can buy time on dedicated machines, with as much or as little help from our staff as agreed. This will allow our customers to first develop an understanding and quantify the usefulness of the technology, before moving on to issues such as how to integrate with peripheral activities, manage health and safety, and how to develop practices and procedures which are pertinent to their specific manufacturing challenges. This will ensure that when a decision is made whether to invest in AM, that most, if not all of the issues around the technology will have been understood and strategies agreed within the customer’s organisation.

TOP

LEFT: Titanium manifold



CENTRE: Renishaw EVO Project

BOTTOM:

Renishaw Additive Manufacturing

Last August the UK’s Deputy Prime Minister, Nick Clegg, also announced that we will be opening a centre at our large facility in Pune, India, recognising the large potential for AM in this growth market

BUILDING PARTNERSHIPS This is the starting point for a partnership approach that we know delivers results based on the real-life experiences that we have had with a number of major manufacturers, who now count additive manufacturing as one of the cornerstones of their future manufacturing strategies. It’s now four years since Renishaw entered the AM market as a system supplier; a move which did leave a few in the industry scratching their heads about our commitment to a sector in which we apparently had little knowledge. However, fundamentally Renishaw is a manufacturing company and we already knew the potential for AM to become a complementary production tool, plus we had been using additive systems, both metal and polymers for over a decade, both for prototyping and as part of a real business supplying dental laboratories across Europe with many thousands of metal tooth structures every month. As a business we produce hundreds of thousands of precision products every year that our users depend upon to meet their throughput, cost and quality objectives. We use AM in our own processes and in the services we provide to our own customers, so we therefore have a vested interest in the successful adoption of AM on multiple levels, just as we do for the probe and sensing technologies that we supply, and which we use to produce those same products on our own CNC machine tools. Those that know Renishaw and the way that we invest for the long term, not just financially, but by developing innovative and transformational technologies, recognise that what’s been revealed so far is really just the tip of the iceberg. This is a long journey and one in which we will not shirk from offering long term support to manufacturers around the world that want to work with us.  For more information visit www.renishaw.com/additive

APRIL 2015 www.tctmagazine.com

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT



LEFT: TAM250 build plate inside machine

We chose the Stratasys uPrint machine for functional prototype testing. This FDM technique allows us to print plastic parts & attach motors.

Watch the video

or call

tiny.cc/drone-tct

+44 (0)1908 904368

to see how a professional 3D printer allows truly functional prototypes to take flight at Aerialtronics:

to discuss your application with our experts:

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

ROLLS-ROYCE SET TO FLY WORLD’S LARGEST 3D PRINTED AEROSPACE PART 

BOEING FILES PATENT FOR 3D PRINTING AIRCRAFT PARTS



Boeing has filed a patent to support the 3D printing of replacement parts for aircraft. Boeing’s patent proposes that parts can be manufactured by downloading a file from a database and then 3D printed within hours to reduce lead times. The aerospace giant is already implementing 3D printing on a large scale with around 20,000 non-metallic parts currently being used on 10 different aircraft production programmes. 

Rolls-Royce is set to flight test an engine featuring the world’s largest 3D printed aerospace component. The Trent XWB-97 engine comprises a 1.5m diameter titanium structure with 0.5m-thick front bearing housing containing 48 aerofoils manufactured using Arcam’s additive manufacturing technology. Initial research on the process and material behaviour was carried out at the University of Sheffield and then sent for piloting at the Manufacturing Technology Centre in Coventry. 

NEWS

This month developments from Rolls Royce and Boeing took flight in the industrial space alongside new machine and software announcements whilst on the consumer side, a new 3D printing license is set to tackle the ever-pertinent issue of IP.

FOR THESE STORIES IN FULL CLICK TO WWW.TCTMAGAZINE.COM

MATERIALISE INTRODUCES THE RENISHAW BUILD PROCESSOR 

EXONE UNVEILS ITS LARGEST 3D PRINTING SYSTEM YET ExOne has announced the largest addition to its 3D printing system. Allowing customers to engage with indirect printing technology for industrial series production, the machine deploys ExOne’s binder jetting technology to selectively dispense microdroplets of specially engineered binder into very thin layers of powdered material. Exerial is unique as it contains multiple industrial stations that allow for continuous production and simultaneous processing. 

Materialise has partnered up with global engineering company Renishaw to deliver the Renishaw Build Processor, the latest in a growing line of tailored 3D printing build processors. Users of the Renishaw AM250 system will have access to a large suite of functions enabling unprecedented control with more support structure generators and powerful build file generation algorithms to improve print outcomes. Find out more in our Process Management Software feature. 

YOUMAGINE ANNOUNCES FIRST AND ONLY OPEN SOURCE LICENSE FOR 3D PRINTING Online 3D printing community YouMagine has introduced the 3DPL, a license for 3D Printed items, designed to allow people to create, improve and share more efficiently. The 3DPL is the first and only license for 3D printed objects and intends to safeguard content creation and develop guidelines that ensure intellectual property disputes are resolved. The license is defined by REMIX, NON COM A REMIX and REMIX MELT REMIX which determine the openness and protection of work. 

VOXEL8 SECURES INVESTMENT FOR ELECTRONICS 3D PRINTER



Harvard-born company Voxel8 has secured a strategic investment and technology development deal for its multi-material electronics printer. The investment comes from In-Q-Tel, a not-for-profit, strategic investment firm that identifies innovative technology solutions to support the missions of the U.S. Intelligence Community. Voxel8’s debut product is the world’s first 3D electronics printer allowing designers and engineers to rapidly create circuits and electronic devices on a desktop machine.  APRIL 2015 www.tctmagazine.com

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Stop by our demo suite at AMUG (Additive Manufacturing Users Group) to discover the latest innovations from Somos速 Materials. With a portfolio consisting of a wide variety of category-leading materials, Somos速 helps you unlock your creative potential allowing you to push the boundaries of projects and generate new applications. Visit Somos速 online at www.dsm.com/somos

VISIT OUR DEMO SUITE

TCT ASIA CONFERENCE 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

TCT ASIA CONFERENCE REVIEW I

that TCT runs its 20th edition of the UK show and conference we’ve seen more changes to the portfolio than ever before, with the inaugural formnext powered by TCT scheduled for November in Frankfurt and the first edition of TCT + Personalize Asia which took place in March in Shanghai. The TCT Asia summit, as the on-site conference was presented, featured for the first time in TCT’s history a bilingual line up with both English and Mandarin speakers sharing the stages. The audience was kept informed by simultaneous translation in all sessions — something those of us tasked with introducing speakers were most thankful for! TCT’s conferences across the globe are a place for delegates to hear from the leading lights of the industry, whether they are the makers of the equipment they use, other users of 3D technologies, or consultants monitoring the state of the industry. The TCT Asia Summit was no different, with a broad selection of speakers that covered everything from the future of the technology to training and case studies. n the year

AM IN CHINA Depending on who you speak with, you may be given the impression that 3D technologies for product development, engineering and manufacturing are still underutilised in China, and the biggest benefits will be for Western economies. The first speaker on stage at the TCT Asia Summit, Dr. Yang Haicheng, Chief Engineer, China Aerospace Science and Technology Corporation (CASTC), immediately dispelled those theories. For starters CASTC were responsible for developing an additive manufacturing system that utilises both fibre and CO2 lasers and is being developed to be used in space — no lack of ambition here! Day one continued with the executive keynotes. The first of which came from the CEO of MakerBot, Jonathan Jaglom, who delivered his inaugural presentation in the position. Despite being only 12 days into his current tenure at the time, Jaglom is a 10-year veteran of the 3D printing industry and spoke eloquently and with deep understanding of the market and the Makerbot mission. Each new slide was greeted with cacophony of synthesised shutter sounds as smartphones and tablets were raised aloft.

W O R D S : J I M W O O D C OCK

Aerospace is big business for AM and nowhere more so than China



ABOVE: New MakerBot CEO Jonathan Jaglom makes his first presentation in the role, to a rapt audience



BELOW: Omer Krieger from Stratasys takes to the stage on the second day

Next on stage was someone who is indelibly linked with the position he holds, Materialise’s CEO Wilfried Vancraen. Vancraen brought his now signature nonsense-free analysis to proceedings, calling out some of the trends he sees in the industry that are at best fads and at worst landfill-fodder. With over two decades at the helm of one of the broadest companies in the market Vancraen is entitled to an opinion or two, especially when they’re grounded in logic and common sense. His presentation on ‘Killer Apps’ was inspired by his talk for TCT at International CES in Las Vegas. The third and final day one executive speaker, Mr Guo Ge of Tiertime, added a local opinion to the mix but with the same positive message for the future of 3D printing globally. Tiertime had a significant presence at the show and were sponsors of the Inspired Minds education initiatives that have been running throughout the months prior to the show. The company is well poised in both its local and international markets with an interesting lineup of machines and some robust plans for continued development. The afternoon saw two conference streams running at capacity covering aerospace and moulding & automotive applications of AM. In the aerospace stream speakers from academic institutions, including Wang Lianfeng ,Director of AM Center, 8th Research Institute of CASC and Huang Weidong, Professor, Northwestern Polytechnical University were joined by speakers from the industry including SLM Solutions’ Stefan Ritt and Henry Peng from the GE Global Research Center. Aerospace is big business for AM and nowhere more so than in China. With both state and private industry set on creating a domestic aerospace industry to rival anything from the West, the opportunities to integrate AM into the relevant supply chains at a relatively early stage are compelling to say the least. The moulding & automotive track saw Graham Tromans — a regular at TCT Show in the UK — return not only to a TCT event but to the stage in China.

››

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TCT ASIA CONFERENCE 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

BELOW Speakers hailed from across the globe, with

simultaneous translation keeping everyone on track

Anyone who has been to China in the last 30 years will know that building and architecture are big opportunities

Graham has become deeply involved in the Chinese AM industry and is advising a number of companies and government initiatives on the development and implementation of the technologies. Joining Graham were speakers from Beijing University of Chemical Technology, Renishaw, and Volkswagen with information tailored to the local market for as well as case studies of existing successful deployments. DAY TWO Day two followed the same pattern as day one and once again saw the sessions fill up. Professor Xu Zhilei of the China Academy of Engineering Physics began proceedings with a fascinating talk informed by his 40 years at the vanguard of the Chinese design community. Prof. Xu is adamant that 3D printing will have a significant role in the design community in China and is of the opinion that even more needs to be done by academic institutions to increase uptake of the technologies by students. The first of the executive keynotes was another change to the published schedule thanks to the change of personnel at Makerbot, with Stratasys’ new GM of the APJ region Omer Krieger taking the stage. Omer is another relative veteran of the industry and like Jonathan Jaglom started his career at Objet Geometries. Omer delivered a well received talk that focused on the role 3D printing could have on the wider manufacturing world. Dr. Xu Xiaoshu was next with some insight that crosses the East-West divide. Dr. Xu is an AMUG Dinosaur winner for SLS technology (one of only around 10) and worked at DTM, 3D

Systems and Solid Concepts before founding Hunan Farsoon in 2009. His unrivaled knowledge of sintering technology and the global markets it is used in produced an engaging talk on the power of AM for inspiring designers across all fields. From the predominantly monochrome world of SLS we moved to the full-colour world with Dr. Conor MacCormack. Colour is an increasingly important component in the 3D printing world in both consumer and professional applications. Dr. MacCormack explained the methods for achieving full-colour 3D prints and the measures that can be taken to ensure repeatability and consistency. The final executive speaker was Cameron Moore of 3D Systems Quickparts with an overview of the services available in the wider Asia market and some of the trends therein. There are a huge number of service providers in China, many dedicated to providing service to global, specifically Western, developers and manufacturers. The expansion of companies providing services into mainland China marks an interesting opportunity moving forward. The second day’s afternoon stream focused on two quite distinct but equally different application sectors: medical & dental; creative & design. The medical stream was complemented by Materialise’s own ‘standing room only’ biomedical conference held concurrently at the event. Perhaps reflecting the impressively buoyant state of the medical research arena in China at the moment the medical stream was the only session with an entirely local speaker line up including specialists from, Shanghai 9th People Hospital, the Chinese University of Hong Kong and the Peking University Third Hospital. Bone repair and implants — as two of the most currently applicable advances — were high on the agenda with a majority of speakers in both

medical and dental sectors either focusing on or discussing the current options. The creative stream, hosted in association with Shanghai Design Week, saw UL’s Paul Bates bravely step onto stage (to fill in for the sadly unavailable Jason Lopes) at very short notice. Thankfully Paul is a consummate professional and has significant experience in the AM world and delivered insights on the need for training for the new AM paradigm and some of the options available to those looking to take advantage of the technologies. Second up was Reebok’s Gary Rabinovitz with a look at the ways AM is being implemented in Reebok generally and specifically in the CheckLight project. Following a panel session Zhao Huaying from Shanghai Xian Dai Architecture & Consulting Co., Ltd explored some of the opportunities and challenges within architecture and building and where AM fits. Anyone who has been to China in the last 30 years will know that building and architecture are big opportunites. The final speaker was the ‘architect’ of perhaps the biggest story of TCT Asia — Steven Ma from Xuberence, designer and maker of the ‘3D printed wedding dress’ which was reported widely in the mainstream press globally. Steven’s design background and understanding of the abilities and limitations of AM has lead to the creation of some truly impressive pieces. CONCLUSION Opportunity abounds in China and the wider Asia market, signified by the thirst for knowledge from the attendees at this first TCT Asia event. Across every sector and industry investment towards a greater understanding and implementation of additive technologies is pouring in — join us next year and see for yourself!  APRIL 2015 www.tctmagazine.com

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TCT ASIA SHOW FLOOR 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

THE FIRST TCT ASIA SHOW FLOOR

here’s about 9,200km between the Birmingham NEC and the Shanghai Convention & Exhibition Center of International Sourcing, yet with the TCT branding in place, players like Stratasys, Materialise, EOS, SLM Solutions and Renishaw building their booths on the expo floor, the two almost felt interchangeable. TCT Asia was the first fully TCT branded event outside of the UK and although the brand has had success in sponsoring the 3D Printing Marketplace at International CES in the US, hosting a TCT only event in a nonEnglish speaking country was somewhat unchartered territory. It is only natural for an event organiser to feel nerves before the doors open, especially for a maiden voyage like this, but those nerves quickly turned into amazement as over 9,000 people crammed into the hall in just three days. The thousands had flocked to see the latest in greatest in 3D printing including; machine launches from Stratasys and Prismlabs; filament being produced directly on the show floor by Nanjing GSMach Extrusion Equipment Ltd; food 3D printing from XYZ Printing; some amazing 3D prints like THAT 3D printed wedding dress; and do the very thing that underpins all TCT events – business. It is testament to our partners VNU Exhibitions that TCT Asia was no imitation of a TCT Show, it was a TCT Show. 

Inspired Minds Competition Draws Students from Across China

CT Magazine + Personalize and VNU Exhibitions Asia were proud to host Inspired Minds at the inaugural TCT + Personalize Asia. The programme, which was sponsored by Tiertime in association with G.P. Tromans Associates, encouraged students to create an entirely new product that used the benefits of 3D printing to its full capacity. The two-day programme was kicked off with an inspirational talk to the competitors by esteemed 3D Printing consultant Graham Tromans, a man who has been an incredible influence on TCT’s dedication to education. Such is Graham’s impact on education in the industry and on Inspired Minds that the top prize was named The Tr o m a n s Trophy.

Following on from Graham’s talk the students then, with the help of experts from Tiertime, set about 3D printing their ideas on the newly launched Up Box. With three prizes up for grabs students from across China have been working on their entries since September 2014. TCT Group Editor, who was on hand to dish out the top award, said: “Part of TCT’s mission is to educate people at all levels from primary education through to people already in manufacturing. As the technologies behind 3D printing continues to develop they will become increasingly important for all economies, both in the east and west. We hope all entrants to Inspired Minds have learned something of value from the experience and that they choose to develop those skills in the future.” The winning entry was designed by a student of Southwest University of Science and Technology in Mianyang – some 2,000km from Shanghai. His design ‘Magic Tribal’ – a moving part, folding mobile phone base – was printed and post-processed on site during the first two days of TCT Asia. 

LEFT: TCT Group Editor, Jim Woodcock presents the first prize to the wining student

APRIL 2015 www.tctmagazine.com

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

LEFT: Queues gather before the TCT Asia show doors were opened



BELOW LEFT: Fried Vancraen delivers another inspirational keynote

BELOW LEFT: From

BELOW RIGHT:

LEFT: The Stratasys

ABOVE: The eventual winner of the Inspired Minds programme

desktop 3D printers to industrial metrology TCT Asia represented the whole spectrum of this industry

Jonathan Jaglom’s first public talk since becoming MakerBot CEO



BELOW RIGHT: Visitirs flocked to see the latest and greatest of 3D Printing over three days



stand was one of many that was difficult to access because of the sheer numbers at TCT Asia

BELOW: The keynote

sessions play to a packed auditorium

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APRIL 2015 www.tctmagazine.com

TCT ASIA GALLERY 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT



BELOW: One of the major talking points at the show was the 3D Printed wedding dress from Xuberance

APRIL 2015 www.tctmagazine.com

019

FORMNEXT PREVIEW

formnext powered by TCT is open for business and we’d love to hear from you. Whether you’d be travelling 10,000 miles or 10 to visit it’s important that you get the most from the event — we appreciate that taking time out of busy schedules has to generate return, and we want to ensure you get that. If you have thoughts, ideas or comments please email James Woodcock on james@rapidnews.com or call 0044 1244 680222.

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

Introducing formnext

TCT has joined forces with Mesago Messe Frankfurt to run an event for additive technologies in mainland Europe. Here’s how, why and what to expect.

GET PHYSICAL Live events remain one of the best ways to learn about additive technologies, the impacts they’re having and how others are harnessing their power. TCT has produced the annual TCT Show + Personalize in the UK (albeit with a couple of different names) since 1996 and as such has been helping to showcase the power of additive technologies for longer than most. When the opportunity arose to apply our decades of collective know-how to a show in mainland Europe the TCT team jumped at the chance. By combining our understanding of the technologies and Mesago Messe Frankfurt’s unrivalled expertise in executing successful events in Germany, as a partnership we believe that formnext powered by TCT will become the international event for anyone interested in modern design, prototyping and manufacturing technologies.

THE ESTABLISHED AND THE NEW formnext powered by TCT mixes the best established practices with some much needed new ideas. Located in Hall 3 of the Messe Frankfurt many visitors will be familiar with the wider travel logistics but will be — we hope — thrilled by the new venue. Hall 3 represents one of the bestdesigned and modern show halls on the planet and will bring to formnext powered by TCT a completely different feel to other large events. The timing is familiar too with formnext powered by TCT being held in November, but again improvements are already tangible with the dates moved away from the US Thanksgiving holiday to 17th–20th of November. Shows are the perfect place to keep up to date with the technology, and the end-of-year timing will also bring the announcements for the following year. Shows are also about meeting people and sharing with them ideas, concepts and, very occasionally, a drink or two. Moving the dates to allow the maximum number of people to attend therefore made perfect sense. 

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DM3D

If we can take old used parts and refurbish the part itself for a fraction of the cost of new then these companies are going to save a lot of money

WOR DS : L A U R A G R IFFIT HS

he benefit of additive technologies means industries have the opportunity to reduce manufacturing costs significantly when compared to traditional processes. Yet some additive technologies are allowing manufacturers to minimise production costs even further including one particular process that enables engineers to remanufacture components at less than half of the cost of a new part. DM3D Technology is a company that employs its proprietary Direct Metal Deposition Technology to not only build industrial parts but also repair them. Created over 20 years ago and developed by the POM Group, the technology was acquired by DM3D Technology in 2013 with the power to produce fully dense metal parts through a strong metallurgical bond to a base material. Enhanced over the years through a series of both private and government research and development contracts, the technology is ideal for the restoration of high value and production parts for demanding industrial sectors. Dr. Bhaskar Dutta, Chief Operating Officer at DM3D explained: “Repair and remanufacturing is a very large part of what we do. This is something you cannot do using the powder bed fusion type technologies so that gives us edge on those applications.” The key areas where this type of technology is making the biggest impact are aerospace, automotive and agriculture. Crucial part replacements can be an expensive inevitability for manufacturers but with DM3D’s process, the lifespan of parts that are already in use can be increased to minimise costs dramatically. Right now DM3D is working with several customers in each of these areas and hopes to take parts up to full production level in the next 18 months. “We use our technology to apply dissimilar metals and extend the tool life so if you have a tool which is wearing out very fast, we can take that tool and apply our special hard metals to extend the tool life,” Bhaskar commented. “Aerospace has a huge demand now because parts are so expensive. Their parts can be repaired using our technology - that brings significant value.”

DMD built diffuser casing for jet engine Bhaskar added that the issue can also be addressed in parts for maintenance in diesel engine heads, agricultural fuel pumps and excavation equipment: “They will buy a completely new part and replace that in the engine. If we can take old used parts and refurbish the part itself for a fraction of the cost of new then these companies are going to save a lot of money.” The company is currently working closely with aerospace manufacturers such as GE Aviation, Barnes Aerospace, MB Aerospace and BAE Systems in both the US and UK on the manufacture and remanufacture of parts, some of which are in certification. Bhaskar explained there are several key ways the company is looking into applications. One is building the entire part with 3D printing and another is by remanufacturing. “For anything that is expensive there is a significant opportunity to repair and salvage the part,” explained Bhaskar. “You can rebuild a part at less than 50% of the cost, sometimes way less. Some jet engine components are very big and very expensive - more than $100,000 and you rebuild them for $4/5000. That’s a big area.” On top of this the company also offers multi-material manufacturing which allows them to build the same component but with different metals to provide various properties to a part, making the part better and more effective than was previously possible with traditional methods.  Bhaskar will present a talk at RAPID on May 18-21 in Long Beach, California on the benefits of manufacturing and remanufacturing for parts in the aerospace industry.



DMD remanufactured fuel pump

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3D PRINTING | ADDITIVE MANUFACTURNNG | PRODUCT DEVELOPMENT

If it ain’t broke … remanufacture it

AUTODESK

PUTTING AN HISTORIC WATERFRONT TO WORK ONCE AGAIN After the uproarious success of the 2015 International CES TCT’s Jim Woodcock took to the road and headed up to San Francisco to take a look at Autodesk Pier 9 and the Autodesk Gallery. Here’s what he found out.

of Las Vegas. Think of the desert. Think of the blue skies and the hot sun beating down. Now forget all that and replace it with grey skies and an Englishman’s ever-present companion, rain. Because that’s what I found when I went to the window of my 24th-floor hotel room in Sin City before I set off for San Francisco. Throughout the 2015 International CES the weather had been unseasonably warm, even for Vegas. This was payback. Still, nothing could dampen my spirits as I took a cab to the car rental centre to pick up an enormous SUV — of course — in which to tackle the near 700 miles of dust-bowl desert and snowy mountains that lay between me and Pier 9. To cut a long story short it was raining in the desert, I needed my coat on at Furnace Creek (which has recorded a peak temperature of 134 °F /56.7 °C) and there was hardly any snow on the mountains. Something to do with the enormous SUVs, perhaps. After a largely free flowing and uneventful journey I arrived into San Francisco from the north, crossing the ever-impressive Golden Gate Bridge on a glorious January morning. It added a few miles to the journey but is honestly well worth it, such is the iconic nature of the structure and the cityscape beyond it.

W O R D S : J I M W O O D COCK

hink

DOWN AT THE WATER’S EDGE Pier 9 is, perhaps obviously, a pier. A real piece of San Franciscan heritage on one of the most famous waterfronts in the world. The area of the waterfront that now houses Autodesk and others in rather fancy surrounds is known as Italy Harbour. In the last decades of the 19th century the area at the foot of Union and Green Streets was filled with fishing boats worked predominantly by immigrants from Linguria and Sicily. 024

APRIL 2015 www.tctmagazine.com

Many of the piers along the Embarcadero and Fisherman’s Wharf fell into disrepair and dereliction over the years as the waterfront lost its relevance as a place of work and industry. The construction of the Embarcadero Freeway, container shipping preferring nearby Oakland and changes to the local demographic meant that the waterfront was no longer the hub of the city. After the tragic Loma Prieta earthquake in 1989 the freeway was so badly damaged as to need complete demolition, once again connecting the city to its waterfront. Since then a number of public and private organisations have returned the area to vitality — and making it a must-see for anyone in the area. Autodesk’s involvement in the Pier 9 regeneration is a perfect example of how the waterfront is being put to work once again. And what work! If you happen to be a tourist of a creative bent then tear yourself away from the clam chowder at the Boudin Bakery and beg, borrow or steal your way into Pier 9. Imagine Willy Wonka’s Chocolate factory for making things and you’re pretty close. From the minute you arrive there’s a palpable energy in the light, airy building — at least some of which comes from the tour groups that must drive the residents to distraction (not that they’d ever let you know).

L to R: The raised

walkway gives views into various pieces of big CNC equipment. An interesting piece in the Autodesk Gallery 3D printed city-scape of San Francisco at the Autodesk Gallery.

TOOLS AND THE ARTISTS THAT USE THEM Conceived as part showcase, part ideas factory and part dream workshop for charismatic CEO Carl Bass, Pier 9 offers all the tools both modern and traditional that an artist or engineer could possibly need to make real their wildest ideas. The creativity spark that puts all this software and hardware to use comes in large part from the Autodesk Artists in Residence Program run from the Pier 9 facility. There are currently 10–12 full time AiRs with 44 part-time. A stipend of up to $1,500 a month is available, plus allowances for project-specific materials. AiRs have free access to Autodesk software (though they aren’t required to use it) along with access to product experts across the portfolio. Training and ‘hand holding’ is a key part of the program — especially given some of the tools on hand. In all Pier 9 has 12,000 square feet of workshop space split into the big CNC tools, wood workshop, metal shop and 3D printing space. Beyond this there are areas relating to food, electronics, nano/bio… you name it.

Walking down the pier leaving the office space behind (itself around 15,000 square feet and housing 150 or so employees) the first making space holds the big guns: the CNC shop. From an OMAX 60120 JetMachining Center running at 50,000 psi to a Mori Seiki Integrated Mill Turn Center (the snappily monikered NTX1000SZM, since you ask) it’s all there. And bar the Mori Seiki it’s all available to be ‘driven’ by Autodesk employees and AiRs once rigorous training has been completed. As an interesting side note, the ID cards used by staff and AiRs hold that training information and are needed to use each machine. No training, no access. The impressive double-height space features a walkway above that allows viewing into the machines are they carry out their computer controlled commands. Depending on your mood, it could just be the best view in San Francisco. Next comes the wood workshop, home to tons (literally) of obsessively ordered hand tools in every shape and size that has ever been. From the aggressively high-tech vibe of the CNC space the wood shop, with walls clad in wood, feels almost cosy. Beyond the hand tools electric saw and sanders give a nod to modernity and another opportunity to get creative. Through the next set of security doors the warm familiar scents of wood and adhesive give way to the sharp bite of hot metal. Again, the space reflects the work not only in the smells and sounds but also the aesthetic with the wood cladding replaced by metal panels. Whether users are looking to cut, join, bend, polish, drill, knurl, grind, blast or press their metal the tools they need are there for them. At this point there appears to be nothing conceived or conveivable to

man that could not be made at Pier 9 – but there’s more upstairs. Namely the 3D printing room, a place that is part workshop, part skunkworks, part gallery and part playground. Seven Objet500 Connex machines get the headline billing — quite rightly — and at the time of my visit most of them were either building parts or being prepared to build parts. The multi-material capability and high-resolution allow the creation of some truly stunning art pieces where the functional materials are put to use in all sorts of contraptions throughout the Pier. It’s no surprise that 3D print shop was the incubator for Autodesk’s Spark Platform and its foray into the 3D printing hardware world with the Ember. A number of prototypes both alive and dead are kept in the 3D print shop and R&D continues to take place alongside the other machines. Autodesk also appeared to have ordered one of every other 3D printer on the market in the process! The full list of equipment, software, guidance and training available at Pier 9 is too much to list and really needs to be seen to be believed. The links to the project sharing website Instructables, which Autodesk acquired, are clear with many of the projects from the workshops making it onto the site. The open plan layout means that projects are on view to all, and the mistakes and triumphs that go hand-inhand along the creative path become part of the collective consciousness. What Autodesk has created at Pier 9 transcends any of the individual goals of the venture and has become a shrine to the defining human characteristics of play, creation, experimentation and sharing.  APRIL 2015 www.tctmagazine.com

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3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

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MATERIALISE 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

MATERIALISE WORLD CONFERENCE

have experienced the frustration of purchasing a 3D printer and it not performing the tasks that we originally purchased it to do in the first place, few of us have turned that frustration into a company that employs over 1,000 people and trades on the NASDAQ. Then there are few people in the world like Wilfried Vancraen, just ask readers of Belgian Newspaper De Tijd, who deemed the Materialise CEO more influential than Pope Francis. In celebration of Materialise reaching a quarter of a century the Belgian multi-faceted 3D printing company are hosting the Materialise World Conference on the 23rd and 24th of April in the trendy Brussels convention centre, Square. any of us

THE TWO-DAY EVENT BOASTS AN INSPIRATIONAL LINE-UP OF SPEAKERS ACROSS FOUR SUMMITS.

MIMICS INNOVATION SUMMIT Over the two days the Mimics Innovation Summit sets out to inspire through presentations covering the most cutting edge applications and cases, presented by renowned biomedical engineers, academics and clinicians. Of the five tracks at the Mimics Innovation Summit highlights include:

ADDITIVE MANUFACTURING SUMMIT Running concurrently with the Mimics Innovation Summit with its focus on software is the more hardware centric Additive Manufacturing Summit. Topics over the two days cover a wide range of the industry from the latest material innovations to new business models through 3D printing. Talk highlights include:

CO-ENGINEERING THE FUTURE OF HEALTHCARE This track will focus on the new technologies that are available for surgeons thanks to advances from companies like Materialise. Although Materialise have many specialities if there was one they were truly pushed on it would be the 3D printing of patient specific devices of which they created over 130,000 in 2013 alone. As well as a tour of Materialise HQ at the end of the day the there is a range of talks on the future of healthcare throughout the one-day event. Highlights include:

3D PRINTING BROUGHT TO YOU Materilaise’s consumer arm i.materialise hosts two days of talks and workshops geared towards those looking to use 3d printing, whether it be artistically, for gaming, jewellery design, interior design, customization, or beyond. Highlights include: ■ 3D Customization by Martijn Joris Co-Founder, TWIKIT, Belgium ■ Customizable 3D Printed game characters : Cut the Rope, Pou, Talking Tom and the Tribez by Ilja Laurs Founder, Nextury Ventures, Lithuania. ■ From Idea to 3D Printed Shoe by Frederik Bussels 3D Designer, Pixel Depot, Belgium and Katrien Herdewyn Footwear Designer, Elegnano, Belgium

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■ 3D Printing: The Next 25 Years by Prof. Hod Lipson, Cornell University. ■ Feasibility of 3D Printing Cardiac Structures From Ultrasound by Dr Alex Pearce, Papworth Hospital ■ 3D Printing Bones in Archaeology: From Stonehenge to Digitized Diseases by Dr Andrew Wilson, University of Bradford

■ From 2D Dynamic Footscan to 3D Printed Dynamic Insole by Dennis Vandebussche, CEO of RS Print. ■ Additive Manufacturing for Helicopters by Jean-Pierre Fabrizio of Airbus Helicopter ■ Integrating Topology Optimization in the Design Workflow by Max van der Kolk of Netherlands Organisation for Applied Scientific Research

■ How 2D Became 3D: X-Ray Based Personalized Guides for Total Knee Arthroplasty by Roger Jaeken, Orthopaedic Surgeon, AZ Heilige Familie Reet, Belgium ■ 3D-Printed Medical Devices and Beyond: Stem Cells, Bionics and the Fourth Dimension by Glen Green, Associate Professor of Pediatric Otolaryngology, University of Michigan, USA ■ What about 3D Technology for the Shoulder? By Olivier Verborgt ■ Chair, Department of Orthopaedic Surgery, Monica Hospital, Antwerp, Belgium

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STRATASYS 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

ASIA IS FASTEST GROWING REGION FOR 3D PRINTING W O RDS : LAUR A GR IFFIT H S

TCT CAUGHT UP WITH STRATASYS AT TCT ASIA TO TALK ABOUT THE IMPORTANCE OF BECOMING MORE LOCAL, INVESTING IN MANUFACTURING AND WHY CHINA HAS BECOME ONE OF THE COMPANY’S BIGGEST MARKETS.

come as a surprise to learn that additive manufacturing titan Stratasys has over 100,000 systems installed worldwide across both its professional and desktop printer lines. What is perhaps more surprising is that 10,000 of those professional machines were sold in Asia, a region that over the last few years has truly began to cultivate its place in the global 3D printing industry. Omer Krieger, newly appointed General Manager of Stratasys Asia Pacific and Japan is responsible for accelerating the adoption of 3D printing across the region, leading a 200 strong team at 10 regional offices including four in China. “It’s been a great period for us in the last few years,” explained Omer at TCT Asia. “I see the industry growing, great interest from customers, from government, from other markets. For us these kind of events are exciting. This is the marketplace, this is where everyone comes to get news and updates.” Currently, the extent of investment and industry penetration is considerably smaller in Asia compared to the West. However the market in Asia is estimated to be worth a massive $1.6 billion by next year - a staggering number for a region that up until now has been considered much slower to jump in to the 3D printing game. “The whole industry is growing very fast,” Omer commented. “The vast majority of it is mainly based in North America but Asia is the fastest growing region for Stratasys. We see t may not

ABOVE Omer Kriegar, newly appointed General Manager of Stratasys Asia Pacific great adoption and interest from countries in Asia especially China. For us China has become the biggest market. In general Asia is maybe a bit behind but moving much faster than other countries. We see great potential and that’s why we’re investing so heavily in Asia.” Stratasys has deepened its footprint in Asia over the last few months in strides including the introduction of a dedicated partner network to increase localised support for its manufacturing systems across the region. “We have two main approaches,” Omer explained. “One of them is being local, as close as we can to our customers. They are the ones that drive this industry so we try to be as local as we can. We have 10 offices around Asia offices mean we have knowledge and support closer to where things are being invented by our customers.” Omer continued: “We are investing heavily in the manufacturing side, this is our biggest potential to change things in the industry. Today manufacturing is a small part of our business but we believe and already know from specific industries that it can become a significant one if not the biggest. When you say manufacturing and talk about Asia, there are huge opportunities.”

Stratasys launched the new objet260 dental selection 3d printer at TCT Asia. The latest machine in the company’s dental range is the most advanced dental 3D printer yet and has been designed to create detailed lifelike models from 3D scans in Stratasys’ cutting edge range of dental materials. Choosing China as the platform to showcase the product for the first time, Stratasys believes delivering its ever growing product range to the Chinese market is key to boosting innovation and continuing to improve its vital presence across the region. Omer concluded: “I think we have enough knowledge to transfer to users across Asia and make them more competitive and better at what they do.”  APRIL 2015 www.tctmagazine.com

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MATERIALISE

WOR DS : L A U R A G R IFFITH S

With a 25-year history in 3D printing innovation, Materialise is a company that focuses on the bigger picture of additive manufacturing. “Solutions provider” may be a term used liberally in the industry but for Materialise, that’s exactly what they are, a provider of solutions for this dynamic, often complex and rapidly growing technology.

ne of those key advances is Streamics, a central additive manufacturing automation and control system that connects people, machines, processes and materials to enable users to streamline their entire additive manufacturing business. “Streamics has two components, one that we call the Robot and one that we call the Control System,” explained Dave Flynn, Senior Business Development Manager, Materialise. “The Robot is the automation engine for automating tasks on 3D part files such as extracting part properties like surface area, volume and also images for previews. That functionality can be used in a standalone way driven by clients on the desktop or it can also be integrated with external applications.” The Streamics Robot also forms the automation basis for the Control System, a platform which takes a product from quote, to order, to build planning by access to the filtering and grouping of parts via type, process, material and then scheduling onto individual machines. “The Control System is a database application, based on a single server that allows you to basically manage all of the information associated with the typical workflow of additive manufacturing,” Dave elaborated. “The idea is you start out with a request from a customer with some electronic part files and follow all the way through to a physical part that’s ready to ship. There’s a lot of information in between

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

Every machine is an island

those two points and the Streamics Control System is really designed to manage all of that information and provide traceability and a database that can then be used for reporting and analysis.” Having spent the majority of his career in the service bureau industry, Dave understands just how crucial software like this can be for maintaining a steady workflow. Recalling how most bureaux traditionally manage their data in a number of home-grown ways from speadsheets to individual databases, Dave says a structured way of handling all of this complex information can really assist users in dealing with a variety of applications. “Typically a shop is dealing with input from multiple users, often different types of CAD format, certainly parts from a variety of applications,” Dave explained. “It could be from civil to really complex or tiny parts and that’s really a challenge. It’s actually the fun part of being a service bureau and managing a variety of applications.” “We had a workflow that worked but when the initial version of Streamics became available we looked at it and said ‘that’s exactly what we’ve been trying to do all along here so we jumped right on it’.” Process management software, isn’t the only area Materialise is exercising its expertise. Build processors have been a major part of Materialise’s portfolio over the last 12 months with leading engineering companies such as EOS, SLM Solutions ›› APRIL 2015 www.tctmagazine.com

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Quickly transform your 3D designs into accurate working models Stratasys 3D Printers enable designers and engineers to quickly transform their 3D designs into uniquely realistic physical 3D models, parts and prototypes. You can touch and feel designs allowing you to easily revise them and achieve design perfection, resulting in a fast time-to-market. For expert advice and support, call Tri-Tech 3D – the leading distributor of Stratasys 3D printers.

T E L E P H O N E : 0 1 7 8 2 8 1 4 5 5 1 | V I S I T: W W W. T R I T E C H 3 D. C O. U K

PUSHING THE ENVELOPE FOR ADDITIVE MANUFACTURING

The Arcam Q20 represents the 3rd generation EBM technology. It is a manufacturing equipment specifically designed for production of components for the aerospace industry. Key Features: • Arcam LayerQam™ for build verification • Latest generation EB gun • Closed powder handling

www.arcam.com 032

APRIL 2015 www.tctmagazine.com

MATERIALISE

ABOVE: Streamics diagram showing both a prototyping and manufacturing environment

The technologies that form the basis of our existing product line are very broad in scope and applicable to the machines that sit on your desk in addition to the ones that have to sit on a manufacturing floor

“The technologies that form the basis of our existing product line are very broad in scope and applicable to the machines that sit on your desk in addition to the ones that have to sit on a manufacturing floor,” Dave explained. “There’s a great deal of commonality between those systems and we think that our tools which are very mature and have been implemented and tested over many years can bring a lot of value to an area of our industry that’s relatively new.” The Materialise build processors have been designed to simplify the 3D printing process whilst working towards a more standardised communication system for both software and hardware. Taking the leap into the desktop world and forming strong partnerships with industrial AM manufacturers, Materialise is staying true to its mission to add value to the 3D printing ecosystem. Dave concludes: “Seeing how additive manufacturing is being adopted as a legitimate technique and being involved in the software that enables the process to function in that type of environment is exciting. I started out beta testing the SLA 1 back in 1988 and its really gratifying to see how far this has all come. There were points along the way were people doubted the value of additive manufacturing but at this point it’s very clear it has strong value and a very promising future.” 

ABOVE: Diagram

shows build processor breakdown

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and most recently Renishaw benefiting from this tailored software. “Given the state of the industry’s maturity on a machine level, the machines themselves and the machine vendors tend to be islands,” Dave surmised. “There aren’t a large number of standards in the industry that people adhere to. There are not yet products that are common to many of the systems - they’re all doing the same thing but they’re all doing it differently.” Dave continued: “We’ve formed partnerships with the machine manufacturers so that we can do two very important things. One is create the files that are necessary to go right on to the machine and build parts straight away out of Streamics and also monitor the process while its building. If you think about a laser printer, if that printer is out of paper, it will tell you that you’ll get a notification. You can look at a print queue and see which documents are lined up. It’s a similar idea for the build processors in terms of monitoring and logging information; we can read values from the machines and report that information in real time to the user. We can also record that information, log it in the database at the end of the builds, we can retrieve build logs and store that information. This idea of having a close link with the machines themselves and automating the build preparation and adding real time monitoring and logging of the information is very important, it’s a critical step in enabling manufacturing applications.” More recently, the company turned its attention to the desktop market, adopting partnerships with both FELIX Robotics and Leapfrog to develop similar technology for an entirely new and much more consumer focused market.

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COLOUR 3D PRINTiNG 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT



RIGHT: Aurora filament by Faberdashery

Colour: F WOR DS : L A U R A G R I F F I T HS

cubism artist and forerunner to the pop art movement, Fernand Léger once said: “Man needs colour to live; it’s just as necessary an element as fire and water”. As humans we see and live in colour. Though the way we interpret various shades and tones may differ per each set of eyes, colour plays a pivotal role in our visual experiences. There are millions of colours on the International Color Consortium (ICC) designed to function seamlessly across all software, yet 3D printing technology varies in the number we have access to. If we see the world in full, vibrant colour, why are we often restricted to a basic palette? We spoke to the colour 3D printing experts across materials, software and hardware to find out why colour is so important. Conor MacCormack, Co-founder and CEO of Mcor Technologies told us what makes 3D printing in colour such a hot topic. “We all see in colour. Designers design in colour and there’s even evidence that we dream in colour,” Conor explained. “If you print out a standard part that’s either in white or any one solid colour and then you add a full bitmap image it just adds so much more detail. I think it’s because we have evolved as humans, we see colour and we see detail. I think colour is becoming more and more important, especially, when you move into the consumer segments.” Mcor is the only paper based 3D printing company on the market. Invented by engineers with the idea that it might be “cool to make it in colour”, Mcor IRIS colour technology works using paper and ink whereby a detailed bitmap image is printed onto the part creating photorealistic colour with ICC colour mapping. Conor continued: “We feel that 3D printing in colour has a long way to go to get to the same standard as 2D printed colour but now colour is getting really strong. For us it’s rench

BELOW: Aurora

filament changes colour under UV light

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becoming more and more important but you need to be able to tie it in to the international colour standard ands that what we did.” COMPETING WITH 2D Moving colour technology from the 2D space into 3D is one of the industry’s biggest challenges. As the technology matures, users expect the same colour quality they are used to experiencing with traditional 2D printing. Mike Scrutton, Senior Product Development Manager at design software pioneer Adobe explained how carrying information through the entire process from 3D design down to the finished printed part is key to achieving accurate colour representation. “One of the interesting lessons we’ve learned in the conventional 2D printing space is the need to have continuity of accurate information all the way through a workflow,” Mike explained. “There are so many parallels there that people are almost saying to us ‘we really want you to bring everything that you did for the 2D industry and help us with some of the problems we’re facing in 3D’.” Full colour is a widely contested definition and current technology that holds the label tends to be received by a mixed reception from the rest of the industry. But full 036

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colour is a big ask with engineers effectively competing against ink jet printers in the 2D spectrum. From machines that offer 60 colours to those that provide thousands of digital materials making the same claim, can they all be full colour? From a software point of view, Mike argues it is about having full control over colour and where it belongs on a product. “We did marbling at school and we tie dyed T-shirts,” Mike added. “The tie dye T-shirts were extremely colourful but we had next to no control as the to design that we were putting onto those T-shirts so it was very colourful but we didn’t really have control of where that colour went. When we talk about full colour in 3D printing we’re talking about not just a part that can be something other than a base material like a white or grey or clear but actually something where a designer gets to accurately choose exactly what colour they want and where they want to put it on their 3D model.” Conor says Mcor has the same expectations: “When we talk about full colour it has to be any colour at any time so at any point in the model from pixel to pixel it needs to be able to change from one colour to any of the millions of colours available and only then can you claim that it’s full colour.”

COLOUR 3D PRINTiNG 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

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LEFT: Mcor colour 3D printing

ABOVE: Examples from Shapeways COLOUR AS A DESKTOP TOOL At this year’s International CES we were introduced to Spectrom, a full colour attachment for desktop FFF 3D printers, which can be plugged seamlessly into most open source machines. Teaming with Robo 3D to develop the technology, Spectrom is about using colour as an additional tool for 3D printing and is set to go into beta testing in the next few months. Spectrom’s Co-founder, Cédric Kovacs-Johnson explained: “What really excites us is colour as a tool and the people that use 3D printers right now for work, prosumers and engineers, they’re starting to migrate to these desktop machines. This is where all the dirty work and prototyping happens. Colour as a tool brings such a new element beyond just the aesthetics. So for example an engineer with a complex assembly of parts can import that and easily have each component be a different colour.” Spectrom is a dye-based process, which takes place pre-extrusion allowing the user to have complete control over colour application, resulting in a predictable and precise print. The technology is based on three aims: “First we needed to be able to reproduce nearly any colour in the spectrum,” Cedric revealed. “Second we needed to have the colour fully integrated so we wanted the colour to be as true as filament you might buy from the store. Third, we wanted the colour to transition in and out extremely quickly and precisely so that would give us the control to do multiple colours per layer.” The idea of bringing full colour to the desktop is an exciting development for the consumer market which so far has felt limited to a basic range of colour options. Launching in 2011 with a background in materials science and product design, Faberdashery is a company that specialises in providing a range of unique coloured, bioplastic filaments to the desktop market. “Colour range is really important,” explained Dr Andrew Dent, Technical Director at Faberdashery. “The key thing is that most of our customers aren’t simply using the technology for rapid prototyping. People are really using the technology for true digital manufacturing so the objects and the items they’re producing are the final pieces. What’s unique about what we do is we’re trying to design materials and particularly colours that are going to be useful for specific applications.” Working with an expert colour-matching lab to manufacture bespoke Pantone colours, all colour formulation for Faberdashery’s 40 plus 3D printing filaments is done in-house without off the shelf

Colour can be a crucial factor to a brand’s character - think distinctive Coca Cola red - and getting that right down to the exact colour code or a shade is crucial to conveying a brand message

colorants. Each colour usually represents around six months of development and can sometimes undergo around 10 iterations. “For us each colour has to have a story,” Andrew added. “Our starting point is perhaps not a specific colour but sometimes it’s the narrative. For instance Aurora, one of our filaments that changes from a pink by daylight to neon blue under ultraviolet light, we were really interested in that storytelling of how things could transform depending on properties of light. There’s a lot of thought that goes into the development of our colours.” COLOUR IS ABOUT IDENTITY Brand identity is something that has been made increasingly important in regards to colour 3D printing. Colour can be a crucial factor to a brand’s character – think distinctive Coca Cola red - and getting that right down the exact colour code or shade is crucial to conveying a brand message. Mike Scrutton commented: “Where companies are using 3D printing to prototype models which are going to represent their brand it’s very important to have those brand colours represented on that final model. People have very clear expectations so being able to reproduce colours accurately is very important to those brands.” Shapeways is a company familiar with the importance of brand identity, striking up key partnerships with the likes of global toy manufacturer Hasbro. As the world’s leading 3D printing marketplace, the expectations from those products are extremely high. ››

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R APID PROTOT YPING

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When we merged the country’s three leading service bureaus into one, we created Stratasys Direct Manufacturing—a powerful resource for designers and engineers to challenge conventional approaches to manufacturing. We partner with ambitious companies like Mission Motors to provide the technological solutions they need to Ricky Orozco

Project Engineer

push the boundaries of design and engineering. When Mission Motors set out to build a high-performance electric motorcycle, they turned to us to help manufacture the motorcycle’s complex integrated dashboard. Together, we produced a design that would have been impossible without our 3D printing and advanced manufacturing technologies. The freedom to create. The power of additive manufacturing. The power of together.

C OMBINING T HE BE S T IN 3D PRIN T ING & A D VA NCED M A NUFA C T URING SER V ICE S

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Copyright ©2015 Stratasys Direct, Inc. All rights reserved. Stratasys Direct Manufacturing, FDM and PolyJet are trademarks or registered trademarks of Stratasys Direct, Inc. and/or its affi liates and may be registered in certain jurisdictions. Other trademarks are property of their respective owners.

NTING

M E D I C A L M A N U FA C T U R I N G

PROJECT CLIENT

MISSION R

MISSION MOTORS PA R T S

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Learn how Stratasys is redefining manufacturing, download our recent white paper and explore more stories like Mission Motors. S T R A T A S Y S T O G E T H E R . C O M APRIL 2015 www.tctmagazine.com

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RTM

ADDITIVE MANUFACTURING

TOYOTA MOTORSPORT GmbH

EXPERTS AT ADDITIVE MANUFACTURING TMG is on the cutting-edge of additive manufacturing, with 10 laser sinter (SLS) machines and with 35 years of top-level motorsport experience, we pride ourselves on delivering superior quality, fast. Our strong relationships with key suppliers ensures TMG works with a range of materials, including the new DSM Somos® PerFORM material which offers high-resolution production with even shorter lead times.

www.toyota-motorsport.com +49 2234 1823 0 | contact@toyota-motorsport.com

THE WAY YOU DESIGN

WHAT YOU CREATE

HOW YOU MANUFACTURE

We invented it. Now it’s your turn. Our 3D digital design and fabrication solutions transform the way you design, create and make with endless possibilities. Explore the potential of 3D printing today at www.3dsystems.com.

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www.3dsystems.com moreinfo@3dsystems.com Tel: 803.326.3900

COLOUR 3D PRINTiNG 3D PRINTING | ADDITIVE MANUFACTURNING | PRODUCT DEVELOPMENT

ABOVE: Mcor full colour paper 3D printing “With colour it’s not just about what you see on the screen it’s that every set of eyes sees colour differently,” Savannah Peterson, Director of Global Community, Shapeways, said. “I think you see that challenge in the world exacerbated when it comes to actually creating your own products.” Raphael Stargrove, Materials Product Manager, Shapeways, added: “I think with colour a lot of it is around content generation. Content generation comes more traditionally from video games, movies. That isn’t necessarily the easiest way to make colour content. Right now these printers act like desktop printers but as we start looking forward to multi material printers we’re going to need a lot more development in through and through colour, voxel based colour and more intuitive ways of actually defining colour.” A STEP IN THE RIGHT DIRECTION On the industrial side, the first company in the UK to introduce multi-material 3D printing to its machine portfolio, service provider IPF has been offering full colour 3D printing to several industries and most famously, to the big screen – 3D printed Starlord mask anyone? Gary Miller, Head of 3D Printing and Rapid Prototyping at IPF explained why developments in colour are the next obvious step for the technology. “We’re printing with three colours, cyan yellow and magenta,” Gary noted. “You can add white to that but we have to sacrifice one of those colours. What we need and what I’m sure is being worked upon in research and development is the introduction of white and black so we’ve got

Some people focus too much on perfection but it’s another step in the right direction.

CYMK, the full colour spectrum. That’s clearly got to be the next stage and once that’s here the demand will be even greater.” The chief members of the IPF team are Robbie, Fred, Barney, Trevor, Colin, Leo and Carol – IPF’s range of high-performance Stratasys machines including the Objet Eden350V, Objet500 Connex and Connex 3. Printing in multiple materials and colours, Gary says though it’s opened customer’s eyes up to the possibilities of the technology but there’s still a long way to go. “Some people focus too much on perfection but it’s another step in the right direction,” Gary commented. “These technologies are moving very quickly now and what seems like it takes ages to filter through, it’s not. 10 years ago I was printing with one material, now I’ve got over 2000 with colour, flexible, different shore hardness’s in different colours, it’s a lot and that’s only in a decade. It’s really gathering momentum now.” Advances in software to improve the transition of colour information and perhaps even a new file format are a key focuses across the industry. The demand for new materials to increase the range of colours and developments from manufacturers to provide a better colour gamut are going to be crucial in providing not just more colourful but true, full colour 3D printing.  For more on colour 3D printing, download the TCT Podcast, Episode 3.

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CARBON3D

PICTURED & INSET: Joseph DeSimone

3D PRINTING’S JUDGEMENT DAY WOR DS : DA NIe l O’ C ON NOr

ames cameron’s 1991 Terminator sequel, Terminator 2: Judgment Day, took the special effects handbook and blew it out of the water; the depiction of its liquid metal, shape-shifting villain set the bar to which visual effects artists would forever strive. The world’s most renowned film critic, Roger Ebert said: “…While that’s happening on the story level, the movie surpasses itself with special effects. There are the usual car chases, explosions and fight scenes, of course, all well done, but what people will remember is the way the movie envisions T-1000.” While James Cameron is oft considered a visionary and a pioneer (incidentally, particularly in the field of 3D for Avatar), even he could not envisage that his concepts for a movie bad-guy could inspire a revolution in manufacturing but, as anybody who has seen Joseph DeSimone’s TED talk from the 2015 conference can attest, it may well have just done that. “The founders, just like anyone else, were caught up by the 3D printing excitement that was going on and thought ‘maybe there’s a way we can improve this’.” Explains Carbon3D’s Chief Strategy Officer Rob Schoeben. “They quite literally thought of the Terminator 2 clip, they saw the T-1000 growing out of the liquid pool into a fully formed object with next to no waste. They thought ‘that’s not at all how 3D printing works today but it should be.”

An average Joe may have just had this thought and not done anything about it but Joseph DeSimone is not your average Joe; he is one of fewer than 20 people in history to have been elected to all three National US Academies – The National Academy of Engineering, The National Academy of Science and the Institute of Medicine; he was also the winner of the über prestigious Lemelson-MIT $500,000 first prize for his invention PRINT Technology, used to manufacture nanocarriers in medicine. HASTA LA VISTA, LAYERS! Armed with this wealth of knowledge in the sciences and that T-1000 theory Joseph DeSimone and his Carbon3D co-founders set about creating an entirely new 3D printing technique, one that was faster and had better mechanical strengths than currents technologies. After two years in stealth Joseph DeSimone took to the TED2015 stage in Vancouver and unleashed Carbon3D’s technology to the world. “In a world of a lot of hyperbole we wanted to be able to come out in a way that was very tangible, it was important for us to not just do a great presentation but show it in action at the same time,” details Schoeben. “We went to TED with a fully-functional device and we did a live technology demo with no safety net.” ››

We went to TED with a fullyfunctional device and we did a live technology demo with no safety net

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CARBON3D:

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CARBON 3D 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

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LEFT: How CLIP works

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RIGHT: Carbon 3D surafce finish

At the start of DeSimone’s 10-minute presentation an empty build platform lowered into a pool of resin, before the clock ticked down the machine completed its task and revealed a concentric geodesic ball that could not be manufactured in any other way. It’s the sort of thing we’re used to seeing produced in that timeframe only via a time-lapse video on YouTube. Carbon3D’s technology purports to be 25-100 times faster than current 3D printing technologies, in his TED talk DeSimone says that it has the potential to be 1,000 times faster. Not only are the parts printed faster but there’s no layering, parts are monolithic. This isn’t DLP on draft setting, this is Continuous Liquid Interface Production or to give it its snappier name CLIP. CLIP’s ability to manufacture parts suitable enough for end-use at a previously unachievable speed comes from Carbon3D’s fresh approach to printing with resin. Like many printers on the market it uses a DLP projector to display cross-sectional UV images into a pool of resin from beneath but whereas many of these processes require mechanical repositioning after each layer CLIP can continuously grow the object by harnessing both light and oxygen thanks to its oxygen permeable window (similar to that of a contact lens) and a “dead zone” - a thin layer of uncured resin between the window and the object. PRINTING YOUR CLOTHES, YOUR BOOTS, YOUR MOTORCYCLE As well as the breakneck speed and layerless properties Carbon3D also claim that one of the main benefits of CLIP Technology is the ability to throw the entire polymer chemistry textbook at the machine. If true this could be revolutionary to both the 3D printing industry and manufacturing industry as a whole. On this note esteemed industry consultant Todd Grimm told TCT: “I see a direct, negative impact on all photopolymer-based technologies, including SLA, DLP and jetting. The speed improvement is significant and the promised level of detail and surface finish are outstanding. CLIP could displace all of these as the technology of choice for model-making, prototyping and

We’re building serious machines for serious companies that are trying to produce final parts

pattern-making. If the materials don’t offer an advantage over current photopolymers, CLIP could still displace the established technologies in production applications like hearing aids and clear orthodontics. But if the claims of advance materials are proven true, Carbon3D should be able to open the doors for direct production in those applications that demand high detail.” And this is Carbon3D’s aim; not to compete with fellow 3D printers but to compete with injection moulding. They’re no fly by night, this is a company who, as well as being headed up by one of the most decorated scientists in the world, have received $41m in funding during their two year stealth period, a company who have recruited a 40 plus strong team from companies like Apple, Microsoft from Ivy League Universities, a company who have already set the bar so high for themselves. “We’re building serious machines for serious companies that are trying to produce final parts.” Says Schoeben. “The Holy Grail is to connect that digital thread from design to prototype right through to 3D manufacturing and Carbon3D as new entrants to this industry will take up the mantle of connecting the thread all the way through because it has been stuck for too long. He continues, “There’s an opportunity to fundamentality change the means of production. We’re trying to enable a new network of manufacturing, lower the barrier to entry and to remove the design constraints without compromise. End products have to be good, it is not ok to say ‘well, this thing isn’t that good but it was 3D printed and because that’s cool I’ll accept the compromises.’ Why do we deserve to set a lower bar for products just because it is 3D printed? “The injection moulding world has constraints and in the places were those constraints are not acceptable we need to meet injection moulding on their terms and trump them at the things we’re good at.” Carbon3D have stated that it will be released as a full product within 12 months; the clock started ticking the moment Joseph DeSimone stepped onto that TED stage. One thing’s for sure, Carbon3D is a story that will continue to run and for this reason… I’ll be back.  APRIL 2015 www.tctmagazine.com

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CENTRAL SCANNING

a t n av s h a v e t h i s

habit of sending you on wild goose chases, off down country lanes that lead to nowhere until your automobile ends up in a ditch, leaving you stranded, without a mobile phone signal as the night draws in. As my TCT colleague and I turned off the M5 just south of Birmingham in search of the cutting edge 3D technology company Central Scanning, the roads began to narrow and the sheep count increased this started to feel like one of those navigational nightmares. Just as hope faded, through the trees and tractors appeared an industrial site with the type of premises you often find British high tech companies lurking. Inside one of these lock ups was one of Europe’s leading 3D digitisation and verification firms and its ever-increasing team, Central Scanning. Central Scanning began trading in 2006 and has grown from Director Nick Godfrey’s one-man-band to a team expected to reach double figures before the end of this year. Having worked in the automotive seating industry for the best part of a decade Nick spotted a gap in the market for a reverse engineering company in the UK and hasn’t looked back since. “We pride ourselves on a good, honest, secure service.” Explained Godfrey. “Of our top ten customers we’ve had half of them since inception, they keep coming back. That level of service we offer is also reflected in the fact that 60% of new customers come through referrals.” Central Scanning were the first resellers of the highly thought of Artec range of 3D scanners in the UK, they also sell hardware from Steinbichler and Surphaser as well as Geomagic software. The reason that they’re such a trusted reseller of these products is because they themselves have become expert users as demonstrated by the breadth of use cases Nick had on display. As well as work in expected sectors all done to an incredible standard with such respect for client confidentiality we weren’t even allowed a peak into one of their rooms, Central Scanning’s reputation is such that they’re often called into sectors you’d never usually expect to require the services of 3D scanning…

If the cap fits…

CENTRAL SCANNING ENSURE IT DOES 

ABOVE LEFT: Central Scanning at the TCT Show

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RIGHT: The digital water feature at Westfield, East London

DIGITISING WATER Renowned installation artists Jason Bruges Studio were commissioned to design a new public artwork for the Westfield development in East London, the studio wanted to create a digital water feature that “captures the essence of water both visually and acoustically”. In order to replicate water’s reaction to wind and light on the 12 metres tall feature’s 7,000 LCD screens they needed to examine an actual water feature in their studio. Central Scanning were drafted in to 3D scan liquid’s responses to various effects. The team went down to London armed with 4 Artec 3D Scanners and some determination to get the job done. By mixing the water with white paint Central Scanning were able to capture and generate a mass of data, which was then used by Jason Bruges Studio in order to create the digital fountain.

REDUCING THE WASTE OF MONEY IN NUCLEAR WASTE

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ABOVE: A Central Scanning lid

In 2013 a Public Accounts Committee report criticised the amount of money the decommissioning of the Sellafield was costing it stated that the private consortium managing the nuclear site had failed to reduce costs and delays. After the report Sellafield had to find ways to cut costs at the same time as keeping up with the rigorous health and safety standards demanded when dealing with nuclear waste. During one project to ship radioactive waste to the Waste Encapsulation Plant engineers decided to modify an old

40-tonne flask that required a new lid. The usual cost for a metrology rig alone was £25,000, Central Scanning were drafted in to see if they could accurately 3D scan the original lid in order to underpin the new design. On this project alone Central Scanning’s 3D scanning expertise saved Sellafield (and the UK Taxpayer) over £20,000. The project was such a success that Sellafield are, with the help of Central Scanning, implementing 3D Scanning and Printing technologies plant wide with potential savings thought to be in the hundreds of thousands bracket. 

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W O RDS : DANIEL O’C ONNOR

3DS

The spirit of the Emory bloodline remains true today: to make old Porsches far better than they ever were, mechanically and aesthetically

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LEFT: Sizing up the new parts

WORDS : JIM WOODCOCK

RESTORING THE BEAUTY TO A

WITH

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VINTAGE PORSCHE

Emory Motorsports has restored historically significant Porsche race cars and built 356 Outlaws in their Oregon and California facilities since 1996. GEOMAGIC AND 3D SYSTEMS’ QUICKPARTS The spirit of the Emory bloodline remains true today: to make old Porsches far better than they ever astefully restyling vintage Porsches is in Rod were, mechanically and aesthetically. Yet Emory’s blood. It’s a for the ultimate brand enthusiast, the Emory family tradition that Special, of which only a precious few have started with Rod’s been made, is the benchmark by which grandfather, Neil others in the genre are judged. Specials are Emory, a renowned custom car builder in one-off cars whose combination of design Burbank, California. Rod’s father, Gary, was and mechanical components will not be a countercultural influence whose restyling duplicated. With his design consultancy on the rise designs ranged from the original “Baja Bug” to race-inspired street variations of the and with the technical precision required venerable Porsche 911. The unique Porsche for today’s manufacturing processes, Rod 356 street and competition cars restyled and Emory’s creative team has needed to marry raced by Rod and Gary, whose aesthetics old-world fabrication techniques with the frequently offended brand “purists,” came to latest 3D tools, including Geomagic software and 3D printing from Quickparts. ›› be known, fittingly, as 356 Outlaws.

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ProJet x60 Series: 260c, 460Plus and 860Pro colour composite material printers. Six machines are in the x60 range.

ProJet 1200: Desktop small object and dental SLA printer.

ProX 200: one of the DMLS (Direct Metal Laser Sintering) range.

ProJet 3500 Series (left) – high-production machines for plastic and castable wax parts. The ProJet 4500 (right) full colour plastic printer.

One of the UK’s leading resellers of the full range of 3DSystems printers 3DSystems printers provide the most advanced and comprehensive 3D printing solutions available today, bringing ideas to life using its vast material selection, including plastics, metals, ceramics and edibles. 3DSystems medicine capabilities include the printing of surgical instruments and personalized surgery and patient specific medical/dental devices. Europac3D are major UK resellers of the 3DSystems printing range and our full service includes: Sales; Installation; On-site maintenance; Training; Materials and parts sales. With our engineering pedigree and an install base of over 500 systems throughout the UK, Europac3D also provide industrial-level 3D scanning equipment, software and portable arms from some of the world’s major 3D manufacturers.

Sales: 01270 216000 sales@europac3d.com www.europac3d.com 3DScanning 3DPrinting 3DInspection 3DSales 3DServices 050

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3DS 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

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This combination of scan/design technology and rapid prototyping came in handy in January of 2015 when a customer asked Emory to help restyle the windshield frame for an early Porsche Roadster. “Our customer wanted to update the windshield design with a lower and leaner profile than the original, while still paying tribute to the car’s design aesthetics,” said Rod Emory. “Obviously 3D CAD data for cars this old doesn’t exist, but we can use 3D Systems Geomagic Design X software

communicate so much, the Emory team wanted to check the new part’s size and fit on the real-life car before committing to full production. So, they decided to 3D print a prototype with help from Quickparts. Quickparts is a leading, global on-demand 3D parts printing service whose customers quickly receive no-obligation quotes for their parts while offering fast online workflows and expert advice. “Once our solid model was prepared, we went shopping for 3D printing services. Since

FAR LEFT: Scan data being processed parts



LEFT: Using a scanning arm to get the data

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ABOVE: The part arrives from Quickparts

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BELOW: The Quickparts User Interface

Geomagic Design X is the industry’s most comprehensive reverse engineering software, combining history-based CAD with 3D scan data processing. to scan a car or its components directly into CAD and design on top of it.” Geomagic Design X is the industry’s most comprehensive reverse engineering software, combining history-based CAD with 3D scan data processing, so Emory can create feature-based, editable solid models compatible with their existing CAD software. Said Rod, “Design X made it easy to seamlessly push data from our Faro Arm’s laser scanner to the CAD environment. Using data points acquired by scanning, we were able to restyle the “A-pillars” (the parts of the windshield frame that bookend the glass) within the existing parts’ footprint.” Since computer simulations can only

the 3-D printing landscape is so new with a wide variety of build methods and materials, we didn’t have to search long before we found Quickparts.com and were intrigued by its QuickQuote process. 3D Systems really understands the challenges customers face while sourcing this type of service and the need for comprehensive information and material choice.” Continued Rod, “The Quickparts web site was easy to navigate. We uploaded our model, talked to customer support about the best printing processes for our part and their respective prices, then plotted a path forward. We finally settled on SLA output, using an ABS-like grey material. The part

arrived sooner than we expected—about a five-day turnaround in total.” Emory got the part and test-fit it to the vehicle while the customer watched and who then immediately provided feedback about the design. This kind of “closed-circuit” validation is critical to successful design processes and wouldn’t have been possible without 3D printing. “The SLA print we received was impressive, with very high fidelity and perfect finish,” said Rod. “On a different kind of project, that print could even have been used as a finished part. Quickparts’ service will definitely be part of our workflow in the future as a way to improve our prototyping, minimize waste and reduce our production costs.”  APRIL 2015 www.tctmagazine.com

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Real. Big. Industrial Strength, Fused Filament Fabrication (FFF), Large Format 3D Printer, Starting Under $20,000!

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US MAp 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

US Service Provider Map If you’re a seasoned reader of TCT + Personalize you will be familiar with a handy map decorated with the names of the leading service providers from one of the additive manufacturing industry’s pioneering regions. Back and bigger than ever, it is of course the US Service Provider Map an annual overview of the US companies that can help you bring your ideas to life.

The number of service providers has grown so much since last year it’s outgrown the mag!

for efficient product development are vast in complexity and cost. Whether you’re a start-up looking to make that initial prototype or a business looking for the best localised manufacturing capabilities for your product, our guide will help you find a solution from a growing number of companies across the US that cover every process, material and skill you need to make the most of this technology. Presented for the first time as an A2 pull-out - the number of service providers has grown so much since last year it’s outgrown the mag - this comprehensive guide to solution providers in the additive manufacturing and 3D printing arena is yours to hang on the wall and use to assist with upcoming projects. he technologies required

For international readers, the map will be available to download for free from tctmagazine.com, Google Play and the App Store. 

APRIL 2015 www.tctmagazine.com

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SOFTWARE SOLUTIONS FOR 3D PRINTING FULL COLOUR MESH HEALING Healing and slicing of texture mapped models

PREPARING CAD MODELS FOR 3D

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PRINTING?

Denoising and wall thickness analysis

SMOOTH BLENDING Automatic hole closing algorithm

FAST • AUTOMATIC • ROBUST

polygonica.com

APRIL 2015 www.tctmagazine.com 054 FA_Ad_192x136_WF_2015_out.indd 1

BOOTH NO: 19

2/17/15 12:38 PM

UNIVERSITY OF EXETER 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

THE FUTURE OF POLYMERIC AM: HIGH TEMPERATURE

With its potential to open up exciting new avenues for businesses in a range of sectors, additive manufacturing (AM) has captured the collective imagination, with the growing industry estimated to be worth £7.5bn within the next five years.

BELOW: A range of topics were discussed in a thought provoking series of talks

A R EP O RT FRO M T H E U N I V E RS I T Y O F E X E T E R

owever, in order for AM to become a mainstream manufacturing technique, as highly regarded as processes such as high speed machining, casting and injection moulding, there are a number of technical and commercial challenges that need yet to be overcome. While the use of metals in AM has grown, a key requirement for industry is for high temperature polymers and composites to be widely and economically available. Representatives from across the world came together at the University of Exeter to discuss the latest developments and what is needed to move this industry forward. An exclusive event, and the first on the topic in Europe, The European strategy for additive manufacturing for high temperature polymers was hosted by the University’s Centre for Additive Layer Manufacturing (CALM). A range of sectors were represented at the event, including defence, aerospace, marine, high end automotive and manufacturers of high temperature polymer products. The event was partnered by manufacturers and suppliers of laser sintering (LS) equipment EOS UK Ltd, and Victrex, the main UK manufacturer of high temperature polymers for a range of processes.

Attendees discovered future options, with updates from the University of Exeter on new grades of materials, including PEEK, glass and carbon based composites, and updates from Victrex about new PEEK materials. They also learnt about new LS systems from EOS, manufacturers of the EOSINT P 800 used by CALM (one of only eight in the world). Delegates also learnt about Airbus Group Innovation UK’s use of carbon nanotubes in AM, collaborative research with South West Metal Finishing, which is developing techniques for improving surface finish of parts, and examples of high temperature polymers being used by Smith’s Detection for anything from its airborne vapour collection system to its ground test and interface box, as well as by Maplebird for its insect scale aerial vehicles. This was supported by presentations and discussions about ongoing challenges and the steps required to take the industry to the next stage. Principal mechanical and lead AM engineer Marcel Gowers, from the engineering company Smiths Group, said: “It was an interesting day, and an excellent opportunity for us to engage with other businesses involved in high temperature polymer AM. It was also useful to have the chance to debate the issues we currently face and potential solutions. One example was ‘how can we improve the surface finish of components printed on the EOSINT P 800 either during or post manufacture’. It was interesting to see some new advances in this area. Additive Manufacturing is an exciting and rapidly growing industry, so it is important that we work together to address these challenges.” ››

APRIL 2015 www.tctmagazine.com

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2600 - 2800 375 - 405

2800 - 3200 405 - 465

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MPa / ksi

43 – 47 / 6.2 – 6.8 43 – 47 / 6.2 – 6.8

50 – 55 / 7.2 – 8.0 45 – 50 / 6.5 – 7.2

50 – 60 / 7.2 – 8.7 45 – 55 / 6.5 – 8.0

60 – 65 / 8.7 – 9.5 50 – 60 / 7.2 – 8.7

– 55 – 65 / 8.0 – 9.5

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Tensile strength at yield Tensile strain at break

4–5 10 – 15

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75 – 80

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APRIL 2015 www.tctmagazine.com

Normal 0.1 / 4

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filled polymers

THE COMPANY

The family company has specialised in the production of complicated small parts, which are characterised by high precision, fit and function. Offering a wide range of stereolithography materials, a variety of production (series) materials can be simulated. Twenty years of experience, a wide selection of materials and plant technology allow “The SL Pro” to respond to its customers different needs and desires. And it reacts quickly to requests with production of your parts within 24-hours wherever possible.

THE CONTACT

Joerg Griessbach – The SL PRO Am Hang 5 09244 Lichtenau Saxony / Germany Mail info@the-sl-pro.com www.the-sl-pro.com Phone +49 37208 882902

UNIVERSITY OF EXETER 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

CHALLENGES AND POSSIBLE SOLUTIONS One objective of the event was to highlight challenges and discuss potential solutions, so clear strategies could be developed and future research could focus on the right areas. Key themes included: • Size restriction: AM is limited by the size of the machines. For wider spread adoption, this is an issue that needs to be addressed. • Cost: current materials for AM are costly compared to those of the same grade in injection moulding. • Functional performance: despite advancements and ongoing developments, the functional performance of AM polymers lags behind equivalent injection moulding options, with reduced elongation, increased brittleness, and a poorer surface finish. • Knowledge exchange and awareness: The use of AM for high temperature polymers and composite materials is in its infancy, so there is a lack

IMAGE: Attendees at the event shared thoughts on laser sintering systems.

BENEFITS AND APPLICATIONS With no tooling costs, short lead times and minimum waste, AM’s benefits for design optimisation are well recognised. The technology is ideal for manufacturing low volume items, tooling requirements, inspection fixtures and design checks. Attendees discovered where these advantages are being realised and considered, with companies like Smiths Detection revealing potential uses of AM with high temperature polymers. Examples included using laser sintering in PEEK to produce parts for a ground test and interface box, and LS double scanning to produce an airborne vapour sampling and collection system. The finished products had excellent hydrolysis resistance – meaning they retained their mechanical properties with exposure to high heat and humidity – and a good quality surface finish, meaning AM was a viable option. Developments suggested by Smiths included the need to increase the surface finish options in AM – meaning users of the technology could specify whether they wanted a smooth, medium or coarse finish for their products.

of knowledge about its potential. Critical to overcoming the above challenges is the development of new polymer and composite materials that aren’t just replications of injection moulding grades, but specifically designed for AM. Work on this is already underway, with Victrex and the University of Exeter having developed alternative materials that are lightweight, fire retardant and strong. Development of new materials and technologies will dictate the future of AM for industry. Attendees said they recognised the advantage of the event, in bringing key players together, to create a clear vision and direction. Fabian Muller, Product Marketing Manager Polymer Laser-Sintering at EOS Gmbh, said: “It was a very informative day, with both research and practical examples of how the technology is being driven forward. At the same time, it was important to see the main challenges ahead of us, which need to be solved in order to enable more than just niche applications. There are some hurdles that still need to be addressed; not only cost hurdles, but also marketing and informative hurdles, in that many people still do not know about high performance polymers.” Another major take-away from the event was the requirement for more training programmes, including appropriate university courses, and Continuing Professional Development (CPD). CALM is

investigating this further and will publicise any future training and courses it can offer. James Bradbury, CALM’s Coordinator, said: “We are delighted with the success of the event – we had a wide range of presentations from different sectors and an excellent turn out, with representatives from the entire supply chain there. Attendees said it was a useful and interesting event and so we would be keen to look at putting another one on in the not too distant future.” He added: “The demand for the supply chain for AM is still developing and adapting and we hope that, by the time there is a fully fledged supply chain, the initial work will help speed up the adoption of AM for high temperature polymers and composites. CALM and the University of Exeter are engaging with the entire supply chain to resolve the challenges that have been identified with key businesses. We will continue to work together to push the adoption of the technology in this area forward.” Oana Ghita, Lead Academic for CALM, said: “The event gave us the chance to understand better the industrial challenges, while presenting our research findings to a selected audience. Over the last couple of years, we have focused on material development, leading us also to research on powder morphology, flow and multi functionality for tailored performance - a perfect match with the industrial needs.” 

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WINSUN WOR DS : DA N Ie l O’ C ON NOr



LEFT: 3D Printed Mansion Completed in 2014 by Winsun

YOU WINSUN, YOU WIN SOME

At TCT Asia Daniel O’Connor takes a look at one of the most talked about companies in the world of 3D printing, Winsun Design Decoration Engineering. the industry for 25 years and pretty much seen everything, it takes a lot to impress Materialise CEO Fried Vancraen in the world of 3D printing. His keynote address at TCT Asia pointed out how tiresome he finds the amount of small FDM printers printing useless objects. However, Fried was suitably impressed with one fellow TCT Asia exhibitor to dedicate a portion of his talk to their efforts. That exhibitor is Winsun - the Chinese company who have made mainstream news for the quick construction of 3D printed houses, apartment blocks and villas. Fried said of the company: “This is a truly innovative use for 3D printing, there are few high value 3D printed products but the fact that Winsun uses recycled material, is low cost and is protected by 98 patents means there is potential to create a really valuable 3D printed product for the world.” aving been in

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Esteemed 3D printing consultant Graham Tromans concurred: “Imagine a natural disaster zone, which leaves hundreds or thousands of people displaced from their homes, with Winsun’s technology it is feasible that infrastructures could be replaced within a matter of days.” LAYING THE FOUNDATIONS Winsun’s journey to becoming one of the most exciting and talked about companies involved in 3D printing started back in 2002. The original concept behind Winsun was to create new eco-friendly materials for the use in the construction industry. One of the six materials created since that date, CRG – fibreglass reinforced gypsum board – is now used in 95% of theatres built across theatres in China. Winsun’s materials have been used in over 400 major construction works throughout China including the multiaward winning Beijing National Aquatics Center - colloquially known as the Water Cube – for the 2008 Olympic Games.

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT



RIGHT: The printing layers are visible



LEFT: Rough printed sections can be decorated with moulded furnishings

ABOVE: Winsun’s Booth at TCT Asia and 70% construction time, claims which sufficiently interested Egypt’s government who ordered 20,000 single-storied 3D printed houses as they seek to create onemillion affordable homes by 2020. Wonders of the world, Winsun houses are not, but they also don’t take decades and tens of thousands of workers to build.

The environmental focus of Winsun’s original concept made the leap into 3D printing an entirely logical one; if Winsun could decrease the wastage of their already green materials by using additive technologies rather than subtractive ones the firm would be cooking with gas – or, indeed, printing in Crazy Magic Stone… In 2004 Winsun began developing a 3D printer head and automatic feeding system that would be suitable for extruding their range of materials on a house-sized scale. Ten years later Winsun were creating global news as they 3D printed ten houses in 24 hours, created the world’s tallest 3D printed building and a 1,100 square meter mansion with internal and external decoration to boot, all using their proprietary 3D Printing for Construction technical system. Winsun claims that the system saves up to 60% on materials, 80% on labour costs

Winsun claims that the system saves up to 60% on materials, 80% on labour costs and 70% construction time CHINA’S AM FUTURE? SAFE AS 3DPRINTED HOUSES The system is not wholly different from that of the KamerMaker by DUS Architects that started building a 3D printed canal house in Amsterdam over a year ago using plastic materials. It is essentially a giant FDM machine (6.6m tall, 10m wide, and 150 meters long), using a paste extruder filled with one of Winsun’s materials that prints sections of buildings that are to be fitted together. Think of it like a jigsaw puzzle; the bigger the pieces, the easier they are

to fit together and the sooner the puzzle is finished. The popularity and newsworthy nature of Winsun’s developments meant the booth; close to the entrance at TCT Asia was barely accessible throughout the three-day show. On display was a selection of Winsun’s material developments as well as portions of the 3D printed buildings. The examples included a print with added mouldings for decoration, a print that was tightly packed with polystyrene for insulation and a print that had been guided around some embedded steel reinforcement poles, which can be cemented into the ground for sturdier foundations. Winsun’s advances in the 3D printing for construction in many ways sum up the additive manufacturing industry in China. While many governments in the west weigh up the technology’s benefits to their economy China are ploughing money into the industry. The dividends are companies like Winsun, who are not only drawing worldwide media attention but contracts from worldwide governments and companies alike. Fried Vancraen suggested that Winsun could potentially bring a high value 3D printed product to market. It would appear that potential is being as rapidly built as one of their 3D printed houses. 

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SponSOred by

AMUG PREVIEW 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

AMUG Preview As this issue hits desks the countdown to one of the industry’s favourite events will well and truly be under way. From the 19th through to the 23rd April users, manufacturers, vendors and media from across the globe will descend on the Jacksonville Hyatt Regency for the 2015 Additive Manufacturing Users Group (AMUG).

ince its inception in the late 80s the AMUG Conference has always focused on growing the additive manufacturing industry by connecting the dots between users and manufacturers, sharing a veritable wealth of knowledge through talks, workshops and exhibits all in AMUG’s convivial, unique style. AMUG isn’t a classic conference or tradeshow, AMUG is “for users by users”, AMUG is, as described by Todd Grimm in last year’s keynote, “a band of brothers (and sisters)”. The 2014 AMUG was the biggest and best to date but the organisers have gone to great lengths to not just, match last year’s event, but to blow it out of the water entirely for 2015. With over 200 presentations in the space of four days, 77 exhibitors at the two-night AMUGexpo, twice the financial support from sponsors, 8 hands-on workshops, and all the networking one could wish for, AMUG 2015 is shaping up to be an event not to be missed. Mark Barfoot, AMUG president, said, ”For this year’s event, we have a record number of sponsors, have every AMUGexpo space filled and are on track for record attendance. I believe this success is due, in large part to the environment of the AMUG Conference — open, friendly, social and informed — that sparks information exchange, creative ideas and building of personal networks.” He continued, “Our challenge, which I believe we will overcome, is to make sure that what AMUG stands for continues when we are hosting a large number of firsttimers and a big base of repeat attendees.” ››

CONFERENCE AGENDA

AMUG rightly prides itself on its unmatched conference agenda and this year boasts another 3D printing industry all-star line up. Each of the four days of conferencing kicks off with thought-leaders setting up and motivating the attendees for the 12 concurrent sessions that follow. As well as the some 200 bespoke AMUG curated talks and workshops, AMUG has expanded its sponsor user group sessions. Sponsors including Stratasys, Somos, Concept Laser, SLM Solutions, GE, HP, NCP Leasing, Prodways, Renishaw, ExOne, EOS, ACT Group, and Rapid Prototyping Services are provided with an opportunity to have focussed conversations with those attendees that use their technologies.

Cloud-sourced manufacturing services 3D Systems’ Quickparts® is your single source for custom manufactured parts, ranging from rapid prototypes to low-volume production plastic and metal parts.

For a QuickQuote® on parts, call +1 877.521.8683 or visit www.3dsystems.com/quickparts © 2015 by 3D Systems, Inc. All rights reserved. ProX is a trademark and Quickparts, QuickQuote and the 3D Systems logo are registered trademark of 3D Systems, Inc. APRIL 2015 www.tctmagazine.com

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APRIL 2015 www.tctmagazine.com

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AMUG PREVIEW

WEDNESDAY, APRIL 22, 2015:

Lonnie Love, group leader of Oak Ridge National Laboratory’s Manufacturing Systems Research Group, will be day two’s keynote speaker. Love’s team has had a big impact on additive manufacturing advancement with the development of a new, large-format technology; printing of cars to show what’s possible; development of process methodologies for materials; and work on multi-property metal parts. Love will share details on these and other projects at ORNL.

On day three, Chuck Hull, the inventor of stereolithography and 3D Systems’ executive vice president and chief technology officer, will be the centre of attention for a “fireside chat” with Todd Grimm in the Innovators Showcase. In an interview-style conversation, attendees will venture into the early days when Chuck was developing stereolithography, giving life to a new industry and overcoming the challenges that innovators face. Chuck will also offer insights through present day with the intent to share his experiences so that they may guide others. ■ 3D Printing Technology for Facial Animation by Brian McLean, Laika ■ Additive Manufacturing: Improving the Care of our Wounded Warriors by Peter Liacouras, PhD, Kevin Wurth Walter Reed National Military Center ■ Design for Economical Metal Additive Manufacturing by Steve Woods, GE Power and Water Advanced Manufacturing Works

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

MONDAY, APRIL 20, 2015:

TUESDAY, APRIL 21, 2015:

CONFERENCE Todd Grimm, AMUG’s AM industry advisor and president of T. A. Grimm & Associates, will kick off the event with insights on recent developments and near term trends. Todd will be followed by addresses from sponsors Stratasys and Somos and 2014’s Technical Competition Winners Gary Rabinovitz of Reebok (Advanced Concept) and Mike Littrell of CIDEAS (Advanced Finishing). After lunch follows AMUG’s focussed tracks designed so each attendee can take away exactly what they need to over the four days conferencing, some highlights include: ■3D Printing at Caterpillar: Applications and Programs by Jim Lahood, Caterpillar ■ Laser AM at the Royal Canadian Navy Dockyard by Matthew Barnett, Dept. of National Defence, Canada ■ High Speed Sintering: The Next Generation for Additive Manufacturing by Neil Hopkinson, University of Sheffield

Love will be followed on stage by sponsor addresses from Concept Laser, SLM Solutions and GE. Day two’s tracks highlights include: ■ Is IP Your Friend or Enemy? By John Hornick, Finnegan, Henderson, Farabow, Garnett & Dunner LLP ■ Applications, Process and Material Development for DMLS by Matt Garrett, Integrated 3D LLC ■ Additive Manufacturing for Aerospace Components by Brian Thompson, GNK Aerospace

AMUGexpo

AGENDA Alongside the exceptional conference line-up, AMUG are also hosting their exhibition on the evenings of Sunday 19th and Monday 20th April. According to the organisers this year’s AMUGexpo is a complete sell out, all 77 exhibitors are encouraged to inform and advise on any questions the technical practitioners have, if this leads to a sale great but that is not the exhibitor’s primary role. The godfather of FDM, Scott Crump explained: “AMUG presents an opportunity for Stratasys to connect with users from varying industries who are enthusiastic about 3D printing. AMUG educates attendees about the latest trends and developments in the 3D printing industry.” There are sure to be many highlights and reveals at AMUGexpo, including launches of an AM specific product from CIDEAS, several new innovative 3D printing technologies for post printing from Post Process Technologies and Varia3D bringing Farsoon’s budget-priced LS machine with the fastest build rate in the industry - the SS402P.

THURSDAY, APRIL 23, 2015:

Jason Lopes of Legacy Effects will anchor the final day of the event. Now internationally recognised for his work using additive manufacturing in effects for film, TV and promotion, Jason notes that his first AMUG conference was a turning point, introducing him to ideas and applications as well as people that knew how to make things happen. Afternoon session highlights include: ■ Metal 3D Printing: Insights, Trends and Technologies by Tuan TranPham, Arcam ■ Hydrographic Printing by Ed Tackett, RapidTech ■ Changing the Way Parts are Made: Disrupting Traditional Manufacturing Methodologies by Bill Dahl, Solidscape

For the full agenda please visit: http://www. additivemanufacturingusersgroup. com/conference_agenda.htm 

WE LOOK FORWARD TO SEEING YOU THERE! SponSOred by

APRIL 2015 www.tctmagazine.com

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MAY 18-21, 2015

LONG BEACH CONVENTION CENTER LONG BEACH, CALIFORNIA

EXHIBITS MAY 19-21

DAY ONE: Kicking off the first day with his keynote on bringing additive manufacturing to space is CEO of Made in Space, Aaron Kemmer. Made In Space have recently installed a 3D printer on the International Space Station and successfully uplinked a tool to be used on board. Following Mr Kemmer attendees have the chance to pick from six individual streams including: • Additive Manufacturing of Medical Devices and the FDA: A Technical Perspective by Matthew Di Prima PhD, US Food and Drug Administration • How High Performance Additive Manufacturing is Changing the Face of Medical Devices: A 3D Printed PEKK Case Study by Severine Zygmont, Oxford Performance Materials • Complexity is Free (Unless You are a Software Engineer) by Karl D.D. Willis PhD, Autodesk

DAY TWO:

Two separate industry events will celebrate 25th anniversaries during the time this remains the latest issue of TCT. The Materialise World Conference in April celebrates a quarter of a century in business for the Belgian company while across the Atlantic RAPID celebrates the same milestone with its biggest ever event. From 18-21 May 2015 at the Long Beach Convention Center, California RAPID 2015 will host a plethora of speakers, tours, tech briefings, workshops and exhibitors on 3D printing, scanning and design. Here are some of the highlights:

EXHIBITION: The RAPID 2015 show floor features all the big players one has come to expect to see at such an event including 3D Systems (Booth #814), ExOne (Booth #822), Stratasys (Booth #1014), Renishaw (Booth #1022), SLM Solutions (Booth #1110), EOS (Booth #730), EnvisionTEC (Booth #922), Formlabs (Booth #660) and over 150 other exhibitors. The show floor is also home to the 3D Playground, a development by the organisers and several industry partners that will give attendees the opportunity to get hands on with 3D printing and 3D scanning technologies. Elsewhere, the Contemporary Art Gallery highlights the new, creative approach to art creation and production that’s made possible by additive manufacturing, 3D printing, 3D imaging and digital sculpture. And, of course, there’s something of a TCT favourite in the RAPID Puzzle Challenge, a sort of treasure hunt/3D jigsaw in which attendees must explore the different additive manufacturing technologies and materials represented on the show floor. As event attendees walk the RAPID show floor, they are able to collect the pieces of the puzzle at different exhibitors’ booths and assemble them into a complete design. CONFERENCE As well as a jam-packed exhibition floor RAPID boasts an exceptional speaker line up over the three-day period. 

Keynoting day two is William Warren PhD with his talk, ‘3D Bioprinting a New You: Science Fact or Science Fiction or Somewhere In Between’. As a man who helped initiate bioprinting Dr. Warren will share his experience on what is real today, and what we may see in the next few years. Of the sessions following Dr Warren highlights include: • 3D Printing Continuous Fiber Composites (Carbon Fiber, Kevlar, Glass Fiber) by Greg Mark, MarkForged • Digital Technology in Smithsonian Exhibits by Carolyn Thome and Megan Dattoria Smithsonian Institution • ASTM F42 by Carl Dekker Met-L-Flo

DAY THREE: For the final day of conferencing esteemed industry consultant Terry Wohlers will give his opinions on the current state of the industry. Terry uses his and his team’s wealth of research to emphasise some of the most important trends from the past 12 months. Some of the highlights of the final day of conferencing include: • Future of Medical Additive Manufacturing: Applications & Challenges Panel • Support Optimization for Metal Laser Sintering by Brent Stucker, 3DSIM • Manufacturing and Remanufacturing of Aerospace Components with Direct Metal Deposition (DMD) by Bhaskar Dutta PhD, DM3D Technology and John Giglio, MB Aerospace Warren

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3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

RAPID 2015 Preview

RAPID PREVIEW

CHRIS ELSWORTHY

3D printers give memes a new dimension

WOR DS : C H R IS E L S W O R T HY C E O of C E L a n d C R EAT O R O F T HE R O B O X 3 D PR I N T E R

to the Success Kid, 3D printers are bringing a whole new dimension to meme culture, by giving people the power to print out their favourite memes and enjoy them in real life. Most recently, following a spectacular performance at the Super Bowl earlier this year, a man from Florida began selling 3D printing templates of the world’s new favourite dancing fish – Left Shark. Katy Perry, or more specifically her lawyers, subsequently told him to stop selling the 3D printing templates. While it’s important that intellectual property is kept safe and that people are not unfairly profiting from the hard work of others (in fact, the Left Shark design was later distributed online for free), it is surely only natural that people will want to design and create things they feel passionate about – especially if those things turn in to online sensations and much-loved memes. The creation of 3D printed Left Sharks shows just how fun and reactive 3D printing can be. One of the reasons why 3D printing is so exciting is because it gives people the power to bring their inspiration and creativity into the real world, just like we see people when they react to stories by sharing and adapting images online. For example, at Robox, we’re all big fans of Jeremy Clarkson and Top Gear, and were naturally saddened to see that Jeremy couldn’t get the steak he deserved after a hard day of filming earlier this month. This is why we used one of our printers to create a special version of Hungry Hungry Hippos, which enabled people to feed Jeremy by playing Hungry Hungry Clarksons. Of course this was just a modification to the original game (you can’t 3D print the whole set) but by creating a customised version of Jeremy’s head as an adaptation to the game, we were able to react to something timely and create something fun that people could enjoy for free. rom grumpy cat

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This is how 3D printing has the power to be genuinely transformative, because people today can be more creative and make or modify new things which previously did not exist. Personally, I’ve always hoped that 3D printing will inspire an entirely new generation of makers – those who feel empowered to create and experiment with their own designs. However, looking back at the 3D printed Left Shark episode, this show shows that trademarks and IP law will have to adjust in order to stay relevant. After all, it is clear now that Katy Perry’s camp wanted to retain control of the design - they have just started selling a rather fetching Left Shark Onesie.

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ABOVE: 3D printed fist pump baby meme on shapeways

People today can be more creative and make or modify new things which previously did not exist

As 3D printing moves ever more into the mainstream, consumers and brands alike will increasingly value the design of the object, rather than the object itself, much how we now value the music file rather than the CD it might used to have been sold on. Clearly though, 3D printing is about so much more than just someone 3D printing wild dancing sharks in their bedroom. If it wasn’t then leading analyst house Gartner wouldn’t have put out its latest predictions that worldwide 3D printer shipments will almost double by the end of this year. 3D printing memes are just a good example of the spontaneous creativity which widespread 3D printer usage could unleash. When everyone can bring their favourite ideas to life through experimentation and

Left Shark 3D print by Fernando Sosa

sheer passion, I won’t be surprised if we see even more 3D printed objects going viral, much as videos and memes do today. But you don’t need to look to the far future to see the huge impact that household 3D printers can have. Ask any manufacturer or engineer and they will tell you about the influence that 3D printing has already had when it comes to prototyping, allowing them to cheaply and easily make one off models and test ideas. This has led many to herald a new age in manufacturing where the barriers to entry disappear almost entirely. Additionally, 3D printing has huge potential when it comes to education, inspiring a new generation of makers and kids with creative vision. Moving beyond 3D printed memes and toys, these new young makers will grow up with the skills in the future to make anything they want, whether its replacement dishwasher parts, personalised phone cases, jewellery or even brand new objects entirely. I’ve been speaking to a lot of schools

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recently about the potential of 3D printing in education, and while adults often question what they would print on a 3D printer, children instantly grasp its possibilities. Their designs might not always work at first, but through experimentation they’re soon creating wellcrafted and genuinely inspirational designs. It’s for these reasons that we designed Robox with ease-of-use-first, so that those who want to can simply ‘plug-in and print’. Whether you’re the parent of a creative young child or the owner of a small business looking to quickly trial several new prototypes, what you want is for your 3D printer to just work. You don’t want to spend hours correcting the bed height and learning about the melting points of different materials. You just want to load your design and click print. As 3D printers become increasingly common in home offices, children’s bedrooms, and garden shed workshops around the world, we hope that this will unleash a new wave of creativity so that more

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ABOVE: 3D printing a hungry Clarkson on the Robox cutout

and more consumers become like Left Shark, not conforming to the strict choreography of big corporations, but instead creating and printing their own inspired and personalised designs. And through that, we’ll start to see the most popular memes bursting from out of the computer screen and onto people’s desks, as they bring the latest trends and sensations to life. 

It’s for these reasons that we designed Robox with ease-ofuse first, so that those who want to can simply ‘plug-in and print’

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university of sheffield 3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

3D printed guides CAN HELP RESTORE FUNCTION IN DAMAGED NERVES

WOR DS : JA M E S W O O D C O C K

cientists at the University of Sheffield have succeeded

in using a 3D printed guide to help nerves damaged in traumatic incidents repair themselves. The team used the device to repair nerve damage in animal models and say the method could help treat many types of traumatic injury. The device, called a nerve guidance conduit (NGC), is a framework of tiny tubes, which guide the damaged nerve ends towards each other so that they can repair naturally. Patients with nerve injuries can suffer complete loss of sensation in the damaged area, which can be extremely debilitating. Current methods of repairing nerve damage require surgery to suture or graft the nerve endings, a practice which often yields imperfect results. Although some NGCs are currently used in surgery, they can only be made using a limited range of materials and designs, making them suitable only for certain types of injury. HARNESSING THE POWER OF 3D PRINTING The technique, developed in Sheffield’s Faculty of Engineering, uses Computer Aided Design (CAD) to design the devices, which are then fabricated using laser direct writing, a form of 3D printing. The advantage of this is that it can be adapted for any type of nerve damage or even tailored to an individual patient. Researchers used the 3D printed guides to repair nerve injuries using a novel mouse model developed in Sheffield’s Faculty of Medicine, Dentistry and Health to measure nerve regrowth. They were able to demonstrate successful repair over an injury gap of 3mm, in a 21-day period. “The advantage of 3D printing is that NGCs can be made to the precise shapes required by clinicians,” says John Haycock, Professor of Bioengineering at Sheffield. “We’ve shown that this works in animal models, so the next step is to take this technique towards the clinic”. The Sheffield team used a material called polyethylene glycol, which is already cleared for clinical use and is also suitable for use in 3D printing. “Further work is already underway to investigate device manufacture using biodegradable materials, and also making devices that can work across larger injuries” says Dr Frederik Claeyssens, Senior Lecturer in Biomaterials at Sheffield. “Now we need to confirm that the devices work over larger gaps and address the regulatory requirements,” says Fiona Boissonade, Professor of Neuroscience at Sheffield. 

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ABOVE: Top-down view of the nerve conduit, as viewed under a microscope The small scale of the nerve conduits, especially the internal diameter, pose significant challenges to manufacture Nerve regeneration following grafting (top) with regeneration following use of the nerve conduit (bottom)

Nerve Guides Manufactured from Photocurable Polymers to aid Peripheral Nerve Repair by Christopher Pateman, Adam Harding, Adam Glen, Caroline Taylor, Claire Christmas, Peter Robinson, Steve Rimmer, Fiona Boissonade, Frederik Claeyssens and John W Haycock is published in Biomaterials. For the full paper, visit: http://authors.elsevier.com/ sd/article/S0142961215000721

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WOR D S : TODD G R IM M

INNOVATION IS COMING

to what the news channels have been telling us for a few years, there has not been a flurry of innovation in 3D printing. We find many headlines that treat each new lowcost 3D printer as yet another innovation. I agree with Fried Vancraen’s comment in his TCT Asia keynote where he stated how tiresome he finds the amount of small FDM printers making useless objects. That’s not innovation and neither is much of what has been introduced for industrial applications. What we have witnessed is immense amounts of incremental advancement. While we need this type of progress, it is not innovation. But that is soon to change. I believe that there will be a wave of innovation in hardware, materials, software and applications over the next one to three years. The surge of innovation hasn’t happened, but it is coming. It will be due, in part, to the same sensationalistic reporting that informed us that innovation is rampant. The massive amount of 3D printing news coverage has given impetus to creative minds. Stories of growth and revolution have created an allure; drawn attention; attracted financial resources and provided evidence that 3D printing is a growth market. The 3D-printing storyline sparked new ways of thinking and creative ideas. The lightbulbs went on and projects were started several years ago. Since innovation and product development take time to bear fruit, we are only now starting to see the leading edge of the wave of innovation — one that will easily continue for several years. We have had a sneak peak at what the future holds. In that cusp between purely incremental and purely innovative, lies material extrusion products. Cincinnati Inc and Oak Ridge National Laboratory gave us BAAM for large, fiber-filled plastic parts. Mark Forg3d gave us a desktop printer for fiber reinforced parts. Winsun has announced its technology for printing buildings and structures. Voxel8 combines extrusion and direct write for electro-mechanical assemblies. ontrary

I believe that there will be a wave of innovation in hardware, materials, software and applications over the next one to three years.

Todd Grimm

is a stalwart of the additive manufacturing industry, having held positions across sales and marketing in some of the industries biggest names. Todd is currently the AM Industry advisor with AMUG

tgrimm@tagrimm.com

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The forerunners of what is to come also include innovations. HP whetted appetites with the introduction of Multi Jet Fusion. When available, it promises to address the demands for speed, functionality, detail and cost. Most recently, Carbon3D emerged from the shadows with CLIP, a 3D printing process claimed to improve throughput by 25 to 100 times and provide a wide variety of materials for highly detail parts. And don’t forget Impossible Objects, which has received far less attention. This company will launch a 3D printer that can make composite parts that can be substituted for carbon-fiber layups. Exciting, isn’t it? But just wait because there is much, much more to come. Although I am not at liberty to share, I have had the pleasure of being exposed to innovative 3D printing technologies that aren’t being discussed publicly. I hope you understand that I cannot elaborate. But please place some faith in my conclusion that there will be many, many more innovative breakthroughs doing unbelievable things. I, by no means, have been exposed to everything that is brewing. I’ve had a peek at a small sliver of the iceberg just below the water’s surface, but there is so much more out of my view. That makes me quite excited to see how the next few years unfold. While I am seeing interesting things, I won’t make predictions of success until I see the solution in the hands of the users and witness the true value that they can deliver. An innovative idea does not guarantee commercial success. Each innovation I mentioned and each on which I have been debriefed holds promise; but the final verdict won’t be made until the user community casts its vote. Creativity, innovation and success take time. Ideas need to incubate and working prototypes need to evolve. That’s why I believe that the next one to three years will be the coming age of new, innovative 3D printing solutions. So catch your breath while you can and get ready for an exciting ride that is likely to give you something you had hoped for from 3D printing. 

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