TCT Europe 22.4 by TCT Magazine

JULY 14

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

“TODAY’S DIY IS TOMORROW’S MADE IN AMERICA.” BARACK OBAMA

3D PRINTING, ADDITIVE MANUFACTURING AND PRODUCT DEVELOPMENT

ISSN 1751-0333

GROUP EDITOR James Woodcock e: james@rapidnews.com

ASSOCIATE EDITOR Daniel O’Connor e: daniel.oconnor@rapidnews.com

DIGITAL AND COMMUNITY EDITOR Rose Brooke e: rose.brooke@rapidnews.com

NEWSDESK +44 (0) 1244 680222

REGULAR CONTRIBUTORS Todd Grimm | T. A. Grimm & Associates | tgrimm@tagrimm.com Joris Peels | www.voxelfab.com | joris@voxelfab.com

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DESIGN Sam Hamlyn Tracey Roberts

C.O.O. / PUBLISHER Duncan Wood

C.E.O. Mark Blezard

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CONTENTS tct + personalize | July 2014

01 COVER STAR 3D Print of Barack Obama, which will go on display at the US National Portrait Gallery, was produced by the Smithsonian Institute and presented at the White House Maker Faire. “Today’s DIY, is tomorrow’s Made in America,” the President said at the event.

REGULARS 07 FROM THE EDITOR’S DESK 17

JORIS PEELS COLUMN

25 TODD GRIMM COLUMN

FEATURES 20

3D DIGITISING THE SMITHSONIAN

TCT SHOW PREVIEW

RAPID REVIEW

HAWK3DPROTO

MIDAS PATTERN

SASAM

MAKER MOVEMENT

3T RPD

60 SECOND INTERVIEW

The Digitization Program has set about giving the public access to the 99% of the museum’s collection not on display.

AUTOMOTIVE FOCUS

THE REAL MAGIC

34 30

Top 3D technology and AM in automotive news from the past month.

3D designer Rainer Duda unveils one of the movie business’s worst kept secret - additive manufacturing.

AUTODESK We talked to Autodesk’s Maker Advocate Jesse Harrington to see how this software giant is taking over 3D printing.

ZAHA HADID ARCHITECTS An exclusive interview with one of Zaha Hadid’s senior architects on how 3D printing could transform construction.

TOOLS, JIGS & FIXTURES Exploring one of the most profitable areas for 3D printing exploration, the field of bespoke jigs, fixtures and organisational tools.

July 2014

A snapshot of what to expect at TCT Show 2014, with exclusive insights into what exhibitors have planned for the three-day event.

Our rundown of the sights and announcements made at Rapid 2014, which this year was held at the heart of US manufacturing in Detroit, Michigan.

We stopped in at Hawk3DProto’s shiny new 3D printing showroom in Yorkshire to learn more about this up-and-coming spin-out.

The Bedford-based firm shows how it blends traditional expertise with cutting-edge tech.

Part two of our look at the European project to create standards and workflows for AM.

An insight into what the RepRap guys and 3D Hubs have planned for TCT Show + Personalize 2014.

3T RPD has helped create one of this summer’s most iconic sporting emblems, the Commonwealth Games Baton.

We asked designer and 3DP champion Daniel Hilldrup to answer some quickfire questions.

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THE EDITOR Baker baker make me a maker Looking back at the couple of decade’s worth of front covers TCT has had it would be fair to say that most of the subjects are fairly esoteric. This month’s cover breaks that mould by featuring one of the best-known individuals on the planet today — The President of the United States of America. POTUS to those in the know. Scanned and 3D printed the faithful replication of The Commander in Chief introduces an issue that is full of surprises. The cover stems from the inaugural White House Maker Faire at which POTUS stated that ‘Today’s DIY is tomorrow’s Made in America’, going on to explain how the great nation was built ‘not by buying stuff, but by building stuff — by making stuff, by tinkering and inventing and building; by making and selling things first in a growing national market and then in an international market — stuff “Made in America”.’ It seems that these days, everyone wants to be a maker. Even the leader of the free world. This sentiment is epitomised by the number of features this issue’s cover touches within the magazine: the lead feature on The Smithsonian Institutes digitisation programme is pertinent to the cover; as is the feature on Autodesk’s 3D printing ambitions; as is the Maker Movement update; as is the TCT Show + Personalize preview. The rise of the maker and the trickle up influence on the AM industry is one of the biggest forces at play in TCT’s world at the moment both in terms of the news we cover and how we cover it. You may have noticed that www.prsnlz.me no longer exists as a separate entity to www.tctmagazine.com. All the content is still accessible through the main TCT website however (it’s far, far too good to get rid of) and we hope to continue the work we started with Personalize into the

future. The fact of the matter is the industry as a whole is converging rather than diverging as we predicted when we launched the newer brand. If you need proof, take a look at TCT Show (+ Personalize, of course) where you will see multi-million-dollar machines rub shoulders with printers that cost less than a thousand dollars, makers hobnobbing with aerospace top brass. This issue also contains the TCT Show + Personalize preview with news from some of the couple of hundred companies you will be able to see on the show floor. The next issue will be the one that we take to the show in September — a scary thought — so make sure you register (for free) on tctshow.com now. There’s further change afoot with within TCT Towers too, as we bid farewell to Rose Brooke after 18 months of flawless service to the cause. Luckily she’s not moving far, taking up the position of Editor on TCT’s stablemate, EPPM. Dan O’Connor also had a move, becoming our Associate Editor and in the next week we will be welcoming a new member of the editorial team. Fresh blood, new ideas, change. They’re what keeps the industry and our magazine going and they should always be embraced. With that in mind I hope you find some inspiration within these pages and at TCT Show — if you do we’d love to hear about it!

Keep on creating,

Jim Woodcock

Design today... ...build tomorrow Unlock the potential for Additive Manufacturing Renishaw’s laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD. Find out more at www.renishaw.com/additive

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THE SMITHSONIAN DIGITISATION PROGRAM

CAPTURING AMERICAâ&#x20AC;&#x2122;S A 8

www.tctmagazine.com | www.prsnlz.me

July 2014

G ATTIC

THE SMITHSONIAN DIGITISATION PROGRAM

The Smithsonian Institute is home to an eclectic array of 137 million objects, artworks and specimens, from Teddy Roosevelt’s Teddy Bear to a 4.374-billion-year-old piece of the earth. But how much of that collection do you think is on display at the 19 Museums, 9 research centres and 180 affiliate museums? The answer is about 1%, the other 99% is either too precious to be on display or frankly doesn’t have the mass appeal to warrant an exhibition space.

WORDS | Daniel O’Connor

merica’s Attic”, does want people to be able to explore the entire collection and the solution appears to revolve around 3D and the Smithsonian Digitization Program. The Digitization Program Office (DPO) ambitiously wants to scan every artefact in the Institute’s collection and present them to the world on their virtual platform. “

“Our office’s mission is to support all of the Smithsonian museums and research centres,” Vincent Rossi, 3D Digitization Coordinator at The Smithsonian Institution told TCT. “In November 2013 we launched our project, Smithsonian X 3D. The Smithsonian X 3D Explorer was donated to us by Autodesk and gives anyone the ability to explore models online using our webGL storytelling tool. It gives people the opportunity to download our models and 3D print. The goal of the Smithsonian X 3D project was to scan an object or archaeological site from every Smithsonian museum and research centre to show the potential of 3D tech.” Vince’s teammate Adam Metallo added: “With 3D data we can distribute our content online through our viewer, delivering highresolution data to scientists around the world. We are also working closely with Smithsonian educators to wrap STEM curriculum around our 3D printable models. Our next goal is to make use of automated systems to scan entire collections instead of one off projects.”

Continued on page 11

July 2014

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THE SMITHSONIAN DIGITISATION PROGRAM Thrown to the whales Though the DPO and Smithsonian X 3D was only officially launched in 2013 and the Presidential effort marks their most publicised work, during an early-stage pilot run the DPO team were given quite the baptism of fire when Dr. Nicholas Pyenson called in 2011. Dr Pyenson is the Principal Investigator of one of the most extensive and astounding archaeological sites on earth, Cerro Ballena. The site, which roughly translates to “Whale Hill”, is located in wellknown fossil goldmine, the Atacama Desert.

A Presidential Project One of the best examples of the work available on the Smithsonian X 3D site is the life mask of Abraham Lincoln taken just two months before he was shot dead That at the age of 65. The DPO team had to scan sculptor Clark Mills’ cast of the 16th President in order to digitise and build the 3D model, but for the 44th and latest President, they were able to scan more than just an inanimate object, they were able to scan the living, breathing Leader of the Free World himself, Barack Obama. The scan that led to the 3D printed bust, which is plastered on our front cover, as well as a 3D printed life mask are destined for the Smithsonian National Portrait Gallery. The SLS 3D prints will sit alongside oil paintings of George Washington, plaster casts of Abraham Lincoln, a Giclée print of Bill Clinton to represent the changing eras of technology since the USA declared independence some 238 years ago.

While working on the Pan-American Highway construction workers began to reveal what would become the densest site for individual fossils of extinct marine life ever discovered. Pyenson’s first sighting of Cerro Ballena gave him shivers, he knew this was perhaps the most important discovery in his field of palaeontology, but it was soon to be paved over and Chilean museum workers had already it is Obama began to bag the bones.

who has become the first 3D scanned and printed President is apt, he has been banging the drum for 3D technologies since his 2013 State of the Union Address and the portraits were presented at the first White House Maker Faire.

In an Avengersesque manner The Oval Office called upon the Smithsonian, University of Southern California, Autodesk and 3D Systems to assemble in order to combine their considerable expertise in creating the best possible accuracy. That it is Obama who has become the first 3D scanned and printed President is apt, he has been banging the drum for 3D technologies since his 2013 State of the Union Address and the portraits were presented at the first White House Maker Faire.

“I had a problem on my hands; how do I capture all the current information about these incredibly large skeletons in a very rapid and accurate way?” Dr Pyenson told TCT Magazine. “The 3D Digitization Office had just started and, by chance, I had bumped into both Adam and Vince who I would later call “The Laser Cowboys”. I met them in my department while they were conducting a pilot study of digitisation on some fossils. I was able to convince their boss and the Laser Cowboys were on a plane to Chile with me within two weeks.”

The DPO team arrived at the site armed with all the technologies they could possibly need. “We used a variety of 3D scanning technologies - laser arm scanning, medium range laser scanning and photogrammetry,” Vince noted. Pyenson continued: “scanning a site of this scale had never been done before, Adam and Vince had tremendous amount of foresight in bringing multiple systems down as contingencies. You never know what might go wrong in the field, one of the mid-range laser scanners ended up collecting uncalibrated data.” Continued on page 13

Three overlapping fossils in the Atacama Desert

Night scanning of La Familia

July 2014

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SMITHSONIAN DIGITISATION PROGRAM

Futureproofing 3D has the ability to transform natural history studies across the globe, the beta Smithsonian X 3D project is an example of how the world’s scientific communities could collaborate on objects both virtually and physically with the aid of a 3D printer. But despite all the tools being in place Dr Pyenson doesn’t believe we’re quite ready yet.

Laser sintered Print of the Fossil

With the big wheels of industry bearing down on them – both metaphorically and literally as 18 wheelers thundered through the site, each passing increasing the chance of disturbing the fossils, which had lain undisturbed for the previous six-to-nine million years - the team had just two-weeks to complete the scanning that Pyenson thought vital for future studies. “With this technology we now have the ability to document the surroundings in precise and faithful detail, it captures information with a specific time stamp and precise GPS co-ordinates. That’s just as important as if it was the carcass of a rare species or if it was a fossil that was eroding out of a cliff face because these specimens are constantly losing information from the second that you retrieve them. We need to document these things as undergo this great path of discovery The term “game they in the field to them ending up at a changer” is often museum for posterity.”

bandied around when writing about this technology, but in natural history studies it has more significance than just marketing hyperbole.

The digitisation of the site has allowed Dr Pyenson and his colleagues to publish their findings, which came to the conclusion that the multiple deaths at the mass graveyard were caused by harmful algal blooms (HABs) that are still a cause of mass strandings today. Because there were no land scavengers in South America during the Miocene period (23.03 to 5.332 million years ago) the skeletons remained largely intact until they were discovered in 2011.

“The tools in this field haven’t changed in 150 years; we still use plaster, we still use hammers and pick axes; to see the 3D models that we collected with technology three years ago under time-sensitive conditions shows how important this technology will be,” continued Pyenson. “When you have the ability to generate 3D models from a cell phone or tablet, well, you realise that that really is a game changer. “ The term “game changer” is often bandied around when writing about this technology, but in natural history studies it has more significance than just marketing hyperbole. “The penetration of smartphone technology means thats there is a chance that somebody seeing a fossil for the first time might be able to capture the relevant data on their smartphone and then send that to somebody that might know more,” enthused Pyenson. “It is a big challenge in natural history studies to understand what previous workers were doing when all you might have from a fossil in a museum drawer is a little note on where it was found. You have to do a lot of detective work that involves tracking down maps and field notes. With 3D you’d have full documentation of what that specimen looked like, when it was salvaged, where it was found. You can draw so much more of a fossil’s long arch from discovery to museum drawer.”

“The sharing of natural history files absolutely changes the way studies are conducted but there are a few obstacles we need to hurdle before that is possible. Although it is absolutely possible to share the files, we have to ensure that, firstly, the files that are being shared have the highest fidelity and it also is a frontier that will have to involve museum administrators and lawyers. Because it is so new there isn’t a good legal infrastructure in place for how we share these 3D files, they’re facsimiles just like a research cast would be.” Pyenson raves about the 3D Systems full 20 ft SLS print of the centrepiece of the Cerro Ballena collection, which is now mounted at the National Museum of Natural History but he is still slightly reserved when it comes to 3D printing’s capability in research usage. “Making a mould cast of a fossil has been done for well over 100 years, I would argue that they’re much higher quality than any 3D printer could achieve. That doesn’t mean 3D printers won’t get better and surpass moulds but what it does mean is that it is a better use of your time to generate a mould if possible. You can take electronic scanning microscope images off a cast made from a silicone mould but you cannot do with 3D printing as the build lines are too big.” “However you may not be in a position to take a mould from an individual fossil, you might be too far away or it might be too delicate, there’s an example on the Smithsonian X 3D website. That fossil from Panama was way too delicate to make a traditional research cast from, so we CT scanned it and built a 3D model, from that we were able to print a full size model and paint it. The printed and painted model looks exactly like the original and will go on display at the museum in Panama. I love finding out all these new avenues and workflows for solutions that relate to the social context of how we do science.”

Dr Pyenson and the finished 3D Print

The Digitization Program will change the way natural history can be studied, potentially globalising and democratising research from scientists at opposites sides of the globe. Digitisation shows that, unlike the Cetaceans found at Cerro Ballena, the Smithsonian Institute will continue to evolve to ensure it never goes extinct. i| http://3d.si.edu

July 2014

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NEWS ROUNDUP: Automotive focus

NEWS

ROUNDUP

The automotive sector is making full use of every 3D advancement going; from metrology and inspection, to CAD, to additive manufacturing itself. Local Motors is making history by embarking upon the first open-source, 3D-printable car project, while the British Government is ensuring the UK’s additive manufacturing sector is being given the opportunity to grow into automotive supply chains. For these stories in full, click to www.tctmagazine.com/topics/automotive..

HONDA PIONEERS 3DXCITE 3D SOFTWARE FOR CRASH TESTING Honda is pioneering ground-breaking 3D crash simulation software developed in partnership with 3DXCITE allowing engineers to view collisions more precisely. The DELTAGEN and LS-DYNA CAE-based software renders the collision in 3D, allowing engineers to study the results more easily from multiple angles and by stripping away layers of the car.

3D IMAGING ‘KEY TO FUTURE OF AUTOMOTIVE’

MAHLE TEAMS UP WITH DM3D TO DELIVER WEAR-RESISTANT COMPONENTS

Mahle and DM3D Technology have joined forces to deliver superior automotive components using DM3D’s proprietary direct metal deposition technology. CEO of DM3D Roger Parsons said the company is “very excited” about the partnership and both parties look forward to developing more automotivecentred applications in the future.

3D imaging and measurement technologies have been highlighted as crucial to the advancement of automotive design and engineering. This is according to Research and Markets’ 2014 Report on the International Image Recognition Market, which pinpoints automotive safety, car security and parking assistance as areas of technological development to watch.

3D PRINTING BOOST AS GOVT FREES UP £100M FOR MANUFACTURING

UK AUTOMOTIVE UPTURN HINTS AT BRIGHT FUTURE FOR AM

In a scheme that has already benefited 3D printing in the UK, the British Government has freed up a further £100 million to help strengthen the manufacturing supply chain. In the previous round, funding went to increasing the scale of metal additive manufacturing.

LOCAL MOTORS SELECTS DESIGN FOR 3D-PRINTED CAR

The Department for Business, Innovation and Skills has revealed figures showing British car production rose by 21.3 per cent in April 2014 - the largest monthly rise for the industry since July 2012. This bodes well for research and development, hardware and skills investment for the sector, which could strengthen the UK’s additive manufacturing industry in turn.

Local Motors has picked the design for its pioneering 3D-printed electric car. The Phoenix-based open source automotive manufacturing business selected Michele Anoè’s Strati model, which will be 3Dprinted, finished and assembled over the course of the six-day International Manufacturing Technology Show in Chicago this September. July 2014

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July 2014

JORIS COLUMN About the Author Joris Peels is a business development, strategy, product development and marketing consultant to the 3D printing industry you can read his blog at http://voxelfab.com/blog/, follow him on Twitter @voxelfab or email him joris@voxelfab.com

e-NABLE, 3D Printed Prosthetics. AN ANTIDOTE FOR A CYNIC.

s you may know I’m in a bit of a cynic. I take a dim view of a lot of the “world changing”, “3D printer on every desktop” talk. As I’ve seen the press descend from some signals and some noise to just noise, I’ve grown increasingly despondent about the press in general. If you can’t call a local university and go by to see a 3D printer, if you don’t bother to go to a local service bureau or read the Wikipedia article on the technology then how the hell do I’ve been able to give you hope to explain this technology to people? And given kids a coherent the amount of misinformation, understanding of the deception and stupidity in the media about 3D printing, how are technology and its these people supposed to explain limitations while Syria to me? If these guys don’t take the time to watch a YouTube getting them to design video to understand a something that could straightforward technology then be 3D printed in two what must I think about the hour workshops. This accuracy of their information on what the Iranian government same level of depth of wants or what is happening understanding is anywhere in the world? Really, you’re going to explain North however not shared by Korea to me? But, you’re unable the world’s journalists. to understand 3D printing? I’ve been able to give kids a coherent understanding of the technology and its limitations while getting them to design something that could be 3D printed in two-hour workshops. This same level of depth of understanding is however not shared by the world’s journalists. In this tight-deadline 24-hour news cycle world the press has no time to learn, explore or do in depth journalism. Instead our newspapers, TV channels and online media are echo chambers through which early consensus about a chosen narrative reverberates incessantly. No depth of understanding is given. X is a breakthrough. X is amazing. X will change Y. X will change Z. Is X all its cracked up to be? X is terrible. X is super disappointing. Then they move on to a new topic. A Greek chorus singing a happy song that turns into a sad one. And this chorus is about to turn against us. Without exploring in depth there are only so many directions one can go, and we’re about to experience the negative side of things and slide into the trough of disillusionment. We deserve this. We had a good run. And collectively we did sprout a lot of bovine excrement into this curious planet’s naïve faces. We forgot to tell them that the machines are limited. We omitted to mention that when we said you could 3D print anything on the desktop that this was actually a blatant lie. We can’t actually make every shape, especially not without support. And even if you could it wouldn’t mean that shape is functional. And yeah you’re going to have to spend 2,000 hours learning CAD if you really want to be able to design. There are some new interesting 3D printers coming out. But a lot of new releases and Kickstarters seem to have done their engineering in la la land. It’s a slick campaign and a cool looking idea that will not work. You watch the video and can immediately Continued on page 19

July 2014

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© Jen Owen of Jen Martin Studios conclude that a mechanical engineer didn’t get within a million miles of this project. This is TinkyWinky our experienced business professional. This is Po who does business development. This is Laa Laa who does the marketing. And... and who did the engineering? Nobody? Interesting. Look, love the look and feel. Good copy on the page. But, did you perchance talk to a materials scientist? Ever think of safety? You know there are like three ways that resin could kill you, right? These kinds of projects will probably not engender 3D printing to the world’s tech hungry. We’ve seen an influx of cowboys, the greedy and the MBAs as well as a lot of people who seem to tick all three boxes. Let’s hope they don’t blow it for everyone. We can extend our happy time a bit with filament recyclers, they really make things much cheaper. A desktop 3D-printed vase will not be $8 but it will be $0.60. Using a filament recycler you can grind up your misprints. You can grind up your broken things, grind up PET, HDPE, ABS and lots of packaging and other household waste to make filament. This will enable closed loop recycling in the home, and kill of much of the $55 million-a-year desktop filament business and blow a big hole in a lot of people’s business models.

But, by making 3D printing much more environmentally friendly it will extend our press coverage and change the market. Because now you can sell a vase for a $1 and make a profit on it or give away a few to friends. This will expand the desktop market greatly and significantly lower the TCO and cost per part of desktop users. Who cares if it doesn’t look consumer friendly, its cheaper than buying it from Wall Mart. Projects such as FilaMaker are our rays of hope. They will keep the camera crews visiting. That is if a capable filament recycler comes out soon.

JORIS COLUMN 3D printed prosthetics, e-NABLE Close to...its not dispair, what comes before despair, that. I blundered into e-NABLE, also known as Enabling The Future. I’ve been smiling ever since. I’d read about them earlier but it really is wonderful to see what they are doing with 3D printing. e-NABLE is a project that aims to make inexpensive 3D printed prosthetics. These come off desktop machines and cost between $25 and $50. They are designed by volunteer designers & engineers from all over the world. People work directly with the users of the hands to scope, get feedback, iterate and design. People work together on designs and components and also individually come up with entirely new reference designs. People volunteer to do the marketing, content, branding, legal, everything. Some people have worn these prosthetic hands for several months. Replacing expensive prosthetic hands that cost thousands and would not be affordable to many. The e-NABLE community is also hyper decentralized meeting in Google Hangouts and communication on Google+. There is a web page. But, most content, exchanges and interaction happen in a decentralized way using free communication tools. All the work and materials have been fronted by the engineers or paid for by the customers so eNABLE has next to no overhead. Its pure decentralized open innovation as has been talked about often but rather actually occurred. How to join e-NABLE? • Sign up for the e-NABLE Google+ Community • Introduce yourself. • Fill out your information, skills, experience and what you want to do. • You will be contacted and matched with a task, person needing prosthetic, engineer etc. That’s it. I’ve spent quite some time managing communities and am very intrigued by this set up. I love the idea of people leveraging their work skills to use the internet to help others. In a time when “liking” something is as close as many get to helping other people this kind of a movement can be significant. It also combines well with ones personal life, letting one drop in, do a task and then drop out if work pressure or the new baby don’t let you volunteer. Instant convenient armchair volunteering for the ADHD generation. I also love that this is a functional application for desktop 3D printing that actually works. Using the key strengths of 3D printing of being able to customise, iterate, change and design quickly they’ve created a family of functional products. Now by using flexible filament and the like many more designs are coming to the fore. If you’d like to leverage your design or AM skills, I’d highly recommend helping out. I spoke to Jon Schull one of the founders of the project. John thinks that “e-NABLE’s crowdsourced humanitarian innovation is not necessarily restricted to hands.” “Arms are being worked on and there are many other areas e-NABLE could impact.” He loves the combination of “emerging technologies and smiling children.” He describes the community as “self-selecting bright community that sometimes may need some ‘cat herding’ or collective vision but generally functions near autonomously.” He also says that “I don’t know yet how we do what we do.” Much of e-NABLE’s development was spontaneous with people getting involved and coming up with novel designs in isolation. Meanwhile collective cooperation, open discussion and some organisation have happened since. They are now trying to collect data on the usefulness of the prosthetics, working on robustness, assembly and new design directions. They are also looking at software tools that will let people collaborate even more and looking for corporate or government sponsors to professionalise the administration and information sharing. If you’re an engineer or business person working in AM please do check out e-NABLE. Theres a lot of effort and knowledge going into the community but strong AM, production, materials and design knowledge is needed. Maybe you could give a helping hand?

July 2014

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AM IN ENTERTAINMENT

The Real Magic behind Feature Films WORDS | Rainer Duda

t is one of the most pleasant hobbies for a lot of people, especially on a rainy day at the weekend. Others use it as a beginning of a romantic evening. We are talking about going out to the cinema and enjoying a movie. But there are two sides of the medal. The enjoyable result on the screen and what many people don’t see - the intense work behind a feature film.

How additive manufacturing is used to improve production pipelines in the entertainment industry.

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July 2014

Modern feature films consist, roughly speaking, of two types of footage. Firstly, the digital side with animated 3D data such as character animations, volumetric special effects, as well as other mind-blowing features. On the other side there is the live action footage which will be merged into the digital environment followed by special post-process techniques – again in the digital environment – to achieve a consistent look for the final image. The question that appears at this point is: “So where’s the connection to additive manufacturing?” To answer this, we have to dig into the live action footage and processes involved in this field. Live action footage is no more than footage recorded of real actors and real practical effects inside a real environment. Usually both branches, digital and real, follow the same startup process. At the beginning there is the concept design phase. The digital branch works with painted images including 360degree pictures for characters and mood boards that artists rebuild in 3D software packages and assets for real footage pass through several design iterations during the model-making process.

RAINER DUDA - FILM

Where the magic happens One really huge part of the model-making process is traditional sculpting with clay. This is where the magic happens. The revolution in the creation of real footage through additive manufacturing is placed right in this sculpting phase and builds a bridge between the concept design phase for digital footage to the model-making process of live action footage assets. Traditional sculpting, however, means a lot of handmade design iterations based on supervisor feedback, followed by lead approvals.

The design phase including final approval for a special asset can and will be made by reviewing the final 3D model within the appropriate 3D software package of an artist.

It could take days to create a special requisite. If we start talking about a couple of assets we reach a bottleneck. These days, production times for shots are getting shorter and shorter, but 3D modeling and rendering helps. The design phase including final approval for a special asset can and will be made by reviewing the final 3D model within the appropriate 3D software package of an artist. Subsequently artists output STL files for the 3D printer, which is a huge time improvement, while multiple assets can be produced simultaneously.

One company which uses additive manufacturing for the creation of requisites, prototypes for mouldmaking is Legacy Effects. Legacy Effects is a veteran studio when it comes to visual and practical effects and its repertoire of technologies and manpower contains highly talented artists for digital visualisation, as well as traditional techniques like hand sculpting and painting. The company has expanded its technology pool with an animatronics department and on top of that, it heavily uses 3D printing. Realistic and futuristic Legacy Effectsâ&#x20AC;&#x2122; 3D printing happens in the model shop, which is equipped with an Objet Eden 260V and an Objet Connex 3D printer to simulate hard and soft versions of pieces. The department also has an EnvisionTEC Prefactory 4 DLP printer for miniatures, and for bigger pieces the team uses the iPRO 8000 SLA from 3D Systems. Applications vary from shot to shot but Legacy Effects is known for its proficiency in making futuristic suits and robots for blockbusters such as Iron Man 2 and Reel Steel. The digital design department works hand-in-hand with the model shop to create a realisticlooking base asset before it goes to the traditional painting department, or even further to the staff who are specialised in moulding. This production pipeline is so optimised it allows the creation of fully-functional suits and robots, which gives the teams Continued on page 23

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HIGH TECH INDUSTRIES

AEROSPACE

Metal 3D Printing High End AM for High End Applications

ORTHOPEDICS

DENTAL Jonas Van Vaerenbergh, LayerWise CEO 44,000 sq ft

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info@layerwise.com NEW HEADQUARTERS

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Opting to use 3D printing is more or less an overtaking maneuver to bypass traditional sculpting.

greater flexibility in the design of multiple iterations. With traditional sculpting there is always the problem when it comes to technical functionalities. Questions will appear if it will work out after the model is done. Now the digital design department can Now the digital design the suit and even make functional tests inside the 3D design application before anyone is working department can on a real asset. If the asset works, the artists will prepare valid STL files. design the suit Apart from the flexibility of testing and even make functionalities before creating something real they can print functional tests multiple assets in a short time period. That can be a helmet part in inside the 3D the morning and a clear visor after application before lunch.

anyone is working on a real asset.

Opting to use 3D printing is more or less an overtaking maneuver to bypass traditional sculpting. Some refinement steps are still required before the asset jumps to the painting department, but even if there are some steps missing, the improvement is noticeable. To give an idea of how additive manufacturing has improved the production schedule pipeline, Legacy Effects created 26 full-size robots for the feature film Reel Steel in a timeframe similar to the process of hand sculpting the first terminator model. Of course the company uses additive manufacturing in the same way as other serious businesses do. If a piece of armour is needed for a special shot but with different materials and a different kind of shore strength, then one master prototype will be digitally designed and printed including all necessary details. That prototype serves for mould-making. Legacy Effects shows us how the potential of 3D printing can be used to save time and money within a feature film production. But apart from that, a new production pipeline allows greater flexibility in a short timeframe. It will be enthralling to see how the next generation of 3D printers will be utilised to let the feature film magic happen.

As is often the case with 3D printing, the effects are two-fold â&#x20AC;&#x201D; a contraction of the development time and, importantly, an explosion in the number of iterations possible during a given period.

i| www.legacyefx.com

July 2014

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July 2014

GRIMM COLUMN

The 3D Printing Race; Picking Your Winners? F

earing obsolescence or investing in the wrong company? I am often asked who will be the short-, mid- and long-term winners in the 3D printing space. If you are on the verge of making a significant investment, you are probably asking the very same question. But I think that is the wrong question, for three reasons. One, there is too much activity and there are too many solutions that have yet to be revealed. Two, the industry is much too diverse; we are nowhere near having a few exceptional solutions for every application. Three, fear of obsolescence isnâ&#x20AC;&#x2122;t a reason for inaction; pick right and you can profit from your selection before obsolescence becomes an issue. The latter point leads to the right question: Which technologies are best for my applications, as they exist in the near term? On the surface, this seems easy. However, with the current line-up of options and all of the R&D activity, selection can be a bit daunting and challenging. This is a good problem to have. We have more 3D printing options than ever before, making it much more likely that you can find a good or great solution for your business ventures. Waiting for the dust to settle is not an option since the menu of 3D printing options will continue to expand. Fuel for Growth Fundamentally, the biggest change over the past few years is the level of attention that 3D printing has received. That attention has garnered more interest, creating more demand, and it has attracted more players offering more alternatives. With all eyes on the 3D printing industry, we now have an abundance of the fuel for growth.

About the Author 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 the AMUG. You can contact him on tgrimm@tagrimm.com

WORDS | Todd Grimm Commentary depicting 3D printing as an industry with explosive growth potential and â&#x20AC;&#x2DC;the next big thingâ&#x20AC;&#x2122; has tapped into emotions that are propelling the technology forward. The user population is growing because 3D printing is now viewed as a must-have rather than an optional expense. The growing user base funnels money back into the industry. Seeking to profit from this growth industry, money is also flowing in from interests outside of the 3D printing realm. Equally important is the mindshare that 3D printing is receiving. Countless individuals, corporations and research labs are pondering how to make 3D printing better and how to further innovate this technology. Money and minds are the resources needed to fuel growth. With ample amounts of each, there has been, and will be, a flood of innovation for hardware, materials, software, processes and services. The activity level is impressive. Think tanks and universities; startups and large corporations; and retailers and industrial equipment suppliers, to name a few, have launched initiatives in 3D printing. These organisations are tackling ongoing challenges and creating new approaches that will advance the capabilities of 3D printing. Some will be winners, maybe even unseating the present leaders. The others will have varying degrees of success.

In this torrent of new solutions, there will be a smattering of great innovations, a whole lot of average ideas, many half-baked plans and a few breakthroughs that are simply ahead of their time.

In this torrent of new solutions, there will be a smattering of great innovations, a whole lot of average ideas, many half-baked plans and a few breakthroughs that are simply ahead of their time. With so many new options, the already mind-boggling number of alternatives will balloon. So picking a winner becomes increasingly difficult. Continued on page 27

July 2014

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In five or 10 years, the pool of options will contract to a manageable number once industry has selected the winners. But before that happens, prospective 3D printing users will have more, and possibly too much, of a good thing.

Having many options is a good thing, but having too many alternatives can make the 3D printing space overwhelming, confusing and imposing. For some, this can lead to paralysis, especially if obsolescence is an important consideration.

Overwhelming Choice Having many options is a good thing, but having too many alternatives can make the 3D printing space overwhelming, confusing and imposing. For some, this can lead to paralysis, especially if obsolescence is an important consideration. For others, too many options lead to buyer’s remorse if they believe that they should have made a better decision. Ignoring paralysis and remorse, we are all still faced with the somewhat daunting endeavor of getting a handle on all of the 3D printing offerings. As more new products arrive, the task will become increasingly difficult. I can empathise. It’s my day job to stay on top of all that is new. Yet, there never seems to be enough time to investigate each announcement. I can’t imagine how hard it would be to get a grip on the 3D printing industry when that project is just one of many.

According to some researchers, the number of options isn’t necessarily the sole factor for indecision and regret. Faced with countless options, a lack of information is believed to be the real culprit. Well, the 3D printing suppliers don’t offer us much assistance in negating this issue. Beyond a spec sheet with a few key details, many accompanied by a note stating that results vary, details are hard to come by. Complicating matters, 3D printing is so unique that many comment that they don’t even know what questions to ask when evaluating options.

Another factor is that 3D printing can’t be generalised. The questions to ask and the details required for each core technology vary. 3D printing isn’t like CNC milling or injection moulding. When evaluating 3D printing, a better analogy would be all plastics (or metal) manufacturing methods. Finding the best 3D printing solutions is more akin to finding the right manufacturing process from a diverse range of options that include injection moulding, blow moulding, vacuum forming, rotational moulding, reaction injection moulding, and others. The final factor is that it is rare that a single technology can address all of your applications while meeting all of your specifications. To do everything, you will most likely need a number of 3D printing technologies. Picking Your Winner So, what to should you do in light of so many choices with more to come? For starters, set a reasonable goal of finding a solution that is good enough. If you make it a goal to find the perfect solution, the evaluation process may become never-ending. Also, recognise that your first system will not be your last. For a comprehensive 3D printing operation, you will be revisiting your needs and adding additional technologies sometime in the future. With this mentality, success is achieved if your printer produces any measurable business benefits. Beyond that high-level recommendation, following are four steps that I suggest. 1. Select an application and define the real needs To simplify the evaluation, focus on the most important application and clearly define what is needed for success. If you try to address all of your 3D printing needs at once, the list of key criteria will become unwieldy. 2. Decide a price point Considering budgets and the needs of the application, determine a system price threshold. This simple act will cut your list of options significantly. For example, if you determine that you need an industrial-grade solution for less than £100,000, you will have whittled the list down to a few dozen products. 3. Evaluate all options At the core technology level, not the product or vendor level, perform a high-level evaluation of all the options. The goal here is to eliminate those that cannot meet your needs. More than likely, this action will pare the list down to two or three options. 4. Investigate the short list Now that you have a manageable list, it is time to do a thorough investigation at the vendor and product level. Dig in an find out every detail that you can. Following these steps, you can minimise overwhelm and confusion. If after all of the investigation you cannot find a good 3D printing alternative, just wait. Odds are that one of those new companies or research labs will develop a 3D printing solution that offers what you are looking for.

July 2014

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AUTODESK 3D

This magazine has been around for a generation now and in that time CAD has remained in the hands of select few trained experts but as Bob Dylan once penned “Times, they are a-changin’”. There’s been a seismic shift towards getting 3D modelling into the hands of the populous and the next generation may well see CAD become as ubiquitous as the editing of photographs is now on platforms such as Instagram and Photoshop.

MOULDING THE MAKERS WORDS | Daniel O’Connor

here’s one company at the forefront of the shift taking CAD from the hands of trained experts, there’s one CEO who has led the way in democratising the software that has been, for so long, so inaccessible at both a price level and pick-up-and-play level. “Carl Bass our CEO is a maker at heart,” Autodesk’s Program Manager and Maker Advocate Jesse Harrington told TCT. “He owns his own makerspace and woodshop on the East Bay of California and he has a very firm belief that software is only as good as the things that are made with it.” Bass first joined Autodesk over 20 years ago and has been the CEO since 2006, Popular Science recently described him as “The Maker King” and “Maker” sits proudly at the forefront of his Twitter profile bio. Jesse Harrington talks about his boss with the same kind of enthusiasm one might talk about their sporting hero, with unbridled zest for what he has achieved and set about achieving.

Education leads to graduation The ever-expanding Autodesk 123D portfolio now includes five apps, as well as various web-based applications that are designed to lower the entry-level of CAD. One such app is TinkerCad, a popular web-based platform that grew exponentially under previous stewardship before unexpectedly shutting down. The outcry from the community and in particular

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“Tinkercad has such an energetic, fantastic and thriving user base that when it closed down we saw an opportunity. These people are the creators, the makers – these people are really enthusiastic about design, we couldn’t just let them fade out so we picked it up,” said Harrington. “It is an amazing package; it is very easy to use; kids can start with Tinkercad and then from there they can move up to the 123D software, or use it in combination with something like 123D Circuits so they can add circuitry, all of those things work with this really nice flow to progress people onto the next stages.” people to

We want graduate from one program to another and to make it easier to hone your skill processes as you progress.

“Over five years ago Autodesk started looking at the maker movement, there is this really nice synergy between digital fabrication and DIY, which is right where we sit,” Harrington explained. “We have been the leader in getting out really great software to all these DIY people that want to start building stuff. We want to make sure that we have the solution for anybody just starting off, so we developed a line of products three and a half years ago called 123D. The 123D family of products is made for the maker market, the software is tailored to make it easy to start digitally fabricating.”

the maker movement was such that Autodesk couldn’t just leave so many potential designers stranded.

July 2014

And that’s precisely the point, the opening that Carl Bass has been so eagle-eyed to spot; these Tinkercad, 123D and other entry-level CAD users are Autodesk’s next customers. Lest we forget that this is a multinational corporation that makes its money from professional software suites, the company has spotted that CAD is no longer just in the hands of designers, engineers and architects, it has, as the buzzword suggests, been ‘democratised’ and if Autodesk can get them early, well, there’s some customers for life. “It’s pretty obvious to see where we are heading; we want people to graduate from one program to another and to make it easier to hone your skill processes as you progress. I think back to five years ago, I spent two years in a design school learning how to use SolidWorks, I spoke to 7-year-olds at The White House Maker Faire who use Tinkercad and are picking up products like 123D Catch of a weekend and making digital models on their smartphone.” That White House Maker Faire that Harrington mentions really marks the turning of this underground movement into a full-blown revolution. Our cover star; the bust of President Obama was presented at the event by the Smithsonian Institute, Obama himself said in attendance: “Today’s DIY is tomorrow’s Made in America,” and Autodesk are hoping to become the complete eco-system in which these burgeoning industries are built.

AUTODESK 3D

President Obama enjoys some maker fun in the White House

“Today’s DIY is tomorrow’s Made in America,”

White House Maker Faire

Barack Obama.

Autodesk’s 3D printer is just part of the Spark platform

Bright Spark To become the de facto organisation to the maker movement Autodesk announced perhaps their greatest leap in the company’s 32-year history, from software to hardware. Back in May Autodek announced their 3D printer and open-source platform Spark – a sort of Operating System for 3D printing. Carl Bass compared this platform to the Google Nexus and Android projects and thinks the multi-faceted open-sourced software plus hardware approach pays off. “Spark is really interesting, it falls right in line with our history for the last few years; we’re all about innovation, we’re all about the sites like Instructables and Creative Market, we’ve started developing a larger collection of collaborative communities,” Harrington told TCT. “Spark is this really amazing vision, what we’re trying to do is create an open platform for development both on the hardware side and the software side, we absolutely embrace and love the 3D printing movement but we see that there is so much potential to grow.” “The Google Andorid platform is totally an inspiration for Spark, we understand that our users are rocket scientists,” he continued. “If we can give them a little bit of room they can make some amazing things. Getting this machine into people’s hands is so exciting, we want to see what they come up with, we’re really looking forward to next year to see what comes out of it.” The Autodesk machine itself will be a resin-based sterolithography printer, and just as in the world of FDM, where we now have materials like TPU, Woodcomposites, Nylon etc., Autodesk hopes that their open-platform allows the users to mimic these developments. “When people get Spark we hope that they start experimenting with material science, we hope they start experimenting with the printer,” Harrington noted. “This is a device we’re giving people to take apart and to say create your own industry based on this platform, that will help Autodesk grow because the better and bigger 3D printing gets the more people will turn to great software like ours.”

Jesse Harrington with Obama bust

It is clear from Autodesk’s intentions that they are not just dipping a toe into the 3D printing and maker markets anymore, they have cannonballed right into the deep-end and the sheer size and ambition of the company could leave competitors trembling in their wake. But why does Jesse Harrington think that there’s been such sudden interest in the maker scene, so much so that the White House have stood up and taken note? So much so that traditionally industry focussed business like Autodesk, 3D Systems and Stratasys are keen to get a slice of the pie? “There’s a combination of three big trends that has led to the explosion in the maker movement; there’s the rise of DIY, there’s a rise of young entrepreneurs using crowdfunding to get their ideas off the ground and then there’s the whole 3D printing scene. The design world as we know it has been turned on its head because of economies, those three factors combine to form the maker movement. When you see those plus the STEM programs, which is the biggest buzzword in the education community, they’ve all merged together at the same moment to form this revolution. When you go to a Maker Faire you see all of those elements in action, at the White House Maker Faire it was amazing the array and the breadth of the makers that were there, there was everything from established 3D printing companies to people that ran FabLabs in Africa, it was just a total array of people that are involved with this movement.” i| www.autodesk.co.uk July 2014

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AM IN ARCHITECTURE

EXPLODING CONVENTION,

EMANCIPATING

CREATIVITY 30

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July 2014

AM IN ARCHITECTURE

Just as the electric car could shift automotive design completely, 3D printing has the potential to transform architecture.

WORDS | Rose Brooke

ndustry vanguard Zaha Hadid Architects in London adopted 3D printing ten years ago for its highly intricate architectural models, but can the industry pioneer envisage using additive manufacturing to produce large-scale structures? Associate at Zaha Hadid Michele Pasca di Magliano has worked on iconic structures such as the CMA-CGM Tower in Marseilles, while he is currently one of the Project Directors on the City of Dreams Hotel Tower in Macau. He feels strongly that new technologies should be explored and architects should not shy away from exploding centuries-old conventions. He explained that while some elements of construction are constantly being updated, much of the industry has not changed since Roman times. “If we could just go to a site with a raw powder and a machine you would save an incredible amount of money before you’ve even looked at your carbon footprint,” Pasca di Magliano stated. “You wouldn’t need all the packaging and all the expensive temporary work you need with concrete. With 3D printing you don’t need formwork, you can just build. It reduces dead materials because you are using materials only for construction.” He noted that the artistic possibilities afforded by 3D printing would mean not being constrained by routinely building large, flat surfaces for speedy, repetitive construction, as the technology would break down some of those limitations enabling creativity. “That’s the wish at the moment,” Pasca di Magliano remarked. “We want more of a vision for the construction side of 3D printing. We want more control over the final product and that’s why we want to use 3D printing. But it’s not there yet for several reasons; from testing to legislation, quality to costs.”

Complementary technology Zaha Hadid Architects views 3D printing as a complementary technology in architecture, utilised much in the same way the jewellery industry uses 3D printing alongside traditional bench craft. There is the potential, said Pasca di Magliano, to additive manufacture small structures leaving room for wiring and services, but for multi-storey and other large structures, the final product will incorporate numerous techniques, but 3D printing would come into its own when building complex shapes. The architect explained: “We look at 3D printing in terms of producing specific elements that are very hard to build with traditional techniques. “We are producing some large structural steel components for a project in Macau at the moment and there are very large, complex geometries coming together on this façade. We have to resolve to build those with a limited number of choices; welding metal plates, or you could cast metal but that’s a very long process and it’s full of unknowns. So if you could print those elements, it simplifies a lot of issues.” Zaha Hadid primarily uses 3D printing to produce models, with inhouse 3D Systems SLA and SLS machines building complex concepts. “We know 3D printing is very good at making small elements, very intricate and complex forms,” Pasca di Magliano said, “[but in the] construction industry it hasn’t evolved much. There’s a number of benefits we’ve seen that 3D printing could offer and it really could open up a lot of possibilities. It’s going to change what you can build. Continued on page 33

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July 2014

For the time being the major use of 3D printing remains in modelling, rather than construction

Plot for life One of these possibilities is the theory that 3D printing could transform the housing market, giving homeowners a ‘plot for life’. “You tend to buy a house and then sell it to buy a bigger one,” the architect explained, “but what if you buy a plot of land and then build a house and keep on building it? And the idea of mass customisation is really interesting. You would no longer have the constraints of the chain industry we have now where every element has to be the same, when in fact every element can be printed once and in theory it could be completely different.” Pasca di Magliano does not want to see 3D printed houses that look like ‘traditional’ houses. That, he said, “would be dull”. Instead, the technology should be used to showcase exactly what it can do and how it can push the envelope. “The process of finding somebody who wants to invest in this and to create a large machine and go through the process of testing it is not going to be quick. And it’s going to be expensive. But we would definitely push for it.” And what would a 3D printing construction site look like? Pasca di Magliano believes that instead of people working with bricks and mortar, there would be people operating robots and machines. And at completion, only the hardware would be removed from site, rather than cranes, formwork and waste.

Tower Marseille model

3D printed buildings are not a pipedream, with the Canal House 3D printing project in Amsterdam due to reach completion in 2015 (which you can see in the previous issue (May) of TCT Magazine), but Pasca di Magliano believes it will be some time before the technology trickles into the mainstream. “The projects we do are at the forefront of the technology and the benefits of the discoveries should be applied to the wider industry, but I think we have to be realistic. If there’s a large investment, it will be in the wealthiest part of the world first. At the moment, unfortunately the volume cost for 3D printing material is too high. If budget wasn’t an issue 3D printing buildings is something we would already be doing.” i| www.zaha-hadid.com

July 2014

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TOOLS, JIGS & FIXTURES

3D printing can be deployed in real-world manufacturing scenarios as a complementary technology that augments and improves existing processes. One of the most profitable areas for 3D printing exploration is the field of bespoke jigs, fixtures and organisational tools.

3D Printing Jigs, Fixtures and other Manufacturing Tools WORDS | Joe Hiemenz @ Stratasys, Inc. The fundamental objectives of manufacturing — improve quality, decrease cycle time and reduce costs — are the primary reasons that jigs and fixtures are so abundant. It doesn’t matter if the operation is fully automated or entirely manual; jigs and fixtures are deployed throughout manufacturing operations with the goal of reducing costs while accelerating production processes. When expanded beyond jigs and fixtures to include all manufacturing tools that serve as operational aids, they are even more widespread. They range from organisational bins and tool holders for 5S (a workplace organisational methodology) to templates, guides and gauges. They include sophisticated robotic end-effectors (grippers) and rudimentary trays, bins and sorters for conveyance and transportation. No matter the name, description or application, manufacturing tools increase profit and efficiency while maintaining quality.

Even though manufacturing tools are widespread, many manufacturing facilities don’t use these tools to their fullest. Making them takes time, labour, and money. To stretch limited resources, there is an option: additive manufacturing. It is simple and automated; it is fast and inexpensive. This allows you to deploy more jigs and fixtures while gaining the ability to optimise their performance. Lowering The Barrier By simply substituting additive manufacturing for your current methods of making jigs and fixtures, you can reduce their cost and accelerate delivery. In these terms alone, additive manufacturing systems are easily justified with short payback periods. But this ignores the larger impact on the bottom line. Additive manufacturing lowers the threshold for justifying a new tool, which allows you to address unmet needs throughout the production process. If you were to look around the manufacturing floor, assembly area, and quality control lab, how many new opportunities would you find for a jig or fixture? What would the value be? Could it: • Reduce scrap and rework? • Decrease direct labour time? • Improve process throughput? • Improve process control and repeatability? And with respect to the bottom line, how much more profit would the company gain? More importantly, why aren’t jigs or fixtures currently being used in these operations if they have value? Most likely, they were not justifiable. Although there is a benefit in having the jig or fixture, the return on investment isn’t large enough to warrant the effort. You may have found that your time and money were better spent elsewhere. Since there is never enough time in the day or money in the budget to do everything you would like to do, the decision to build a manufacturing tool puts priority on:

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July 2014

TOOLS, JIGS & FIXTURES Making the tool fabrication process faster and more affordable, additive manufacturing will increase the number of jigs, fixtures, and other manufacturing tools, which will improve the bottom line. Additive manufacturing can also optimise manufacturing tool performance. Before additive manufacturing, designs that were sufficient to do the job were acceptable for jigs and fixtures. Due to the expense and effort to redesign and re-manufacture them, revisions were reserved only for those that did not work as specified. Although “good enough” may have added a few seconds to an operation or increased the scrap rate by a small percentage, the savings might not have warranted further investment in the tool.

• Processes that aren’t possible without a jig or fixture • Most obvious and urgent needs • Largest threats and most likely problems • The quickest to implement and produce results

Additive manufacturing changes that thinking. For a few dollars, it can deliver the next generation manufacturing tool in time to have it in service the next day. For a tool that has marginal performance, all that is needed is a little time and initiative to redesign it. Doing so may only drive out a few seconds from an assembly operation, for example, but that time adds up. If the fixture makes 500 items per day per worker, a two-second savings reduces direct labour by 70 hours per person per year. For the same part, a one per cent reduction in scrap would save 1,250 parts per year. The bottom line: additive manufacturing lowers the threshold so that manufactures can put more jigs and fixtures, with optimised designs, into service. This drops more money to your company’s bottom line.

• The easiest to implement. Deciding when and where to use a jig or fixture is no different from any of the other daily decisions we make. Action is taken when value outweighs investment or when the path has little resistance. Additive manufacturing lowers the justification threshold by increasing your return on investment and decreasing the obstacles between a great idea and a solution. It does this by simplifying the process, lowering the cost, and decreasing lead time.

Additive manufacturing lowers the justification threshold by increasing your return on investment and decreasing the obstacles between a great idea and a solution.

When using Fused Deposition Modeling (FDM) as the additive manufacturing approach to make jigs and fixtures, the process has just three steps: prepare the CAD file, build the tool, and post process it. Unlike conventional fabrication methods, FDM requires little experience and minimal direct labour. In many cases, jigs and fixtures are manufactured with only 15 minutes of hands-on labour. More importantly, they are manufactured with little training on how the process works and no need for prior experience. Combined, this makes FDM an ideal “self-serve” option for jigs and fixtures. According to Natalie Williams, Quality Manager at Thogus Products, an injection moulder that specialises in low-volume manufacturing and highly engineered materials: “It is so much easier for me to model a fixture and print it myself than it is to design it and work through an outside machine shop.” For Thogus, additive manufacturing is easy and fast. “For one 12cavity CMM fixture the lead time, if outsourced, was 7 to 10 days. I built it overnight,” she says. Manufacturers using FDM 3D Printers to create custom manufacturing tools often experience lead-time reduction from 40 to 90 percent. Additive manufacturing also can increase return on investment substantially by reducing the cost of a jig or fixture. Typically, companies realise savings of 70% to 90% when compared to outsourced fixtures that are machined or fabricated. For Thogus’ 12-cavity fixture, the savings were 87%. “The machine shop wanted $1,500 (£900, €1,100) for the fixture. I made it for less than $200 (£115, €150) in materials,” said Williams.

Implementing an Additive Manufacturing Approach Before creating your first 3D CAD model and loading a 3D printer, take materials and dimensional tolerance into account. While additive manufacturing is ideal for many manufacturing tools, it isn’t right for all of them. The main consideration for materials is whether plastic will suffice. Traditionally, jigs and fixtures have been fabricated in metal. For some, metal may be a requirement. For others, metal may have been just a practical option because it is conducive to milling, turning, bending and fabricating. In this case, additive manufacturing may be an option. With a range of materials to select from, the FDM additive manufacturing process can offer chemical resistance (petroleum, solvents), thermal resistance (up to 390° F/ 200° C) and resilient mechanical properties. Plastic manufacturing tools may also deliver some unexpected advantages. For example, Thogus uses FDM-made robotic attachments that absorb impact. In the event that the robot arm crashes into an obstacle, the FDM part is likely to isolate the arm from damages, which prevents expensive repairs and downtime. In another example, BMW uses plastic, handheld tools because they are lighter and easier to handle, reducing worker fatigue. When deciding whether to try additive manufacturing on some initial tool-making projects, for dimensional accuracy, pick tools requiring tolerances larger than 0.005 inch (0.127 mm). Tighter tolerances are possible, but as a rule, stick with this value when keeping the process simple. Continued on page 37

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TOOLS, JIGS & FIXTURES Design Your current inventory of jigs and fixtures were designed with consideration for the capabilities and limitations of the fabrication methods used to create them. By adhering to design for manufacturability (DFM) rules, you made them practical, kept cost to a minimum, and made lead times reasonable. These rules don’t apply to additive manufacturing. They have no bearing on time, cost, quality, performance, or practicality. In some cases, adhering to old DFM rules may actually have the opposite effect. So, throw out the old rules and start with a clean slate and a fresh design. The additive nature of the process gives you unmatched freedom of design. What may have been impractical is now realistic and reasonable. Jigs and fixtures can have complex, feature-laden, and freeform configurations without adding time and cost. In fact, added complexity may even reduce cost and time. For example, pockets, holes and channels reduce material consumption, build time and total process time. To leverage additive manufacturing, let the function and performance of the jig or fixture dictate the design. Follow the lead of companies like Digital Mechanics AB and BMW. Digital Mechanics capitalised on the freedom of design for a vacuum-assisted robotic gripper. Conventionally made, the gripper had external hoses hanging off it. With additive manufacturing, each finger of the gripper was given an internal vacuum channel that eliminated the hoses. For BMW, freedom of design allows assembly line workers to have a tool that reaches under, behind, and inside the rear of the bumper. Manufacturing engineers focused solely on the function, which resulted in an organically-shaped bumper-reach tool.

The additive nature of the process gives you unmatched freedom of design. What may have been impractical is now realistic and reasonable.

Design freedoms can also improve the ergonomics of manufacturing tools. The weight, balance and position of the tool have direct effects on technician comfort, process cycle time and ease of access and storage. To achieve optimal ergonomics, simply design it into your tools. For example, BMW redesigned a badge alignment fixture to improve balance and reduce weight. This reduced worker strain and improved the cycle time for badge attachment.

One very simple way to leverage the freedom of design is to consolidate assemblies into single parts. Often, jigs and fixtures are composed of many pieces. This is unnecessary with additive manufacturing. If reproducing an existing tool, start with a redesign that consolidates as many components as possible into one piece. If designing a new item, create it as one piece. Only split off parts when it is advantageous to the operation of the jig or fixture. Integrating parts into a single component has many advantages:

• Eliminate tolerance challenges Holding tight tolerances is costly. If two mating parts are combined into one, then all costs and concerns about controlling the tolerances of the mating parts are eliminated.

• Eliminate assembly time Assemblies, obviously, must be assembled. This takes time, especially for one-off items like jigs and fixtures, where perfect fits are not guaranteed.

• Minimise documentation and overhead The sum of the parts is less than the whole when it comes to time and cost. Consolidating parts reduces costs for actions such as design, documentation, quoting, ordering, and inventory management.

Management No longer consider your jigs, fixtures, and other manufacturing tools as assets. Instead, think of them as expenses, and disposable. As assets, jigs and fixtures are stored (inventoried) between uses. They remain in inventory until the product line is retired or they are worn beyond repair. With the time, cost, and effort of making manufacturing tools through conventional methods, they are too valuable to be discarded as a disposable, expendable item.

This approach carries many indirect costs, however. There is cost for the shelf space (warehousing expense); cost to manage and track the inventory; and cost to locate a jig or fixture when needed. For sporadically used tools, these costs can be quite significant. The opposite can be true with additive manufacturing. Often, it takes more to inventory the jigs and fixtures than it does to re-make them. So, companies adopt a management approach called digital warehousing where only the digital file is carried in inventory. It may seem unthinkable to scrap a perfectly good manufacturing tool, but for those with infrequent use, this approach reduces cost and labour. Make a fixture when it’s needed. When its job is done, send it off with the scrap material for recycling. Then digitally warehouse its design between uses. This print-on-demand approach is also handy when a replacement is needed for a broken manufacturing tool or duplicates are needed for increased production to meet an unexpected surge in sales. Conclusion Additive manufacturing can lead to big changes that maximise profits by driving out every wasted second and penny from the manufacturing process. For those who aren’t ready to toss out longestablished design guidelines, simply replace the usual fabrication processes with additive manufacturing. Either way, the savings on the manufacturing floor and in jig and fixture production will be substantial. If you have a 3D CAD drawing and access to an additive manufacturing machine, you are ready to start making manufacturing tools with as little as 15 minutes of hands on labour. Combine the simplicity with typical time and cost reductions of 40 per cent to 90 per cent, and you will understand why additive manufacturing spurs companies to make more jigs, fixtures and other manufacturing tools than ever before. i| www.stratasys.com

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TCT SHOW PREVIEW

TCT SHOW PREVIEW 2014 he 19th edition of TCT Show + Personalize features the biggest names in the industry in addition to some of the most exciting and innovative new kids on the block across the expanded show floor, as well as on the stagee. Returning to TCT Show will be the RepRap Hub, the dedicated zone for the Maker community, and the TCT Bright Minds classroom, in addition to the all-new Start-Up Zone, which serves as a platform for the new generation of 3D printing businesses.

Inspiring executive speaker sessions include presentations by Hans Langer, EOS CEO, and Fried Vancraen, Materialise CEO, ‘Brooklyn Rising’ by Bre Pettis and Jenny Lawton, the CEO and President of MakerBot, and 3D Systems Vice-President of Personalized Surgery and Medical Devices Andy Christensen will demystify medical additive manufacturing. There are dozens more speaker sessions to choose from, including inspection and metrology, software and TCT Introducing.

Not convinced yet? Read about what some of our exhibitors have in store. 3D FilaPrint

3DPRINTUK

3D FILAPRINT, the UK’s number one 3D desktop filament stockist will be exhibiting a wide variety of specialty filaments from the very best manufacturers around the globe: Orbi-tech, Fenner Drives, Taulman 3D, twoBEars, MadeSolid, 3DX Tech, plus 44 colours of ABS & PLA with free samples to give away and EDUPACKS for the educational sector. Find out about 3D printing materials at the company’s stand and enter the ongoing prize draw. The company will be offering a five per cent discount on any item purchased during the TCT show. i| www.3dfilaprint.com

3DPRINTUK returns for a second year to TCT with a fully scaled up version of the last year’s stand. Bigger items, more extensive guides, more staff and a larger bit of real estate at the show representing the rapid growth they have achieved over the past year and their presence as a potential leader in the UK 3D printing industry. In the last year the young team has pulled quite a few tricks out of their sleeves, why not visit the company’s stand to see what it has done and what it will be capable of in the future! i| www.3dprint-uk.co.uk

3D QuickPrinting 3D QuickPrinting has invested in two cutting edge Stratasys 3D printers. The company can 3D print parts in strong ABS plastic for customers who require functional prototypes, jigs and fixtures and even small batch production. It also has an Objet 3D printer allowing it to 3D print parts using a UV resin for fine details. As a young, dynamic start-up the company promise not to be beaten on the speed of quote and says that its competitive pricing structure will be sure to grab visitors attention. The company’s booth will be ‘fun ‘n’ friendly’ having an expert team to advis visitors how to move new designs forward allowing the company to ‘print your dreams’. i| www.3dquickprinting.co.uk

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3T RPD With the UK’s largest combined capacity for plastic and metal AM, prototypes and end-use production, parts can be built in a range of materials including nylon, aluminium, titanium and inconel. Experts in industrial 3D printing, 3T will be showcasing a range of exciting new parts that demonstrate how the industrial process is evolving for production parts, as well as example parts produced using their newly launched plastic material, Flame Retardant Nylon. With over 15 years of experience in AM, 3T is trusted by OEM companies from a range of industry sectors including aerospace, automotive and medical, and carry AS9100 (Aircraft, Space and Defence), ISO9001 and ISO13485 (Medical) production certifications. i| www.3trpd.co.uk

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3D Printing Association The 3D Printing Association (3DPA) makes it’s debut at TCT Show + Personalize this year. The organisations role is to advance the awareness and implementation of 3D printing and additive manufacturing around the world. 3DPA is dedicated to providing manufacturers, designers, resellers and the wider 3D printing community with a committed resource that promotes, develops and supports all elements of the industry. i| www.the3dprintingassociation.com

TCT SHOW PREVIEW Akemake

citim

AKEMAKE has announced the release of the new Spirula speakers. This 3D printed model is the first speaker in the world printed from Timberfill material made by Fillamentum. Yes, it is 100% wood! The model will be initially available exclusively on Akemake website for free download and will only be printed in really low volume depending on online demand. Free 3D model is now available for download, just visit the website: www.akemake.com i| www.akemake.com

CITIM manufactures prototypes and small batch series for various industries and is a leading and experienced supplier of metal AM components with 6 x EOS machines and 5 x SLM Solutions systems. citim looks back on many years of experience in the field of rapid tooling. Innovating casting processes complete its range of services, which include nylon casting, vacuum casting, laser sintering, PolyJet, injection moulds, die casting moulds, sheet-metal forming tools, precision casting and sand casting. Need some fast advise on technical possibilities? citim is at your side! See the company at TCT Show, booth E22. i| www.citm.de

ALCHEMIE ALCHEMIE is one of the leading UK manufacturers of Epoxy and Polyurethane resin products for the prototyping and modelmaking industry. For TCT 2014 the company will be further enhancing its already successful range of products by exhibiting its latest materials for RIM production parts and vacuum casting resins. Alchemie has always held a strong position within the rapid prototyping sector and this year will be launching a new, non-mercury UV stabilised clear material; a high strength UV stable flexible and clear material; and a high impact RIM material. i| www.alchemie.com

AMUG THE ADDITIVE MANUFACTURING USERS GROUP (AMUG) is an all-encompassing technology users group that educates and advances the uses and applications of additive manufacturing. AMUG members use commercial AM/3D printing technologies and solutions from companies such as 3D Systems, Stratasys, Somos, Concept Laser, SLM Solutions, ExOne, EOS, and Renishaw. The cornerstone of AMUG is the Annual Education & Training Conference which is open to owners and operators of AM technology will take place April 1923, 2015 in Jacksonville, Florida, where AMUG members will meet to share information, tips and tricks on additive manufacturing. Stop by booth B39 at TCT Show to learn more about AMUG and how to get involved in the fast growing additive manufacturing community. i| www.am-ug.com

Arcam ARCAM will present the new Production Powder Recovery System and also show parts in its recently released new material Inconel 718 at TCT Show + Personalize this autumn. i| www.arcam.com

Buzz Technology

CEL-UK

With roots in product development and production line machinery manufacturing, Buzz Technology will be launching a cutting edge 3D printer and showing potential crowd-funding projects such as ecopackaging and construction industry. At this stage, Buzz Technology wants to hear from 3D printer manufacturers/distributors, retailers and house builders who might be interested in licencing its IP or joint venturing to bring its innovations to market. Interested parties can email TCTshow@buzztechnology.co.uk i| email TCTshow@buzztechnology.co.uk

Artec Group Artec Group will be bringing the world’s first 3D full body scanner the Shapify Booth - to TCT Show. The fully automatised Artec Shapify booth takes high-res body scans in 12 seconds, converting them into printable models in 3-4 minutes. The end product is a ‘shapie’ 3D printed selfie. Also on show at the Artec stand will be its professional handheld 3D scanners Eva and Spider, unrivalled in their scanning quality, speed and versatility. Used in countless industries, find out how Eva and Spider can benefit your line of work at the Artec stand. i| www.artec3d.com

CEL-UK will be exhibiting the revolutionary Robox – a 3D printer which is a comprehensive micromanufacturing solution that could fit into any home, school, or office. The ‘plug and play’ system offers users the ability to print everyday items at the touch of a button, the company’s technology is reportedly simple to use and encourages people to tap into their inner creativity. CEL will be demonstrating the Robox to show how every child, parent, inventor, teacher and tinkerer can enjoy the benefits of 3D printing. i|www.cel-robox.com

Central Scanning

CDG CDG will be on-hand at three separate points at TCT Show 2014. On Stand A17 3D Systems’ full colour ProJet 4500 will be demonstrated while on Stand A22, visitors will see the very latest QB3D 3D printing and scanning tech, including the new Cube3, CubePro and ProJet 1200 3D printers plus the Sense and iSense 3D scanners. Finally on Stand A21, Geomagic’s full suite of 3D software tools, including 3D scanning, reverse engineering and inspection packages will be on show. In addition, there will be the new Geomagic Capture 3D Scanner and the high-resolution Breuckmann StereoScan & SmartScan solutions. i| www.cdg.uk.com

CENTRAL SCANNING is exhibiting at TCT Show in collaboration with Tri-Tech 3D. This joint venture allows the company to demonstrate the flexibility and presence in the market for high quality 3D scanning and 3D printing. Central Scanning will be demonstrating the latest technologies from Steinbichler, Artec 3D and our all-new Surphaser scanner. Artec 3D, Steinbichler and Surphaser technologies will be on show throughout the exhibition. Visit Stand D21 to discuss any individual requirements you may have and have a closer look at the scanning systems on show. Central Scanning aims to ‘provide the best solution for you from a simple service job through to complete installations’. i| www.central-scanning.co.uk

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£15,995.00 1 Includes,warranty, cleaning station and 12kg’s of material

Stand G14

enquiries: info@blueprinter.dk 40

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July 2014

TCT SHOW PREVIEW

GoPrint3D

EOS

CMA Moldform CMA MOLDFORM specialises in the development and manufacture of rapid prototypes - both one-offs and production runs, optical art moulding, fine-scale models, RIM, centrifugal, pressure and vacuum castings, and high capacity rotacasting. CMA will be exhibiting examples of production and rapid prototypes, including some newly developed and unique grades of resin materials. From scanning to CAD, SLA, SLS and CNC, CMA produces quality mouldings using a wide range of specialist resins. CMA can offer high impact, high temperature resistant, colour-coded and assembled components for a wide range of applications. i| www.cmamoldformltd.co.uk

CREAT3D

At TCT Show, EOS will present its M 400 additive manufacturing system with 1 kW laser and a build volume of 400 x 400 x 400 mm, designed to transform the process from a prototyping and small-volume production tool into a manufacturing centre for highvolume production of high-quality, industrial metal components, directly from CAD data. For additive production of plastic components, EOS’ latest system is the P 396. It offers many features that meet the growing demand for increased manufacturing efficiency, process stability and build capacity. A latestgeneration CO2 laser rated at 70 W, together with completely revised temperature regulation, enables double-digit increases in productivity. i| www.eos.info

ES Technology ES Technology is the UK distributor for the German AM manufacturer Concept Laser, and will showcase metal AM processes at TCT Show this autumn. The company will display component parts made in a range of materials, including aluminium, titanium, inconels, stainless steels, bronze, silver and gold. Concept Laser offers a range of machines to suit the whole gamut of industries and applications and we will have live demonstrations of the Mlab. Visitors to the stand can see how the current use of metals in AM is developing and working in production-based environments. i| www.estechnology.co.uk

Global Precision CREAT3D specialises in desktop 3D printing and will be at the TCT Show 2014 on stand G27. Desktop 3D printers have many applications, helping companies to streamline design processes, reduce prototyping costs and bring greater innovation into early stage product development. In action at TCT Show, amongst others, will be the newly released CubePro range from 3D Systems, the Leapfrog Creatr HS, with its dual-head, multi-material capabilities including dissolvable PVA support and the new Z18 from MakerBot, a low cost printer with a huge 18 inch build height. CREAT3D will also be showcasing the brand new Fuel3D scanner. i| www.creat3dprinters.com

GLOBAL PRECISION is an international team of specialist engineers, project managers and technical support personnel dedicated to ensuring the successful completion of your manufacturing projects. Global Precision works from concept through to full production, working alongside customers as a bolt on/bolt off new product development and manufacturing partner. The company’s experienced international team are your global manufacturing partners working to ensure high quality, minimal risk and a service users can rely on. Project successes have seen the company grow over the last 10 years and become a key and long-term service provider to a range of global OEMs. i| www.globalmanufacturing.co.uk

See a range of best-in-class 3D printers in action at GoPrint3D’s stand F43. Choose between resin, plastic and paper-based solutions. Highlights include the Formlabs’ Form1+ and Mcor’s Iris alongside the Makerbot and UP! Plus. Talk to the company about hiring 3D printers short or long term, events, workshops, training as well as its 3D printer sales and ‘printing on demand’ services. Visitors to the stand can try the 3Doodler, the world’s 1st 3D printing pen and ask the company about its bundled deals for education. GoPrint3D is a division of Express Group Ltd, Formlabs’ European partner, MCor’s UK Reseller and 3Doodler’s UK Education Reseller. i| www.goprint3d.co.uk

Guyson International Leading industrial finishing equipment manufacturer Guyson International will be exhibiting equipment from its blast finishing and ultrasonic cleaning equipment ranges. Featured will be blast finishing equipment used by many of the leading rapid prototype and additive manufacturers for smoothing out step lines, creating the perfect keyed surface prior to painting and providing a myriad of value adding surface finishes to a vast range of components. Complementing the blast equipment, ‘Kerry’ branded ultrasonic cleaning equipment, includes ultrasonic baths and tanks; perfect for cleaning prototypes after surface finishing. i| www.guyson.co.uk

Hawk3DProto HAWK3DPROTO is the 3D printing division of Cutwel. It is the UK and Ireland’s sole supplier for BEETHEFIRST, the desktop 3D printer from the Portugual-based manufacturer BEEVERYCREATIVE. The company is also an authorised reseller of Stratasys’ Idea Series range. On stand H38 at TCT Show, visitors can see live demonstrations of the BEETHEFIRST and Mojo 3D printers. Senior 3D Printing Manager Ben Hawksworth will be on the TCT Introducing stage during the show, explaining more about the exciting technology Hawk3DProto is championing. i| www.cutweltools.co.uk

EnvisionTEC ENVISIONTEC is a leading global provider of 3D printing solutions for the rapid manufacture of customised products utilising its proprietary consumables across a variety of markets. Since its first patent submission in 1999, EnvisionTEC has developed and released 3D print solutions consisting of 3D printers, print materials, replacement parts as well as training and other services. EnvisionTEC’s proprietary, multi-platform technology delivers high precision, surface quality and functionality as well as the ability to use a wide range of materials at production speeds that it believes are superior to those offered by its competitors. i| www.envisiontec.com

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T +44 (0)1270 216000

E sales@europac3d.com

W www.europac3d.com

ScanAlign Photogrammetry Kit ®

Large and complex objects can now be scanned accurately and with no incremental errors by combining the real-time scanning of either the Artec Eva or Artec Spider with a calibrated network of markers placed upon the object to be scanned. By taking pictures with the pre-calibrated Nikon D3100, xyz coordinates of the coded markers can be fed into the Artec Eva or Spider to supply an accurate reference system around the component.

The ScanAlign kit contains everything needed for scanning and includes either the Artec Eva or Spider 3D scanners

See the ScanAlign kit in action on the europac3d channel on

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July 2014

The workﬂow is simple – pictures are taken with the high-resolution Nikon camera from different viewpoints. The ScanAlign software calculates the coordinates of all reference points in a single step without any further interaction. The ﬁnal coordinates can be transformed into any coordinate system, such as car/aircraft alignment, before being loaded into your scanning software. Call Europac3D for a demonstration of this simple yet highly effective & accurate scanning solution.

TCT SHOW PREVIEW Höganäs Digital Metal

John Burn

HÖGANÄS DIGITAL METAL offers a revolutionary and innovative manufacturing technique for metallic components. It is a proprietary precision ink-jet technology for additive manufacturing. This offers a unique capacity to rapidly and cost effectively produce highly complex and intricate designs and features for metallic parts. As the world moves steadily towards more generative and flexible manufacturing methods, Digital Metal is at the forefront of this development. The company believes that being part the global Höganäs Group guarantees its financial stability in the long term. i| www.hoganas.com

JOHN BURN is one the largest resellers of materials for product design, development and manufacturing. John Burn is also a reseller for a number of different 3D printing systems, offering expert advice and service. This year the company will be promoting 3D printing technology from the TierTime and EnvisionTEC ranges. Products from Sika and Synthene will also be on display. The stand will feature a concept model, The ‘Super Normal’ Bentley, designed by RCA student Hoe Young Hwang, developed with the support of Bentley. With a long and respected history with the design, prototyping, pattern making and foundry industries John Burn continues to bring game-changing technology to this ever-evolving group of innovators. i| www.johnburn.co.uk

LPW Technology

MarkForged

LPW TECHNOLOGY has been pioneering the use of laser deposition solutions since 2007 and in that time has worked with leading industry organisations and academics. This combined knowledge and experience continues to develop innovative processes and turn concepts into reality. LPW has developed a range of metal powders specifically for Laser Metal Deposition (LMD), Selective Laser Melting (SLM), and Electron Beam Melting (EBM). LPW manages the metal powder lifecycle through analysis and quality products that offer successful performance and cost effective solutions. Helping clients worldwide save energy, save money and increase choice. i| www.lpwtechnology.com

Designed to overcome the strength limitations of traditional 3D-printed materials, the revolutionary Mark One 3D printer is the world’s first 3D printer designed to print continuous carbon fibre, fibreglass, and Kevlar. Now you can print parts, tooling and fixtures with a higher strength-to-weight ratio than 6061-T6 Aluminum. Visit the company at booth F42 to see the Mark One 3D Print continuous fibrereinforced thermoplastic parts that are 20 times stiffer and 5 times stronger than billet ABS. Demonstrations will also include the company’s groundbreaking new cloud based software and many new patent pending Fused Filament Fabrication and Composite Filament Fabrication features. i| www.markforged.com

Midas Pattern

Matter and Form

Majenta PLM MAJENTA PLM is the UK’s leading Siemens PLM Software solution provider of expert services and support for CAD, CAM, CAE and PLM. We will be showcasing the latest functionality in our CAD offerings (NX and Solid Edge) along with our partnership with Physical Digital, enabling clients to optimise their workflows between 3D scan data and our product portfolio. The ability to capture high quality accurate scan data closes the loop from concept through design and evaluation (CFD, FEA) into production and then quality inspection of the final part back into CAD. Visit the company on stands A34 and A36. i| www.magentaplm.com/physical-digital

The Matter and Form 3D Scanner is an affordable, high-resolution 3D scanner. The company was founded by designers and programmers who needed a high-resolutioin 3D scanner but couldn’t afford it; so they made their own. The company says it is ‘determined to help others do more in their creative, professional and recreational lives’. It launched an Indiegogo campaign, raising nearly $500,000 (£300,000) in 2013. The Matter and Form 3D Scanner began shipping that July. The company has recently launched its Approved Reseller program and has signed non-exclusive distribution partners worldwide. See the company on Booth H18. i| www.matterandform.net

MIDAS specialises in producing large, low-volume, high-quality, polyurethane mouldings as well as offering customers the facility to create large prototypes in very short timescales. Large production mouldings are particularly suitable for use as equipment enclosures in medical, analytical and scientific applications, where valuable technology must be enshrouded in large, complex, multi-part moulding assemblies. Midas offers two tooling systems: FASTrim, a low cost solution to producing even large prototypes in as little as 10–15 days, and MRIM, a composite tooling system offering low set-up costs for high-quality mouldings in volumes from 1 to 2,000 per annum, with a guaranteed life of 5000 off. i| www.midas-pattern.co.uk

Mcor Technologies MCOR TECHNOLOGIES, manufacturer of the only line of desktop paperbased 3D printers, will unveil new breakthroughs in Selective Deposition Lamination 3D printing technology at TCT Show on stand D18. Visitors to Mcor’s stand will; discover new breakthroughs in paper-based 3D printing; learn how Mcor’s TRUE-colour 3D printers can dramatically cut costs, shorten design cycles, improve designs, and enable everyone access to professionalclass 3D printing; see the Mcor IRIS; hear about recent announcements such as Mcor printers becoming the first 3D printer to adopt an international colour standard. i| www.mcortechnologies.com

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Life’s a lot more colourful with the new Connex3 Introducing the Objet500 Connex3 from Stratasys, the world’s only multi-colour multi-material 3D printer. ( VIVID COLOUR + FLEXIBLE + TRANSPARENT + RIGID )

To find out more call Tri-Tech 3D – the leading distributor of Stratasys 3D printers.

TELEPHONE: 01782 814551 VISIT: WWW.TRITECH3D.CO.UK

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July 2014

TCT SHOW PREVIEW ooznest

Nikon Metrology NIKON METROLOGY offers the most complete and innovative metrology product portfolio, including state-of-the-art optical and mechanical 3D metrology solutions complemented by vision measuring systems. Visitors to the company’s stand can see the broad range of products, running live interactive demonstrations. i|www.nikonmetrology.com

Norge NORGE presents Ice9, the first low-cost SLS 3D printer designed for printing nylon or Polyamidebased functional prototypes that users can safely test and use. The Ice9 SLS printer has an engraving/cutter function allowing users to work on materials such as wood, paper, foam or felt. The laser will draw or cut any shape using a standard vector file made with Adobe Illustrator or Inkscape. After 18 months of intense work, the company is looking for community assistance to get the machine to market through a Kickstarter campaign. i| http://vimeo.com/98841406

Praxair Surface Technologies PRAXAIR SURFACE TECHNOLOGIES offers a complete line of powders for additive manufacturing, thermal spray and other applications in its portfolio of metallic and ceramic materials. The company offers one of the world’s most advanced powder manufacturing facilities and an engineering staff dedicated to developing customised innovative powder solutions to exceed the needs of our markets. Stop by the company’s booth to see samples, ask questions and hear the latest news related to Additive Manufacturing from a global leader in the metal powder industry. i| www.praxairsurfacetechnologies.com

Quill Vogue Annoying isn’t it? You have spent hours designing the perfect 3D printed part, it goes to print, it finishes printing, tad ah! Unfortunately not quite, your printed part is encased in support material but you need the part straight away. Pay a visit to the Quill Vogue stand to see how the company’s range of FDM, PolyJet and Projet 3D post processing solutions can remove the support material for you, saving you time, money and labour, while improving your throughput and quality of finish. i| www.quillvogue.com

At this year’s show ooznest are looking forward to ending a year of operation on the high and exhibiting our new products as we head into our second year. As new UK distributers of Openbuilds VSlot Extrusion, we are delighted to be bringing working examples of these products to the show. We will also be demonstrating our new build-it-yourself Prusa Based 3D Printer Kit which includes many upgrades plus an all metal extruder and auto bed leveling. Finally we will also be showcasing our new range of ABS and PLA 3D printer filament, as well as our wood and brick filaments. i| ooznest.co.uk

PRODWAYS

POLY-SHAPE

PRODWAYS will present for the first time to the UK market its new product lineup of 3D printing manufacturing systems incorporating the company’s unique MOVINGLight Technology. This disruptive proprietary technology based on moving DLP and strong UVA LEDs provides two major competitive advantages to industrials: unparalleled quality of precision parts and distinctly improved production profitability for a wide range of industrial and biomedical 3D printing applications. Prodways aims to complement its current lineup of material solutions developed internally and by its partners Dreve and DSM-Somos with a complementary offering to expand the frontiers for 3D printing and additive manufacturing. i| www.prodways.com

POLY-SHAPE is a young and innovative company specialising in direct manufacturing. POLY-SHAPE has developed an innovative direct manufacturing procedure and produces technical parts for the aeronautical, automotive and medical industries. From a CAD 3D image, POLY-SHAPE manufactures the part through the laser fusion procedure. This procedure, which does not require any specific tooling, guarantees extremely short delivery deadlines. Parts produced in this way have superior mechanical properties when compared with foundry-made products and can be directly used on engine test benches or in real conditions. The company has now proven more than 20 different standard materials, has been supplying several Formula 1 and WRC teams and is even certified by powertrain manufacturers in the aeronautic sector. i| www.poly-shape.com

Simpleware SIMPLEWARE provides software solutions for generating CAD or STL files from 3D image data for 3D printing and additive manufacturing. The company’ssales team will be available at stand A24 during TCT Show to discuss the software, including the ability to create STL files with guaranteed watertight surfaces suitable for multi-material printing. Simpleware software also offers robust tools for adding lattice structures to industrial parts, which can reduce weight without compromising performance. Users of the software can add lattices to CAD files and image data and can export models with lattices as volumetric meshes for simulation. i| www.simpleware.com

July 2014

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EOS e-Manufacturing Solutions

Optimized automotive tool insert for injection molding. Source: Innomia/EOS

EOS Additive Manufacturing: Productive and Flexible Tooling Solutions EOS Additive Manufacturing enables highly productive, flexible, individualized tooling solutions. It allows complex forms and functional integration: conformal cooling channels result in reduced cycle time, lower scrap rates and attractive costs per part.

www.eos.info

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July 2014

TCT SHOW PREVIEW

Ultimaker GB ULTIMAKER is committed to sharing open source 3D printing. In this emerging field the company believes that there are endless opportunities for crosscurricular learning development; the company’s CREATE Education Project provides free resources and support. The company shares its knowledge as it says ‘we believe we can achieve even more when working together’. Ultimaker reportedly only works with the best materials and has high standards when it comes to its products and services. It says that its machines are made from the highest quality parts. The global Ultimaker community is online 24/7 helping, sharing and inspiring each other. i| www.ultimaker.com

shootdigital The most respected brands in the world have relied on the Manhattan-based studio shootdigital to produce museum-quality 3D-printed models and installations. Now shootdigital has launched its own line of art and design objects through an exclusive network of select shops and galleries. Its service epitomises the potential of additive manufacturing at the end of the spectrum in which cost is no object and innovation is measured almost entirely in aesthetic terms. Its palette consists of 24k gold, silver, black nickel and copper, among others. See this amazing collection at booth G20 as well as in TCT’s Innovation Showcase. i| www.shootdigital.com/services/printing

Steinbichler

This year STEINBICHLER UK LTD will be presenting the new varge volume handheld laser scanning system the T-SCAN LV / T-TRACK LV at TCT Show. The high scanning speed of the handguided laser scanner offers flexibility, high precision and outstanding speed. Adapt the modular and flexible system configuration for your individual application, combine with the hand-guided T-SCAN LV laser scanner to quickly and efficiently digitise large objects. Visitors will also be able to see the range of Blue Light optical 3D scanning systems available from Steinbichler UK. Visit Stand D20 to discuss your individual project requirements. i| www.steinbichler.co.uk

Strand7 STRAND7 is the Australia and Cambridgeshirebased company responsible for the research and development of the Strand7 Finite Element Analysis (FEA) software. Strand7 software is a general-purpose FEA system comprising integrated pre-processing, post-processing and solvers. At TCT, the company will demonstrate the latest Strand7 release, including advanced nonlinear capabilities such as generalpurpose contact; Strand7’s powerful API, which allows developers to build their own applications on top of Strand7; and integration to CAD through support for a number of industry-standard file formats. Visitors to its booth will receive a Resource Kit containing a Strand7 trial version, sample models and practical case studies. i| www.strand7.comco.uk

Tethon 3D

Voxeljet

TETHON 3D provides innovative supplies and service for ceramic 3D printing. The company’s stand at TCT Show will include examples of 3D-printed earthenware, stoneware and porcelain for visitors to hold. Explore applications of ceramic AM in diverse industrial, medical and design industries. Watch a video showing the company’s process of 3D computer modeling and see how its ceramic powders and binder combine to form solid object that will be cleaned and then kiln fired. Any commercial glaze may be applied to these ceramic 3D printed objects, producing hundreds of finishing options. i| www.tethon3d.com

VOXELJET is a manufacturer of industrial 3D printing systems and 3D printing services for the ondemand production of moulds and models for metal casting. The company will present its latest 3D printing solutions at TCT Show. This year voxeljet is exhibiting on a large stand where visitors can see a diverse range of 3D printing technology. voxeljet says that it ‘offers the knowhow, experience and capacity for the rapid and cost-effective production of your prototypes and small series’. i| www.voxeljet.com

July 2014

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RAPID REVIEW

RAPID has become one of the must-attend events for the AM and 3D printing community in North America, with the annual conference and expo taking in a different US city each year. This year the event co-located with The Big M and NAMRC events at Detroit’s COBO Center, just down the road from SME’s Dearborn headquarters.

RAPID 2014 WORDS | Jim Woodcock

he ‘M’ may have been ‘Big’, but it was RAPID that took the lion’s share of the floor space at Detroit’s COBO Center with the established players in attendance alongside some newer companies and first-timers. New launches tend to appear at Euromold (ready for fresh sales in the following January) but the Detroit event still managed to throw up a few surprises. The biggest (literally) was an Inconel 625 part (image left) taking pride of place on the EFESTO stand. Built in an EFESTO 557 — the world’s largest argon-filled DMD system — the piece stood at over 2 metres tall and took some 330 hours to build. EFESTO’s metals processing technology is used in the aerospace, defense and automotive industry amongst others and was on show for the first time in Detroit.

Form1 launch event

Form1 Plus first show

Polar 3D in action

Form1 launch event

Just prior to RAPID EFESTO and RPM Innovations, another specialist in metal 3D printing technology and applications, announced a long-term global strategic partnership to offer a comprehensive range of professional grade, industrially hardened and production proven Laser Metal Deposition equipment and services for metal additive manufacturing. Metals deposition technologies were represented elsewhere on the show floor with Optomec taking both a stand and running its own evening event to update visitors about their on-going developments. During the event — and while on stage at the conference — the company promoted AM as a tool to add value to existing products through augmentation rather than building from scratch. The company’s Aerosol Jet technology, used for printed electronics, was also generating interest at the event. Another DMD innovation is from UK-based Hybrid Manufacturing Technologies, a company that span out of the work undertaken at De Montford University and MTC (amongst others) in the UK. HMT’s mission has always been to bring additive technologies to existing subtractive platforms, which co-founder Jason Jones sees as the most likely way AM will secure significant

backing in the manufacturing sector. Interestingly, Optomec and HMT are both pursuing the ‘modular’ approach allowing users of existing CNC machinery to add in AM capability to supplement, rather than replace, high-speed machining. At the other end of the industry, a handful of new extrusion-based machines were in evidence, including the eye-catching Polar 3D desktop system. The Polar 3D does away with the traditional X and Y axis and instead opts for a spinning, circular build plate that travels along a single linear axis, and uses polar coordinates. The system allows the full build volume to be used (for parts with a circular cross section) and was producing parts that were on par with those from established X & Y axis machines. The company is focusing on the education market, to which the machine looks well targeted. Continued on page 51

July 2014

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RAPID REVIEW

Detroit newspaper comic printed on one of the days of the event... coincidence?

Across the road from the COBO Center is this fire-station — as seen in the 3D printfest that was Real Steel. Sticking with the extruded filament approach but dwarfing the Polar 3D was the 3DP Unlimited X1000 with its 1000 mm x 1000 mm x 500 mm build volume. The company explains that the system is built ‘by engineers, for engineers’ and the scale alone opens up some interesting avenues for parts and even production. 3DP Unlimited is a division of PBC Linear and continues the trend for manufacturers of related products entering the 3D printing market with their own take on the tech. The large-scale offering looks more like an air hockey table than a 3D printer but the example prints looks pretty impressive. Materials suppliers were well represented at the event, with UK-based companies LPW Technology and Sandvik Osprey present alongside US-based Additive Metal Alloys (AMA) and France-based EraSteel catering to the burgeoning metals market. Argyle Materials, Somos and Synthene were demonstrating their products for plastics-based 3D printing and beyond. Stratasys demonstrated its own materials developments for the multi-colour, multi-material Objet500 Connex3, adding new palettes that allow flexible colour digital materials.

The ‘Best in Show’ award was presented to EnvisionTEC, which wowed the attendees with its solutions ranging from largeformat, high-resolution printers for plastic parts through to the bioplotter for 3D printing of organic materials.

The ‘Best in Show’ award was presented to EnvisionTEC, which wowed the attendees with its solutions ranging from large-format, high-resolution printers for plastic parts through to the bioplotter for 3D printing of organic materials. The award was presented for ‘being interactive, technically and aesthetically impressive, and visually appealing and engaging’. Conference and show attendees (exhibitors excluded) received ballots with their registration credentials and the EnvisionTEC exhibit was chosen by popular vote.

i| www.rapid.sme.org

Graham Tromans on Stage

Detroit’s own Robocop

3DP Unlimited’s large format FDM-style printer

July 2014

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HAWK 3D PROTO / CUTWELL A smart, quiet gallery space complete with slick, lit podiums topped with some of the smartest desktop 3D printing technology on the market is not what one expects when stepping inside a warehouse on an industrial estate in West Yorkshire.

Hawk3DProto: REALISING A VISION I

t is clear from the care that has gone into realising the concept of the 3D Printing Showroom at family-run Cutwel that the tooling supplier’s dedicated spinout Hawk3DProto is a serious business investment for an established manufacturing player.

But ultimately, it is the user Hawk3DProto wants to strike up a dialogue with, which is why such care has been put into the Showroom with help from Elle Court Properties Ltd and Pennine Signs as a venue for anybody from schoolchildren to makers to product designers and architects. “Our showroom is unique,” said Hawksworth. “There’s nothing else like this in Europe, maybe further! Because nobody gets an idea in their head like I do.” He concluded: “We’re rebranding to Hawk3DProto and stepping away from Cutwel. We want people to know we’re here to stay, we’re here to 3D print, we’re here to compete and we’re here to thrive.”

Senior 3D Printing Manager Ben Hawksworth has led the project, turning his vision into a business strategy. Much trust has been put in Hawksworth by Managing Director Paul Hawksworth, who made no bones about the fact Hawk3DProto is entirely down to his son’s perseverance and vision.

i| www.cutweltools.co.uk

Moving to the new Cleckheaton site gave Hawksworth the opportunity to bring his idea to life, asking the MD if he could claim the mezzanine overlooking the warehouse for Hawk3DProto. After starting out with just two Up! Plus 2 3D printers, the space now boasts a BeeTheFirst 3D printer from Portuguese manufacturer BeeVeryCreative, as well as the uPrint and Mojo from Stratasys’ Idea Series, and the trusty Up!. “I want people to come through that door and experience that ‘wow’ factor. We’ve got a lot of good feedback and we’ve gone to a lot of detail from the graphics to the lighting,” Hawksworth said. The amount Cutwel has invested in the Hawk3DProto mezzanine remains undisclosed but it goes without saying the business understands the importance of being seen and making an impression in an increasingly competitive marketplace. Naturally, as the sole UK and Ireland supplier of BeeTheFirst, Hawk3DProto will be exhibiting at TCT Show + Personalize 2014, where both the BeeTheFirst and a Mojo will be up and running for everybody to see. “If I saw a machine at TCT Show and it wasn’t working, I’d be asking why have you brought it? It’s like going to a car showroom for a test drive and being told you can’t. We’ll have full live demonstrations of both printers,” he said. The fledgling 3D printing business is having an industrious year, nevertheless Hawksworth cannot be stopped from thinking big. Sand and metal 3D printing technologies are a potential target to add to the growing bureau offering, while multi-colour, multimaterial systems such as the Connex3 from Stratasys were mentioned as potential acquisitions in the coming years. July 2014

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July 2014

MIDAS PATTERN

Rapid manufacturing is alive and kicking in the UK. Midas Pattern Company, the Bedford based firm, is living, breathing proof of how the UK can learn from its proud manufacturing past and move forward.

High-quality hand-made pattern equipment made in mahogany and epoxy resin to produce magnesium wheels for the Jaguar ‘E’ Type.

ff the bat, Midas use the slogan ‘Integrating Technology with Traditional Expertise’. That may sound like marketing talk but spend some time with Managing Director and co-founder Alan Rance and his team you’ll realise there’s nothing in the remotest bit hype-driven about Midas. It is the Ronseal of manufacturing; it does what it says on the tin. “Our motto from day one has been ‘Quality on Time’, yes it sounds cheesy, but that was on our business card on September 1st 1989 and it is still there today, because we truly believe in it,” says Rance. In those 25 years Midas has grown from two traditional pattern makers using traditional skills and timber, into a 90-strong team, with seven CNC machines, six paint shops and much more. But while they have expanded, the thoughts of the traditional manufacturer have never been far away.

“Our motto from day one has been ‘Quality on Time’, yes it sounds cheesy, but that was on our business card on the 1st September 1989 and it is still there today, because we truly believe in it,”

MADE IN THE

UK WORDS | Daniel O’Connor

“We built a business on the back of the skill we had to make patterns to that standard, patterns that were not only second to none in terms of quality but at a quicker speed than our competitors. We made all of that equipment in just over two weeks, to achieve that was practically impossible and so few could have done it but we had the desire, the motivation and the skill. I think that is the best example of where we come from; traditional craftsmen that have grown with the mentality of the pattern maker that can make anything. “ Those days, however romantic they seem, are long gone. Times were changing in the manufacturing world and for Midas to grow they had to be flexible and adapt to their environment quickly. Continued on page 57

“We had a customer come to us right at the start, 1990, and they had a drawing of Jaguar E-Type wheels,” explained Rance. “This was one of the biggest magnesium foundries in the UK, based in Sittingbourne, Kent, we’d only been trading a little while and they knocked on our door to say: ‘Can you make these patterns?’ We said ‘yes’. Two of us made the pattern equipment for the front and rear road wheels traditionally. Everything was made by hand so we had to segment the parts so that the timber wouldn’t shrink and move, that was part of the skill. A lot of the equipment was cast in epoxy resin directly off wooden masters. Anyone that looks at these pictures can see that they are total quality. There is nothing that could in any way be improved in terms of accuracy, longevity and in terms of the first impression.

A handmade model can be seen here (bottom right), illustrating how models used to be made.

July 2014

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MIDAS PATTERN

“CNC machining came along and in the space of two years absolutely ended traditional craft pattern making. Nobody could compete with CNC machining, those E-Type wheels made using a rule, a Vernier and hand woodworking machinery, you could measure any two dimensions on a CMM on that pattern equipment and that would come up inside 0.3mm, with CNC we’d expect that to be within 0.1mm but when you think about those tolerances the difference isn’t that huge, it is testimony to the skill we have. But you don’t have to train a CNC machine like you would a traditional craftsman, in fact one man can run three patterns on the machines, change was inevitable.” While those around them panicked about the new technology and what it would mean for jobs, Alan Rance and his partner, like any good businessmen saw the threat as an opportunity.

just as the foundries did.” Polyurethane moulding is what Midas does best, be that for bespoke electrical devices such as medical equipment or for JCB diggers, it is all done to the highest possible standard and is where the firm sees most repeat business.

“We love going to TCT, we always enjoy it, we have great conversations and we win plenty of work there, so it is a good show for us. We come to TCT with all this heritage, we come from the foundry industry something that is true and something to be greatly proud of. We’ve diversified and developed to offer a service nobody else can; nobody else can achieve the quality we can.”

“We took Midas up to a dozen pattern makers in four years making patterns from 2D drawings. We got to the point where sustaining that was quite challenging, I was winning patterns, making patterns, running all the workforce and doing the accounts, life was quite stressful. We knew that if we wanted to keep this company growing at the rate it was, we needed to diversify. At that point we decided that our ability to make patterns was key, so instead of making a pattern that was going to a foundry to make a metal casting, we thought, why not make a pattern that we could mould off? Why don’t we make a pattern, make a resin mould and make plastic castings? We knew other people were dabbling with it, making and reshaping rubber moulds, we wanted to do it properly. We made a pattern, we made a resin mould and we put polyurethane into that. That is how it started. We knew then that not only would we win more patterns but we’d get repeat business

“We’re a company that produces 30,000 polyurethane mouldings a year. Every single one of those could be seen as a one-off prototype or a one-off model, they all have to go out of the door to the exact same standard. That’s an incredible ask and there’s nobody else in the UK that is moulding at our level, to this standard using our processes.” People power The additive manufacturing industry in particular could perhaps be criticised from time to time for focusing too heavily on machinery rather than people. Take a look at the mainstream press and you’re guaranteed to find at least one article this week that talks about how this amazing technology has made something rather than the skill of the designer, machine operator, fettler, painter or polisher. This is certainly not the case with Midas, Alan Rance and co. have built a company that is forged on the relationships of human beings, be they customers, be they workforce. “I’ve learnt far more from watching people do things wrong than do things right,” said Rance. “Ultimately, you treat people the way you want to be treated yourself, that’s it, there’s nothing more to it. If you’re a tyrant you’re not going to keep good people, if you’re a nice guy and treat people with respect they’ll stay. At Midas we have many good people who have been here for

a very long time.” It might seem unusual for a company that specialises in moulding to be at TCT Show + Personalize but Midas is actually something of a staunch supporter having had a presence at the last eight shows, and 2014 is no different. “We love going to TCT, we always enjoy it, we have great conversations and we win plenty of work there, so it is a good show for us. We come to TCT with all this heritage, we come from the foundry industry - something that is true and something to be greatly proud of. We’ve diversified and developed to offer a service nobody else can; nobody else can achieve the quality we can.”

A tool made by Midas before moulding.

“Midas proves that it is possible for well organised, conventional manufacturing to compete very effectively against rapid build layer manufacturing. If you communicate well and liaise throughout the design process, right through to the manufacturing phase, time can be removed in all areas. When you look at some of the things we do here, whether it is CNC model making or whether it is our FASTrim prototyping process, they will compete head-to-head, day-to-day with rapid prototyping and that’s the key to Midas’ success - it is the common sense of what we do.” i| www.midas-pattern.co.uk

July 2014

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SASAM

This article is the second of two parts, the first of which was published in TCT magazine 22:3, May 2014.

SASAM Project: First European Standards at the European Level

he SASAM project has applied its approach to develop the norms and standards surrounding the use of AM. Once the scope of standards — which focus primarily on materials, processing techniques, post-treatment techniques, parameters and final product test methods, and characteristics — were determined, the state of the art on normalisation was established to see if aspects were already covered in existing standards. It was determined that several plastic materials used in AM were already treated within ISO/TC 61 “Plastics” and metal powders within ISO/TC 119 “Powder Metallurgy”; some laser technologies were covered by ISO/TC 172/SC 9 “Electro-optical systems” and data exchange of CAD/CAM systems by ISO/TC 184/SC 4 “Industrial Data”. In parallel, in the US ASTM has set up a “Committee F42 on Additive Manufacturing Technologies” that is working on several actual norms related to AM. All previous work served to identify the specific features and items that shall be treated by the norms/standards as AM, to indicate how the existing norms/standards shall be elaborated to cover the specific features of AM and to provide scientific and technical basis for future norms/standards in the form of scientific articles and other information sources (databases, web-resources). Therefore, in order to manage the multi-disciplinary character of AM with an integrated approach a New Work Item Proposal (NWIP) was established: “Additive Manufacturing - Rapid Technologies (Rapid Prototyping) - Fundamentals, terms and definitions, quality parameters, supply agreement” to be developed by ISO (ISO/TC 261). Priority subjects were determined and consortium formed three Working Groups (WG):

• • •

WG1 – Design in additive manufacturing (methodology, algorithms and data formats); WG2 – Materials / Processes (primary materials characterisation, processing parameters setting-up and control, post–treatment auxiliary processes);

Metal

4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Ti Grade 1

Ti AI

TA6V

(powder bed fusion) (medical)

(powder bed fusion) (aeronautic)

(powder bed fusion, clad) (aeronautic repaired)

Inconel 625 and others

Inconel 718 and others

(powder bed fusion) (aeronautic)

Co-Cr (powder bed fusion) (dental, orthopedic)

Aluminium and ligth alloys

Tool Steel

(powd fusion bed fusion / clad) (to be defined)

Stainless Steel

(powder bed fusion) (Mold industry)

(powder bed fusion) (jewelry)

Polymers

4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 PA12

PA11

(powder bed fusion) (medical, automotive, aeronautic, military)

(SLS)

PA Flame retardent (aeronautic)

ABS

Ruber like

Med 610

PC ISO

PEEK

PA6

(fused deposed molding

(powder bed fusionand ink jet printer)

(inkjet printingObjet) (medical)

(fused deposed molding)

(powder bed fusion)

3.5

Ceramics

3.0 2.5 2.0 1.5

0.5 0.0 Alumina

Zircona

Sic

HAP

(green bed (green bed (green bed (green bed sintering, powder sintering, powder sintering, sintering, powder bed sintering, ink bed sintering, ink aeronautic / high bed sintering, ink jet printing) jet printing) t° applications) jet printing) (medical) (medical) (medical)

5.0 4.5

TCP

HAP + TCP

(green bed sintering, powder bed sintering, ink jet printing) (medical)

(green bed sintering) (medical)

Other Subjects

4.0 3.5 3.0 2.5 2.0

design opportunities and restrictions,

1.0

1.5

0.5

and Materials and material properties

0.0 Postprocessing

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Monitoring process

Lattices structures:

List of post processing

(recommendation, (link to part quality: recommendation to process ex. dry machining, optical, power clean the parts machining, particles specific cleaning monitoring...) remove from parts technology...) (plasting) (see information from compoligth project / Frits)

July 2014

Gold, Bronze, copper, silver

5.0

process-specific design,

are described.

5.0

1.0

WG3 – Test Methods / Products Characterisation (test methods, physical and mechanical characteristics of final products).

WG1 – Design in additive manufacturing The guidelines for the Design in AM present the general methodology and the procedures applied in the course of the conception and engineering of the product. It gives an indication about what decisions and in what sequence the different design steps could/have to be taken and sets up the basis for the standard design methodology specific to AM. In general, it shall be supported by a set of Technical Specification documents, where process details such as:

• • •

Figure 1 Priorities established within SASAM’s WG2

SASAM

Lattice structures fabrication,

SASAM’s Standards Structure & Guidelines Once the priorities were established and scientific and technical work performed, the SASAM consortium developed the guidelines for the development of the future EU / World standards in AM concerning several priority subjects and provides the support for the subsequent detailed elaboration of standards structure and content.

Multi-material manufacturing.

Among other things, SASAM consortium has worked out:

From the technical point of view, the subsequent development / elaboration of ‘Design in Additive Manufacturing’ documents shall also treat some strategic for AM aspects such as:

• • •

Topology optimisation,

Design guidelines for AM will help users to maximise unique possibilities of AM and give prior warning of the limits. WG2 – Materials / Processes Tasks of this WG were split up in two sections with the aim of identification of the most relevant items and information sources for:

• • •

• •

A specific approach to component design related to AM.

•

An extended set of items important for the eventual normalisation in AM. This items include materials (metals, plastics, ceramics), process (monitoring and optimisation, post-treatment procedures), test methods (tensile strength, fatigue resistance, etc.) and product characterisation (geometric requirement and tolerance, mechanical properties, sensorial properties, etc.).

•

A general methodology for the development of AM standards regarding the majority of the above mentioned items. SASAMs strategic approach to the eventual AM standards is: whenever possible to use as the basis the existing ISO, ASTM norms and to elaborate them (extend to AM) by introducing into them specific characteristics, procedures and values related to the nature of AM and to the particular properties of manufactured components.

•

A number of case studies were created and resulted in detailed recommendations for the development of AM standards concerning the materials and products characterisation representing, according to the competence of SASAM Consortium, the actual priorities for AM.

Materials Process: Auxiliary Procedures Classification and ranking of the identified items with highest priority for the normalisation in AM.

Figure 1 establishes the priorities for each group. WG3 – Test Methods / Products Characterisation WG3 methodology was very similar to the one used for WG2, which most relevant items and information sources were:

• • •

Standard characterisation tests and methods used at present Physical / Mechanical / Other properties Identification of the specific characterisation tests and parameters proper to AM products.

The most important items those displayed in Figure 2:

Results Implementation SASAM Consortium foresees the continuation of the work engaged and the implementation of the accomplished results by:

Figure 2 Priority given to items within SASAM’s WG3 5.0

Mechanical Requirements

4.5

Design algorithm which takes into consideration the particular features of AM and enables the realisation of the advantages specific to AM.

•

Transferring SASAM results to the corresponding Technical Committees (TCs) of CEN and ISO;

•

Initiating communication with TCs in order to implement SASAM approach and methodology for AM standards;

•

Supporting the standardisation activities of TCs by the involvement / contribution of experts in AM;

•

Monitoring the relevant R&D activities (European AM platform, EU funded projects, scientific publications, technical releases, etc.) in order to feed standardisation activities with the information providing necessary scientific and technological basis for the developed AM standards.

4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Hardness

Tensile strength

Impact strength

Compressive properties

Flexual strength

Fatigue testing

Creep

Aging

Frictional coefficient

(Metallic specimen)

Aspect and geometry requirements 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Appearance

Surface texture

Colour

Size, length and angle dimensions, dimensional tolerances

Geometrical tolerancing (deviations in shape and position)

Sheer resistance

Crack extension

The basis for global standards has been set up and SASAM consortium has groundwork towards achieving this. Continuation depends on the stakeholders working and pulling for them, as it could be the beginning of a well-deployed industry competing with established manufacturing technologies as well as enhancing and complementing them. SASAM project was supported by the European Commission within a NMP-SA-2012-319167 (G.A II.30.4). It was structured in 5 Work Packages (WP) and planned for 18 months, from 1st September 2012. It was lead by TNO and 18 partners like Siemens, SINTEF or CETIM, several research organisations like SIRRIS (B), University of Loughborough (GB), or Inspire (CH), and several national standardisation institutions from The Netherlands (NEN), France (UNM) and Sweden (SIS) participate in it. For further information visit www.sasam.eu and www.am-platform.com.

July 2014

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July 2014

MAKER MOVEMENT UPDATE

Maker Movement UPDATE WORDS | Rose Brooke

he White House may have had their Maker Faire, but TCT Show + Personalize 2014 is celebrating the Maker Movement for three days this autumn with representatives from this burgeoning side of the industry exhibiting, teaching and preaching at the leading 3D printing “There is always and additive manufacturing event.

something new and exciting to see from iconic and innovative companies, to established global giants exhibiting together.”

This year’s outing will see the return of the RepRap Hub, headed up by RichRap’s Richard Horne, a stalwart of the Maker Movement in the UK and internationally. He said: “The RepRap community is delighted to be back at TCT for a second year,” adding that this year the Maker community has a larger space for Makers and RepRap developers to play with, in addition to a dedicated RepRap presentation zone. “There is always something new and exciting to see from iconic and innovative companies, to established global giants exhibiting together,” Horne stated.

And for the first time, there will be a 3D Hubs UK Maker Meetup at TCT Show this September, while top brass from the international 3D printing community will take to the stage to share some insights with visitors for the TCT Introducing speaker session. Netherlands-based 3D Hubs is the fastest-growing maker community on the planet with more than 5,000 3D printers on its platform giving 750 million people around the world access to 3D printing from within a 10 mile radius of their home. 3D Hubs’ mission for TCT Show includes showcasing the latest in 3D printing technology and introducing more people to this thriving platform. With the arrival of the 3D Hubs Maker Meetup, the introduction of a dedicated RepRap Hub presentation zone and networking space, in addition to the return of the RepRap Hub complete with the RepRap team who will be on-hand to answer any question under the sun from enthusiastic hobbyists or curious beginners young or old, this year’s TCT Show marks the importance of the Maker Movement in 3D printing and invites everybody to participate. “I visit TCT Show to meet people, listen and make real connections. I really look forward to meeting and talking to as many people as possible,” said Horne.

July 2014

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3T RPD

The Queen’s Baton, A LABOUR OF LOVE WORDS | Rose Brooke

fter the World Cup and after Wimbledon there is another sporting event that will unite people all over the world, the Glasgow 2014 Commonwealth Games. Ahead of this athletic highlight of the summer, the Commonwealth Games Queen’s Baton has been working its way across the planet on the famous Queen’s Baton Relay, visiting 70 nations on a route covering 190,000 km over 288 days. One of the most exciting aspects of the Baton itself is that it was made using 3D printing.

© Glasgow 2014 Limited/Commonwealth Games Federation. All Rights Reserved 3T RPD was commissioned by 4c Design to build the titanium lattice frame for the Queen’s Baton, with the design taking inspiration from Scottish materials, Scottish design and traditional Scottish craft. There are four elements to it. In addition to the lattice framework, the elm handle was made by boat-building craftsmen at GalGael in Glasgow, while the granite gemstone that tops the Baton was hewn by Kay’s, which makes curling stones. The coin that crowns this gemstone was designed at the Glasgow School of Art. Speaking to the BBC earlier this year, 4c Design’s Will Mitchell explained how a great deal of trust was put in 3T RPD when the CAD files for the lattice were sent down to their West Berkshire headquarters for the design to be built over the weekend. The DMLS process took over 30 hours as the baton was built from a bed of titanium powder, with the exterior skin being polished to a high shine, while the layer underneath remains the same as when it emerged from additive manufacturing, resulting in a dramatic effect. The finished item comprises over 4,000 layers and incorporates Mitchell’s organic design inspired by Charles Rennie Mackintosh. One element of the Baton will remain secret until the Games Opening Ceremony, the Queen’s message, which will be illuminated from within “We have achieved something that’s truly great and I love it,” Mitchell stated. i| www.3trpd.co.uk 62

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July 2014