TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 1
issue
NOV 12
20|6
tct xxx
10 Reasons to Make the Move to Multi-Material 3D Printing AM and Industrial 3D Printing Matrix TCT Live Review and EuroMold Preview Through the Doors: Pro2Pro leading product development and additive manufacturing since 1992 tct 20/2
1
TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 2
TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 3
tct
Volume 20/Issue 6 www.tctmagazine.com
EDITORIAL Group Editor James Woodcock E: james@rapidnews.com T: + 44 (0) 1829 770037
EDITORIAL ADVISORY BOARD Todd Grimm, T.A. Grimm & Associates, Inc. Jeremy Pullin, Renishaw PLC Dr Joel Segal, Nottingham University Graham Tromans, G. P. Tromans Associates Terry Wohlers, Wohlers Associates Dan Johns, Bloodhound SSC
SALES Group Advertising Manager Carol Hardy E: carol@rapidnews.com T: + 44 (0) 1829 770037
ART Production & Design Manager Sam Hamlyn E: sam@rapidnews.com T: + 44 (0) 1829 770037 Graphic Designer Adrian Price E: adrian@rapidnews.com T: + 44 (0) 1829 770037
C.O.O. / PUBLISHER Duncan Wood E: duncan@rapidnews.com T: + 44 (0) 7798 844259
C.E.O. Mark Blezard E: mark@rapidnews.com T: + 44 (0) 1829 770037
SUBSCRIPTIONS Circulation Manager Tracey Nicholls E: tracey@rapidnews.com Qualifying readers | Europe - Free | North America & Canada - £30 | ROW - £115 Outside qualifying criteria | UK - £80 | ROW - £115
The TCT Magazine is published bi-monthly by Rapid News Publications Ltd Unit 2, Chowley Court, Chowley Oak Lane, Tattenhall, CH3 9GA, UK. Telephone: + 44 (0) 1829 770037 Fax: + 44 (0) 1829 770047 © 2012 Rapid News Publications Ltd
While every attempt has been made to ensure that the information contained within this publication is accurate, the publisher accepts no liability for information published in error, or for views expressed. All rights for The TCT Magazine are reserved. Reproduction in whole or in part without prior written permission from the publisher is strictly prohibited. ISSN 1751-0333
The TCT Magazine is endorsed by the following organisations as a leading resource for information on Rapid Product Development and Additive Manufacturing technologies.
AMUG
The Global Alliance of Rapid Prototyping Associations
The Additive Manufacturing Association
Medilink WM
Member of Gauge and Toolmakers Association
3 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 4
TCT 20-6 progress_Layout 1 07/11/2012 15:56 Page 5
NOV 12
!From The Editor
3D printing, government and policy printing will place major strains on laws and government policy in the UK” is all well and good, but without a hint of a timeframe (or even a likelihood) it’s all so much bluff and bluster.
The report aims to outline the need for governmental intervention in all aspects of ‘3D printing’ from the home user to the multinational company. In part, this becomes a self-justifying proposition — by representing ‘3D printing’ in such nebulous terms, the proposed need for a coherent policy framework is strengthened. The press release that promoted the report states in the opening sentence that, ‘The government needs a plan for the arrival of 3D printing, to ensure that the UK can reap the full economic benefits of this revolutionary technology and to address risks such as illegal gun production.’ Illegal gun production? Is this one of the most significant challenges associated with AM and 3D printing? Sadly it seems that the report and the recommendations are tainted somewhat by the hype of the moment. The overall message here appears to be — 3D printing may be, in some form, important in some way to some people and those effects could, via unknown routes, impact on the UK economy. So we need to have lots of meetings in London. I may be being a little unfair. This report is intended as a way to start a debate on 3D printing at a policy level, something that is currently lacking. Claiming that “3D
Could the money that this initiative would inevitably cost get a low-cost 3D printer into every school? Would that help the UK compete where AM and 3D printing are used commercially? To an extent this report rests heavily on the current belief that AM and 3D printing will quickly revolutionise everything from toys to games to aeroplanes in a manner that could be either beneficial, detrimental or in most predictions, both. Maybe it will, maybe it won’t. Where government could be really useful here is by ensuring that the current stakeholders in AM and 3D printing have access to the resources they need, including high-quality engineers, to develop the processes and materials and get them to market. The best way of ensuring that the UK doesn’t miss the ‘huge growth opportunities of 3D printing’ is not to concentrate efforts on additive technologies, but on wider manufacturing. At this point the markets (including consumers) will make up their minds. Where the government could be really unhelpful is wrapping the fledgling technologies red tape and cotton wool. Jim Woodcock Group Editor james@rapidnews.com
FROM THE EDITOR
Here in the UK, The Big Innovation Centre — an initiative of The Work Foundation and Lancaster University — has released a report entitled ‘Three Dimensional Policy: Why Britain needs a policy framework for 3D printing’. The full report makes for interesting, if sometimes uncomfortable, reading.
5 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 6
www.tctmagazine.com
TCT VOLUME 20 | 6
contents
15
column: The Real Benefits of AM
18 column Bloodhound
Objet’s multi-material 3D printing capabilities can be leveraged across product design, development & manufacturing... and beyond. The front cover image comes courtesy of MIT Media Lab’s Neri Oxman.
tct news and comment
on the cover:
column Todd Grimm
10
29
For more detail, please see page 8.
29
feature: Streamlining Bureau Quoting Operations Quoting for jobs (whether won or not) takes a significant amount of time for service bureaux — Asiga’s Ray Ericsson looks at how a cloudbased solution may streamline the process.
Todd Grimm
18
21
Asiga QuoteServer
08 cover star Lead News
editorial insight
on the cover
01
05
15
TCT Live 2012 Review
01
column: Beam Me Up Scotty... I’m An Engineer Dan Johns, Bloodhound SSC
05 10 6
editorial insight
21 tct news and comment
review: TCT Live 2012 Get the low-down from the leading dedicated AM and 3D Printing show in Europe... maybe the world!
News for engineering, product development and manufacturing. tct 20/6
35
feature: Sponsored by Renishaw AM and Industrial 3D Printing Matrix and Buyers’ Guide A roundup of the machines available today for the professional users, with specs, prices (where submitted) and details of materials.
TCT 20-6 progress_Layout 1 07/11/2012 11:57 Page 7
leading product development and additive manufacturing since 1992
64 Profile Initial
53
59
60 Euromold Preview
Design for AM: No Rules or New Rules Mike Ayre takes a look at the common belief that AM and 3D printing processes free the designer from all design constraints. Is there any truth in this widespread belief?
feature:
feature: Wohlers’ Executive Summary
Reverse Engineering and AM for Military Mechanical Parts Replacement A look at how EADS Innovation Works has deployed RE hardware and software along with AM to create spare parts for military vehicles.
Through the Doors: Pro2Pro, Telford, UK Jim Woodcock takes a trip to Telford in the UK to see how Pro2Pro deploy a range of processes intelligently to create some extraordinary products.
feature:
59 Wohlers’ Executive Summary
49
Charles Clarke
feature:
53
EADS
45
45 Design for AM
2013 Matrix
41
Through The Doors Pro2Pro
35
41
49
60
EuroMold 2012 It’s already time to pack the bags and head back to Frankfurt for another edition of EuroMold — one of the biggest dates on the product development and manufacturing calendar.
feature: SpaceClaim Engineer 2012+ — Just Do It! Charles Clarke takes a look at how SpaceClaim have shaken up the industry and some of the features of their new release.
tct 20/6
preview: Sponsored by Objet
64
profile: Initial France-based Initial have been active in 3D scanning and AM for many years, over which time they have amassed a formidable armoury of processes.
7
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 8
!Cover Star
Multi-Material 3D Printing in Product Design & Development
Based on its innovative use of inkjet printing technology, Objet’s 3D printers are the only 3D printers in the world able to combine different materials within a single 3D printed model. Objet is also the first 3D printing technology in the world to offer a choice of over 100 different 3D printing materials, ranging in properties from rigid plastic to rubber-like, opaque to transparent, and standard to engineering-grade ABS toughness. When talking about ‘multiple-material’ 3D printing, we actually refer to a number of different capabilities — which we will aim to categorise and clarify in this white paper. We will also outline the uses and advantages of this unique 3D printing technology for companies using rapid prototyping during the design and development of manufactured end products.
10 Advantages of Dual Material Jetting Objet’s 3D printing technology is able to control every nozzle in every print head independently. This means that preset combinations of model materials can be jetted from designated nozzles to create new materials, different material parts within a model, as well as different material models that are being printed at once. Here are ten benefits of this unique dual-material jetting in more detail:
1.
Fabricate Composite ‘Digital Materials’ Objet’s Digital Materials are multi-phase composite materials created by the Objet Connex 3D printing system. Digital Materials are new, composite materials with attributes that are not available in the individual constituents.
Dual Material Jetting — The Technology Objet Connex 3D printing technology works by jetting two distinct Objet materials. The technology can work with any mix of rigid and flexible materials, various transparent and opaque materials, and different colour materials.
Based on this multi-material jetting technology, the Connex family of 3D printers is able to simultaneously print two resin materials to create 106 different types of Digital Material. Starting with 17 cartridge-ready materials, Objet Connex users have the ability to choose from a total of 123 different materials and composite material combinations.
Each material is funneled to a dedicated liquid system. The liquid system is connected to the Objet printing block, which contains eight printing heads. Every head includes 96 nozzles, each measuring 50-microns in diameter. Each material has two designated printing heads that work in sync. Objet Materials Objet’s range of over 123 3D printing materials is based upon proprietary acrylic-based photopolymer resins. These materials are jetted as a liquid from sealed cartridges inserted into the machine. Once a layer of material is deposited on to the ‘build tray,’ it is immediately cured by a UV light. The UV light follows the print head and turns each liquid material layer into a solid. The material is immediately ready to be built upon with successive layers. These fully cured models can be handled immediately after printing — a unique advantage over other rapid prototyping technologies and materials which can require lengthy post-processing treatments.
8
Loading and unloading the print cartridges is similar to the process of installing and removing inkjet cartridges from a paper-feed printer.
This additional set of materials improves upon the mechanical properties available from the existing materials — providing new values of tensile strength, flexural strength and Izod Impact. Rubber-like Digital Materials enable the precise selection of new “Shore A” values to suit the specific application purposes of the designer. Objet’s Digital Materials are generated on-the-fly, based on the two cartridgebased materials that are installed in the system. The selection of the Digital Material is made by the user through dedicated software that determines the appropriate jetting parameters. The materials are created automatically during printing, without the need for additional human input.
tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 15:56 Page 9
2.
7.
3.
8.
A Recipe for Future Scalability 106 Digital Materials can be derived from just a small number of primary materials. Every additional new material introduced therefore opens up tens of new digital material options. With Objet’s multi-material technology, the potential palate of Digital Material combinations will continue to expand and grow exponentially. Simulate Plastics with Engineering Properties When the Objet multi-material process combines specific rigid materials with specific flexible materials, the resulting Digital Material can be tougher than the individual material components from which it is comprised. Objet’s ABS-like Digital Material is an example of such, combining the toughness of one material with the temperature resistance of a second material to provide a hybrid that can simulate ABS-grade engineering plastics. Using this advanced material, designers, engineers and manufacturers can achieve advanced functional simulation of their intended end-product without the fear of easy breakage.
Simulate Opaque Shades with Clear Transparency Popular in the medical industry, Objet’s Connex line of multi-material 3D printers is used to create accurate models of body parts in transparent material with the internal structures in black, white, blue or grey shade combinations — so that they are visible ‘beneath the skin.’ The capability to use the 'opaque within a transparent model' also has many applications within other industries such as mechanical engineering. More Efficient Short Series Injection Moulding 3D printing mould tools in Objet ABS-like Digital Material and using this for the injection moulding of the intended plastic has several advantages including: n Real prototype in hand early on in the design process n More economical small series production n Fast mould validation — reduced time to final mould n Reduced time-to-market for final part and reduced overall costs
4.
Segregate Different Materials within One Consistent Model Digital Materials can produce a uniform part — made of one consistent colour or rigidness, however you can also segregate different materials and Digital Materials within a single 3D printed object. Because of the different nozzles within the print-head, Objet Connex 3D printers can selectively deposit up to 14 different materials (12 digital materials created on-the-fly, plus the two materials straight from the cartridge) in a different part of the model with sharp, defined material boundaries.This ‘mixed part’ 3D printing capability eliminates the need to design and print separate parts using different materials and then assemble them together in a post-printing process, such as gluing.
Combine Rigid Material with Rubber-like Over-Moulding Objet Connex 3D printers simultaneously print parts with different mechanical properties. This capability enables the user to test 3D printed prototypes that are very close to the production part in terms of mechanical properties and material combinations, e.g., over-moulding and double injection. Prototyping in this way aids in the selection of the materials that will be used in the final product. This capability improves the communication between different groups and decision makers in the company, such as R&D, internal/external customers, engineering, marketing, sales and management. This pressing need exists in most of the current products in consumer goods and electronics, automotive, shoe and medical industries. A cellular phone with a rigid body, rubber-like keys and over-moulded parts is one example of such an application. Other examples are a car wheel printed complete with its rubber-like tire or a shoe sole with overmoulded, rubber-like treads.
5.
Segregate Different Material Models on the Same Print Tray In order to maximise system yield, the Objet Connex has the ability to simultaneously build different material parts on a single tray. This can improve productivity for companies requiring high-volume prototyping. Using this feature increases the system’s efficiency, enabling multiple build varieties to be printed at the same time. This allows designers to then quickly select the most suitable model.
COVER STAR
9.
10.
Combine High Temperature Material with Rubber-like Material Combining Objet’s High Temperature material with Rubber-like materials enables the formulation of high-temperature parts with over-moulding. Automotive air-ventilation systems, for example, can now be printed in Objet’s High Temperature material with Rubber-like over-moulded edges to produce an air-tight fit for moving opening/closing paddles.
6.
Create Greyscales and Tones For example, when using Objet Rigid Black and Rigid White primary materials it is possible to combine them in various ratios to create different greyscales. Creating greyscales and tones makes it possible to print marks and signs on a model, mark desired areas of interest and even add captions. The application uses for this capability are endless, ranging from artistic designs to functional simulation of assembled goods that, in the consumer world, are typically made of different material parts and then assembled.
When combined to produce Digital Materials, the High Temperature/Rubber-like combination produces composites with both durability and temperature resistance — suitable for a range of applications such as medical devices, surgery planning, automotive parts or models used in high-humidity environments. Objet Ltd www.objet.com
tct 20/6
9
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 10
!News !3D SYSTEMS BUYS KOREA-BASED RAPIDFROM 3D Systems has acquired Rapidform, a leading global provider of 3D scan-to-CAD and inspection software tools, located in Seoul, South Korea for $35 million in cash, subject to final closing adjustments. Rapidform’s reverse engineering and inspection software empower product developers to deliver improved product quality and shorter time-to-market. By combining scan data processing, mesh optimisation, auto surfacing and CAD modelling in a single, integrated tool, Rapidform has unlocked the power of 3D digitisation for engineers and manufacturing professionals worldwide.
3D Systems expects Rapidform to contribute $15 million of revenue and deliver between $0.06 and $0.09 in earnings per share to its 2013 non-GAAP results. “This is a game-changer for our customers and shareholders, and is well-aligned with our strategic plan,” said Abe Reichental, President and CEO of 3D Systems. “We are thrilled to welcome Calvin Hur and his team to our company and we expect that the integration of the Rapidform proprietary products with 3D Systems’ extensive portfolio will result in accelerated growth within the rapidly expanding 3D content-to-print space.” “I am very pleased and honored to become part of 3D Systems, a world class leader and innovator,” said Calvin Hur, CEO of Rapidform. “Joining 3D Systems provides us with the scale, resources and strategic platform to realise our vision of democratising the scanto-CAD workflow for the benefit of designers and engineers.” Comment It has been a while since 3D Systems made a significant purchase but the Rock Hill outfit seems to be back to the road more travelled over the last couple of years. The acquisition of Rapidform for $35m gives 3D Systems a route into the reverse engineering sector that helps to complete its content-to-production ethos. When 3D Systems acquired ZCorporation it failed to (or chose not to) retain the Creaform hand-held scan system that was being sold as the ZScanner. Although 3D Systems has some digitisation technology through another acquisition, Vidar, it lacks a scanner (or, more likely a range of scanners and other reverse engineering hardware) to call its own. It would be a safe bet that the next 12 months will see the acquisition of a company that either has the reverse engineering hardware products 3D Systems needs, or the IP that they can incubate and release their own proprietary products.
10
3D Systems Corporation www.3dsystems.com tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 11
!News !STRATASYS ADDS BLACK ULTEM 9085 HIGH PERFORMANCE THERMOPLASTIC Stratasys debuted black colour ULTEM 9085 for use in its FDM additive manufacturing process at the SEMA Show in Las Vegas, USA.
“The majority of our tan ULTEM users have requested the material also be available in black, because it gives a uniform look to product assemblies,” said Fred Fischer, Business Development Director at Stratasys. “It also helps mask dirt or grease found in mechanical systems or under the hood, in the fuselage, or on the manufacturing floor. For many users, the black colour will eliminate the need for
non-value-added post-processing step of painting or coating.” Like standard ULTEM 9085, the black colour material has a V-0 flammability rating. The material is heat resistant up to 320°F (160°C) and is inherently flame-retardant, offering full FST compliance including OSU heat release of less than 55/55, or 55 kw min/m2 for heat release and 55 kw/m2 for peak heat release. Comment: Perhaps the biggest positive for the FDM process has always been its ability to create !WINDFORM SP, A NEW MATERIAL WITH SUPERIOR TECHNICAL CHARACTERISTICS CRP Technology has launched a new material in the field of polyamide-based materials: the Windform SP. Its reportedly superior characteristics make it an ideal solution for a series of applications, not just for the motorsport industry. Windform SP is a composite polyamide based carbon filled material characterised by deep black colour and it can be considered a “Top” level material within the polyamide Windform materials for 3D Printing and additive manufacturing. CRP Technology, leader in the field of 3D printing and additive manufacturing for more than 15 years, is pleased to present this new material which has excellent mechanical properties. In addition it has the advantage of
parts in a number of high-end engineering plastics, and plastics that accurately mimic or are identical too those used in production, such as the ubiquitous ABS. The release of a black version of the highly regarded ULTEM material is so obvious that I was surprised it had not been done already — given the material’s extensive use in automotive and even aerospace applications it makes perfect sense. Stratasys www.stratasys.com increased resistance to shocks, vibrations and deformations. Comment: CRP has been instrumental in facilitating the uptake of additive technologies into the motorsports world because of its innovative materials. The Windform series is widely used across F1 and elsewhere thanks to a broad range of desriable mechanical properties. The latest Windform SP material is suitable in the traditional automotive contexts for engine compartment prototype, functional test and even pre-series production parts. Beyond this the company also expects the material to find uses in aerospace applications, particularly in the burgeoning unmanned arial vehicle market.
NEWS
ULTEM 9085 from SABIC Innovative Plastics has superior strength, is light weight, and has other desirable characteristics, including FST rating. The FST (flame, smoke and toxicity) rating is a safety standard that ensures a material won’t promote a fire, release harmful smoke, or emit toxic fumes, and it is particularly valued in the transportation industries.
CRP Technology www.crptechnology.com
11 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 12
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 13
!News The production of electrodes is important in the manufacture of many types of tooling so the availability of a faster, more automated method for their development will increase efficiency and reduce lead times across a number of industries. !DELCAM LAUNCHES INTEGRATED ELECTRODE SOLUTION Delcam has launched a completely integrated solution for the design, machining and inspection of electrodes. The close integration has been made possible through developments
!UK GOVERNMENT OFFERS INVESTMENT IN AM Innovation in additive manufacturing technologies is to be boosted through £7 million of new Government investment in research and development, Universities and Science Minister David Willetts has announced. Grants for collaborative R&D projects in additive manufacturing will be awarded through an open competition to be managed by the Technology Strategy Board (www.innovateuk.org), the Engineering & Physical Sciences Research Council (EPSRC — www.epsrc.ac.uk), the Arts and Humanities Research Council (AHRC — www.ahrc.ac.uk) and the Economic and Social Research Council (ESRC — www.esrc.ac.uk). Comment: Perhaps in response to the establishment of the National Additive Manufacturing Innovation Institute in the US, the UK has kickstarted its own investment in the AM world thanks to this £7m ($11m) research investment. While there is some way for the UK to go in terms of capitalising on the possibilities afforded by AM, this is a good start — incidentally the annoucement came only days after The Big Innovation Centre released a paper urging the UK government to not only invest in but also create a policy framework surrounding AM and 3D printing. I am sure the money will be welcomed (provided it isn’t all siphoned off into the coffers of one or two academics) but whether increased regulation and government level policy creates the same response wait to be seen. Technology Strategy Board www.innovateuk.org
At the heart of the novel Delcam solution is a new file format — the .Trode file. This contains all the information for each electrode project, including the electrode design and the associated machining and inspection
!VERO STRENGTHENS IT ONLINE PRESENCE Vero Software has strengthened its online presence with the launch of new individual brand websites, replacing the former Vero and Planit sites. In addition, a Vero corporate Facebook page has been created, along with individual Twitter and YouTube accounts for each brand. Vero is a leading developer and distributor of CAD/CAM technology, supplying a number of industries with market leading brands such as VISI, Edgecam, Radan, Alphacam and Cabinet Vision. The Vero Group has enhanced its position within the industry after the recent coming together of Vero and Planit. Group Marketing Director Marc Freebrey said: “We’ve worked hard to strengthen the identity of each individual brand within the new Group. We understand customer loyalty to their product and were keen to ensure each one had a dedicated web presence with tailored content. Vero UK Ltd www.verosoftware.com
!ENVISIONTEC ANNOUNCES MOVE TO NEW HEADQUARTERS IN DEARBORN TO SUPPORT ACCELERATED GROWTH EnvisionTEC, Inc., manufacturer and distributor of patented 3D rapid prototyping and manufacturing solutions, has announced that it has relocated into a new 39,000 square foot facility in Dearborn, Michigan. With more than two times the space than the previous location in Ferndale, Michigan, EnvisionTEC's new global headquarters will house the North American operations team, tct 20/6
information, plus the set-up sheets for its manufacture and use. Comment: Delcam are consistently one of the most active and innovative companies in the manufacturing space, constantly developing its solutions and leveraging them in new ways. The introduction of the new Electrode Manufactring Solution demonstrates perfectly how the company can re-purpose and combine existing products to help users solve another manufacturing problem. Delcam www.delcam-electrode.com
!SIEMENS TO ACQUIRE KINEO CAM Siemens has acquired Kineo CAM, headquartered in Toulouse, France, a provider of computer-aided motion software. Kineo CAM’s solutions are already proven components of Siemens PLM software products, maximising customer productivity in various industries by optimising motion, collision avoidance and path planning. Through the acquisition Siemens will be able to further enhance the computer-aided motion capabilities of its software and strengthen Siemens’ ability to grow market share. The newly acquired company has over 200 customers worldwide and after closing will be assigned to the PLM Software Business Unit. The purchase price was not disclosed. “By acquiring Kineo CAM we add another advanced technology to our PLM portfolio. This technology enables our customers to make better informed decisions about their products, and to devise manufacturing, maintenance and repair strategies”, said Chuck Grindstaff, CEO and president of Siemens' PLM Software Business Unit.
NEWS
in Delcam’s PowerSHAPE CAD software, PowerMILL CAM system and PowerINSPECT inspection software.
Siemens www.siemens.com
including sales, marketing, customer support, training and distribution. The new building's increased capacity supports the company's strategic objectives to further expand its product offerings, maintain its superior customer support, and create operational efficiencies to meet the needs of a rapidly expanding global 3D Printing market. EnvisionTEC www.envisiontec.com
13
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 14
TCT 20-6 progress_Layout 1 07/11/2012 11:58 Page 15
The Real Benefits of Additive Manufacturing WORDS | TODD GRIMM @ T.A. GRIMM & ASSOCIATES, INC
Efficiency is the fundamental advantage of AM, and it is not proportional to the three characteristics that are exhibited by the strongest AM applications. Unlike any other process, AM retains its efficiency when production volumes are low, complexity is high and changes are frequent. Together, these four elements comprise the four pillars for ideal AM applications. These are the four things that you should always keep in mind as you are rationalising or justifying the use of AM. And these are the four characteristics to have in the forefront of your mind as you look for
ways to expand the use and grow the value of AM within your organisation. The Goal It is a bit controversial to boldly state that speed is not a primary benefit of AM, but it is true. Since the dawn of the rapid prototyping age, suppliers have touted AM’s ability to reduce time to market. While that is a powerful advantage, one that could result from accelerated product design, product testing or production, it is only possible if AM accelerates the bottleneck operation. If you are unconvinced, read the manufacturing classic “The Goal” by Dr. Eliyahu M. Goldratt, a business consultant whose Theory of Constraints has become a model for systems management. In his fictional account, Goldratt clearly shows that there is little or no advantage in improving process speed before or after a
GRIMM COLUMN
No, the real benefit of additive manufacturing (AM) is not speed. Although speed can be advantageous, it is only a feature of AM that translates to a benefit when a lead time reduction produces results. The real benefit of AM is efficiency, a measure that considers speed, effort, process delays, process steps and personnel time.
y t i l i b i x Fle
Complexity
Volume
Efficiency
Having dispelled some of the myths surrounding Additive Manufacturing in the last few issues, Todd Grimm now gets to the real and tangible benefits that users of this group of technologies can unlock in their day-to-day.
15 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 16
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 17
bottleneck operation. Speeding up the upstream process just puts more work in the queue. Speeding up the downstream process increases the time that it sits idle waiting for work. Considering this logic, speed is a benefit of AM only if the function it performs is the bottleneck. For example, if AM prototypes arrive weeks before electronic assemblies, the electronics throttle functional testing. The result: no decrease in time to market. However, under the umbrella of efficiency, the benefits of task time reduction and responsiveness remain even if processes are not accelerated.
In the cases where they would approach the project through conventional means, they find that AM is an alternative with unmatched advantages when making just a few complex parts or making frequent changes. Applied to real problems and opportunities — as opposed to using AM just for frivolous endeavors — everyone wins. The individual responsible for the project or task implements a solution with much less effort. The company realises increased process efficiency, decreased expenses, shorter timelines and better product designs. All of which will show up on the corporate profit and loss statement. Four Pillars Now that I have made the case for the four pillars, let’s look at each individually.
Shift in Goals About six years ago, I angered Z Corp. management during my keynote at its annual users group meeting. In the first 30 seconds of my presentation, I told the audience to forget about speed…to forget about the “rapid” piece of rapid prototyping…which was, and still is, a major differentiator for this 3D printing process. The anger and anxiety subsided as I clarified my statement. As I’ve already stated, the benefit is efficiency. Moreover, raw speed only becomes an advantage when you do something beneficial with the process acceleration. One example offered was conducting more design revisions in a set time span. Even further back, I published a companion piece to the presentation I was to do at one of the early TCT conferences. I didn’t know it then, but I was making the case for the four pillars of AM’s advantages. Blended in with efficiency were the benefits of AM that catered to human nature, items such as tactility and procrastination.
Efficiency: According to Dictionary.com, efficiency is “accomplishment of or ability to accomplish a job with a minimum expenditure of time and effort.” This is what AM offers for part-making and tool-building when extensive postprocessing and secondary operations are not needed. What efficiency does for AM is alter the input|output equation. With less time and effort invested (input), the action is more easily justified. Admit it, the harder something is to do, the less likely you are to do it. AM makes part making a simple task rather than an involved project. So, we are more likely to make what we need, as frequently as we need it. In the concept phase, for example, this means that designers will be more likely to make multiple models from multiple design revisions when using AM. That same logic carries through to mechanical design and manufacturing.
Yes, you need to have corporate gains to use AM, but these will follow. Making the process more efficient will translate to measurable results in the departmental budget and corporate ledgers. Industry Echoes I am quite pleased that this message is coming back to me from industrial AM practitioners. I can’t take credit for the shift in philosophy, but I do find it rewarding that this mindset is taking hold. Just this month, as I was conducting research for a white paper, three of four people that I interviewed overtly stated that AM is their go-to solution because of efficiency. The fourth implied it. These people stated “AM is a simple, quick, and affordable problem solving tool” and “AM is the path of least resistance.”
Complexity: For any conventional fabrication process, high design complexity decreases efficiency (and increases cost). AM, on the other hand, has no link to complexity, and therefore, complexity does not diminish efficiency. While part complexity is not a requirement for AM, it does increase its advantages. So, AM becomes a preferred alternative as complexity grows. Flexibility: Frequent changes and multiple revisions are inherently inefficient, and to be avoided, when machining, moulding and casting. With AM, they are encouraged.
GRIMM COLUMN
Volume: The high efficiency remains even when making parts in extremely low volumes and for a single instance. This is counter to mass production, where efficiencies are gained with large lot sizes and long runs. It is also counter to everyday tasks where repetition increases efficiency. Considering throughput, AM is most advantageous when quantities are low — as low as a one-off, bespoke product.
The goal of that document was to turn the focus to personal and departmental gains rather than corporate results. That remains the fundamental intent of the four pillars. People change their ways when they are forced to (management initiative), have to (problem solving) or want to (easier for them). The four pillars accommodate each scenario.
With only a modification to the design, AM will efficiently reproduce 3D objects with no additional time and labour needed. So, the fourth pillar to build on is AM’s flexibility in accommodating frequent changes to address the problems and opportunities that arise.
Versus any other tools or resources at their disposal, they told me that AM: n Requires less effort on their part (e.g., documentation) n Requires less upfront analysis and planning (e.g., no need to ask “can I” or “how”) n Requires fewer steps (e.g., design, print and done) n Requires fewer dedicated, highly skilled resources (e.g., toolpath creation)
Speed and lower costs may result from the application of AM to design and manufacturing applications, but the unmatched benefits are the combination of efficiency with low-volume, high-complexity, and everchanging parts.
The bonus is that AM is usually cheaper and faster than other methods when part quantities are low, complexity is high and revisions are frequent. Realising the efficiency advantage, these companies find that AM is an alternative, not a substitute. What happens is that they make objects with AM that they otherwise would not. Therefore, they are putting more models, prototypes, tools and parts into service than they would if they followed the conventional route.
This is the fundamental value proposition of additive manufacturing. Keep these real benefits in mind as you go about your daily duties, and you will find more applications for the technology — applications with real benefits to your department, division and corporation.
tct 20/6
17
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 18
“Beam me up Scotty,
I’m an Engineer”
WORDS | DAN JOHNS @ BLOODHOUND SSC
Many of my generation grew up in the shadow of the Apollo missions, which inspired us to look up and wonder what space exploration was really like. If you asked a 10 year old in the 70s what they wanted to do when they grew up, they’d have probably said ‘be an astronaut’ and some would have then carved out a career path to being a test pilot as this is a prerequisite to joining NASA. These dreams were also born out of TV programmes like Star Trek, with all the engineering and medical gadgetry, Star Wars with X-Wing fighters and Jedi Lightsabres, and even Moonraker, the James Bond film that gave us the Space Shuttle long before NASA ever thought of it. I on the other hand found maths quite interesting at school and subconsciously understood the laws of probability. It was highly unlikely that I could ever be an astronaut and nor could I ever be a Jedi Master, so my ambition was brought down to earth by a far more achievable goal — A rock star.
18
I have no idea how many people saw the moon landing on TV, but if today’s network of digital media channels were available the number
would be significantly higher. Just recently an estimated 8 million people watched online when Felix Baumgartner set a new world record and broke the sound barrier as he reached 833.9 mph free-falling from the edge of space. That’s faster than Andy Green’s current Land Speed Record of 763mph and just using gravity to accelerate. Even today these technology-centric, human endeavours create huge interest, and that’s exactly why Bloodhound SSC can inspire the next generation, and why we invited everyone to watch live our first Cosworth pumped hybrid rocket experiment from a bomb proof shed in Newquay last month. We are showing everyone the technology that makes Bloodhound work; we openly transmit the data and we are sharing the experience along the way. The technology in these types of projects has always been my inspiration, and probably why I remain fascinated with 3D printing. To me a 3D printer is just an early stage Star Trek Replicator, building things particle by particle, voxel by voxel. If we go down the material scale to an atomic level then why not imagine then being able to build anything atom by atom?
tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 19
Above: The ‘bomb-proof shed’ in which the rocket that will power the Bloodhound SSC land speed record attempt was tested.
So there you have it, the Star Trek Replicator is theoretically possible, and the sooner MIT does something about it the better. I’ve spent many years in aerospace directing the technology strategy to scale up these machines to make large scale components. However the material science needs to be directed to smaller scales, below nano scale, if we want to achieve real functionality like nature, manipulate the very stuff everything is made from, and then build anything we like. Even the USS Enterprise NCC1701. Bloodhound is constantly inspiring, and not just the children from the 5000+ schools registered with us, or the 11,000 names on the fin, or the 6000 1K Club members. It also continues to inspire us; the people working on the project, by the people we meet from other projects. On my very first day at Bloodhound I was awe inspired when I met Neil Armstrong. He talked a lot about rocketry and the risks involved, and he gave us all a lesson in differentiating Science from Engineering. I was left with a sense of how small our project felt compared to his achievements and those of the Apollo missions. It was not much different when I met the Space
We often get asked what we will do when we finish the Bloodhound project, to which I’ve never really had an answer, so I asked the Discovery crew the same question. They simply said they would just carry on doing the things they love to do; like medical research, robots, science and engineering. This is when it dawned on me that Astronauts today are not test pilots anymore; they are people like us who do science and engineering. The Apollo missions were about learning to get into space, today we are learning how to work in space. It’s now more likely that if you study STEM subjects you can actually go into space as a career and make 3D Printed components on the Space Station. So now I know what I want to do when I finish this project, I’m going to apply to NASA and become an Astronaut!
Editor’s Note: If you were not able to watch the Bloodhound SSC test rocket firing live from Newquay you can check out Cisco Bloodhound TV online and relive the moment that a bomb-proof bunker became home to the biggest rocket firing the UK has seen since the Second World War. Check out http://www.bloodhoundssc.com/bloodhound-tv to see the firing and all the latest updates from the Engineering Adventure that is Bloodhound SSC.
BLOODHOUND COLUMN
Shuttle Mission STS-133 Discovery Crew last year when they talked about their experiences working on the International Space Station and the end of the Shuttle program.
If you don’t believe me, read the work of Professor Richard Feynman, noted as the father of Nano-Technology, he said: “I want to build a billion tiny factories, models of each other, which are manufacturing simultaneously… The principles of physics, as far as I can see, do not speak against the possibility of maneuvering things atom by atom. It is not an attempt to violate any laws; it is something, in principle, that can be done; but in practice, it has not been done because we are too big.”
19 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 20
20 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 21
TCT Live + Personalize
Following the extended TCT Live 2011 as we co-located with Interplas, the 2012 outing was back to two days — but what a duo they were. While the raw number pointed to a modest increase in traffic across the days, there was a palpable excitement to proceedings this time around.
thank goodness we didn’t. Well over 100 people made it to the Seminar theatre, spilling into the aisles to hear what Graham had to say. Perhaps the most startling metric beyond the sheer numbers of people that turned up were the number that were there for the very first time. Of the amassed crowd, less than 5 had been to the show before!
If you haven’t visited or exhibited at TCT Live for a number of years I would urge you to make room in your 2013 schedule now.
What this proves to me is that TCT Live is more relevant to more people now than it has ever been before, and while as a company we have more competition now that at any time previous, we are confident that TCT is delivering on its promise to promote and help grow AM and associated technologies across engineering, product development and manufacturing.
The ebb and flow of the show floor is something that, for the inexperienced organiser, exhibitor or speaker can cause significant panic. The first morning is always in the lap of the Gods, with a crash on a major road or poor weather (or as is sadly the case, both) leading to a trickle of attendees through the door rather than the rush that everyone wants to see. I say ‘everyone’ because having visited a few rather quiet shows since TCT Live, it’s a little awkward walking through the halls with the eyes of every stand firmly on you! No such worry at the NEC however, as the first morning got off to a superb start. Half an hour after the show had opened the stands were buzzing, and when Todd Grimm began his Keynote at 10.15 am (following an ‘individual’ introduction from the inimitable Jeremy Pullin) it was standing room only. And so it continued.
The machinery manufacturers reported that traffic was good across the days, and that the visitors to the booths had greater knowledge about the processes and how they were looking to implement them than ever before. Hopefully reading TCT has had something to do with that, but it has also been a stellar year for the promotion of additive technologies in the mainstream media. Suffice to say, there is still a lot of confusion surrounding the finer details of processes, costs and abilities — luckily the answer to every conceivable AM or 3D printing question can be found at the NEC during TCT Live!
The second day was opened by Professor Phill Dickens from Loughborough University in the UK. Phill has held a number of positions within the Additive Manufacturing Research Group at Loughborough and has been one of the most influential members of academia working in AM. His presentation also drew in the early morning crowds as he talked about the past, present and future of the technologies he has dedicated so much to.
The conference is a significant part of what TCT Live is all about, and the line up this year was truly reflective of the growing and diversifying industries that additive technologies now impact. The Jewellery stream once again proved popular and was consistently busy throughout the afternoon. Speakers including Mark Bloomfield and Silvia Weidenbach explained how additive technologies can be used to help create artwork and jewellery in a way that has previously been impossible.
Another industry stalwart, Graham Tromans, runs a session that introduces newcomers to the world of AM and 3D Printing every year at TCT Live, providing the history and context as well as the most recent developments. I must be honest — at one point before the event, we had very briefly considered removing this staple from the programme… but
Throughout the other sessions attendees got to see presentations from Prodrive, Foster + Partners, Cookson Precious Metals, GlaxoSmithKline and more. If you missed it, you missed out — but selected presentations will soon be available online and, of course, there is always next year!
TCT LIVE + PERSONALIZE 2012
2012 Review
21 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 22
22 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 23
Left: The Areion gets some admiring glances on the show floor.
The Areion Race Car Areion, the first fully operational race car with a stereolithography body. Designed by Formula Group T, with design and manufacturing support from Materialise, this electric car was created as part of the Formula Student competition, and competed in a series of races in the UK, Germany and Italy, before its feature display at TCT. The car was developed through Materialise’s co-creation mode which supports organisations that wish to leave behind today’s design limitations and produce small product series in a profitable way. The car is also an excellent example of how state-of-the-art additive manufacturing technologies can support designers through those ever critical design verification and communication/presentation processes.
Right: The body shell of the Areion was built on Materialise’s in-house Mammoth SLA — the biggest SLA in the world.
An Aston Martin DB5
Batman Arrives
PropShop UK are model makers to the film, television and theatre industries and produced one of the most dramatic stands at the show. Designed to look like an impromptu set from the rear, the stand featured a plethora of famous bits and pieces from TV, theatre and blockbuster movies alike. The centrepiece of this impressive stand was the Aston Martin DB5 1/5th scale replica (which featured on the front cover of TCT 20/04), which was used in the latest installment of the James Bond saga, Skyfall.
Global TCT are UK resellers for voxeljet, producers of some of the largest machines available for patternless and fully automatic manufacture. Their stand centrepiece was this fantastic 1000 mm x 800 mm model of Batman. The model took around 20 hours to build and would be the largest single build to date off of a VX system. The model was created as a joint venture with a scanning company, and a local university also had an input in processing the data. As well as reselling Voxeljet’s machines, Global TCT runs a VX 500 (which features a 500 x 400 x 300 mm) as part of its own bureau service. Voxeljet offers the largest build bed size in AM at 4 m x 2 m x 1m.
Propshop were sat next to 3D Systems resellers Print It 3D who supplied some of the additive tech that was deployed in the production of the many models. PropShop Modelmakers Ltd www.propshop-uk.com Print IT 3D www.printit-3d.com
Global TCT Ltd www.globaltct.com voxeljet GmbH www.voxeljet.de
Above: Wheely cool — the intricate details of the 1/5 scale replica’s wire wheels. They don’t make them like this anymore!
Right: Despite the menacing looks this impressive model helped to draw in the crowds and certainly caused a stir on the show floor.
TCT LIVE + PERSONALIZE 2012
Materialise NV www.materialise.com
23 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 11:59 Page 24
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 25
Titanium F1 Roll Hoop On the Show Floor The Brief: Since 2009, 3T RPD has been gaining experience in building structural components for the Formula 1 motorsport sector. Of these types of parts the rear roll hoop structure is one of the largest and most demanding from the point of view of Additive Manufacturing (AM). However, for each of the teams 3T works with, this safety critical item is also one of the most important and therefore any work that has been carried out has to be kept strictly confidential. This poses the daily problem for 3T of how to demonstrate the kind of work that is possible in AM, whilst also maintaining customer confidentiality.
The roll hoop is one of the highest points of an F1 car and a traditionally built roll hoop is a heavy component to have at a high point. A target weight for the roll hoop was set at 1kilo — a potential weight saving of one to two kilos. Since every F1 car must be at least a certain minimum weight, it is common practice to use ballast to balance the car and to meet this minimum, thus reducing the weight of the roll hoop means it is possible to put the equivalent, saved weight lower down in the car which helps to improve the car’s performance. To demonstrate 3T’s success at building structural components like the roll hoop, they created a completely new design. The company wanted to create a generic, lightweight and aerodynamic roll hoop structure that, in concept, could be fitted to any F1 car and that is designed specifically to be produced by the metal AM process. A further objective for the design team was to ensure that the roll hoop could be designed as a part that, in principal, could satisfy all the FIA safety criteria, including the 120 kN front push test.
The roll hoop has received positive feedback from the F1 sector, helping to further the understanding of the capabilities of additive manufacturing and increase confidence in the performance of the materials produced by this technology. Furthermore, with additional iterations of the design software, and the respective FEA, it would be possible to model its performance under FIA test criteria.
The Solution: The solution was to design and build a “concept roll hoop” to demonstrate their experience, share learnings and promote greater understanding of the potential of AM. 3T approached Within Technologies since they offered a new approach to design that freed up the designers from constraints imposed by traditional manufacturing technologies. The Within Enhance software, with its unique optimisation process coupled to an internal FEA package, was used to create an original lightweight design, incorporating thin walls and internal features, without compromising the hoop’s structural performance. Furthermore, a key feature of the software is that it optimises the geometry of the design to minimise the amount of support structures that are commonly associated with the metal AM process.
The very nature of the metal AM process requires a support structure to be used during the build of any downward facing surfaces, since the powder bed alone is not sufficient to hold the liquid phase created when the laser has melted the powder. 3T’s roll hoop was produced vertically, to demonstrate the capabilities of building tall components (the part stands 22.5 cm high). Only one small region under the front face of the hoop required support structures to be added for the build phase, whilst the rest of the roll hoop design was self-supporting, thereby minimising the need for support structures. This resulted in faster build times, less waste material, and less post-process finishing operations.
Following on from a successful TCT Live, 3T has taken delivery of a new EOSINT P395 from Germany-based EOS. The P395’s acquisition follows the company’s installation of the UK’s first EOSINT M280 in late 2011 and reinforces the company’s commitment to remaining at the forefront and plastic and metal additive manufacturing. The P395 boosts 3T’s capacity, enabling the company to continue its growth and also enhances the company’s ability to meet customers’ deadlines and quality needs.
TCT LIVE + PERSONALIZE 2012
To come up with a meaningful design for a F1 roll hoop 3T first had to fully understand all aspects of the use of the roll hoop. The part’s primary function is to protect the driver’s head in the cockpit but other key roles are to act as a critical air intake for the car, and as camera mounts and pick up points for the car itself.
This latest investment in hardware has been matched by further investments in research and development resources and in obtaining quality standard certifications. Earlier this year, 3T was the first AM Company in the UK to hold AS9100 Rev C, ISO 9001:2008 and ISO 13485:2003 and so the purchase of the new machine is the next step in 3T’s high-end AM production plan.
The Result: The WithinTechnologies approach enabled 3T to produce a part much quicker than could have been made via traditional manufacturing techniques. In fact, the resulting design contains internal features that would be exceedingly difficult and costly if built using any other manufacturing method. The part has maintained its aerodynamic line and features an area to allow for the addition of a camera mount or other component. By selecting the Ti6Al4V titanium alloy, 3T has ensured the part would be lightweight whilst having maximum strength and thus the greatest potential for performance enhancements.
3T RPD Ltd www.3Trpd.com
25 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 26
26 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 27
The Personalize Pavillion - Jim Woodcock
When we realised that personal 3D printing (as opposed AM and 3D Printing used in any commercial sense) was gaining such momentum, we decided to launch the www.prsnlz.me website so we could better cater to the personal and commercial tech user. However, when it comes to the showfloor we realised that the commercial and personal interests have a significant crossover — many commercial users want to know exactly what a sub £3k machine can do for them while the personal users will always want to see what todays £500k machines are doing, with the hope that these will one day become accessible too.
visitors is invaluable and important in helping us advance our product. We will certainly be back again next year as this was a great experience.”
The Personalize Pavilion was a huge success and was absolutely packed from open to close on both days. In fact, I had to wait until the end of the show to see many of the exhibitors (and some I had to wait even longer than that to see!) as their stands had been continuously busy.
Leapfrog have been one of the most talked about companies on the www.prsnlz.me site, thanks in part to their sturdy looking machines and larger than average build sizes. The two machines, Creatr and Xeed, were on show, but again I didn’t personally see any printing going on. The stand design put the printers right up front, which is always good to see, but given the size and ‘density’ of the designs, it did form something of a barrier!
MiiCraft were also victims of their own success and the chaps hardly had time to grab a drink during the two days! The MiiCraft was on show though sadly I didn’t see the machine working. The models that were brought along were however of a fantastic quality and the little DLPbased machine looks a really neat package. I am sure it will appeal to some commercial / professional users as much as the maker and home 3D printer communities, especially anyone needing small, highresolution parts in a selection of polymers. Wayne Lin from MiiCraft commented: “We can’t say enough great things about this year’s TCT Live event. It certainly helped introduce MiiCraft to the 3D Printing industry and gave us great results in promoting our MiiCraft 3D Printer. Not to mention, all the awesome feedback that we received from the
Sculpteo used the occasion to launch their iPhone case printing service, 3DP Case (http://3dpcase.sculpteo.com/en/) The stand featured examples of some of the huge variety of design and materials that sculpteo offer, with a lot of interest in some of the ceramic parts on display. The company reacted to the launch of the iPhone 5 within just six hours from release, updating their cases and app to fit the new platform. One of the ‘crossover’ stands included work from the stunning Arkitypo range of 3D printed letters. These incredible typographical sculpture represent a letter of the alphabet each and were produced mostly using ZPrinting. The stand was manned by Jon Fidler, famed for his work on 3D printed sculptures of stadia from across the world, including London’s Olympic Stadium — equally impressive stuff. I call this a crossover as the processes are perhaps not within reach of the home user directly (though they certainly are through services like Sculpteo), but also the design capabilities will not be available to everyone. The pieces do demonstrate the fabulous artifacts that can be produced when imagination and 3D printing combine.
TCT LIVE + PERSONALIZE 2012
Ultimaking Ltd turned up with a selection of Ultimakers and drew possibly the largest crowds of the day. When I finally got chance to speak with them, the overriding view was that the attendees had been well informed, knowledgeable and probing! Other shows tend to have a more standoffish approach, where attendees are expected to coo at the pretty objects more than they are get involved with the machines. Here however we saw the team going into huge detail about the workings of the machines, the models they were building and how the technology could be used.
Makerbot also made it to the Pavilion and although they had a working machine on show it was disappointingly (given the fanfare the week earlier) not the Replicator 2. The machine seemed to get a reasonable interest but the company certainly could have done more with the Replicator 2 as it promises to appeal to the makers, home printers and ‘prosumer’ market.
Left: A quiet time for the Ultimaker crew!
Above: Some Arkitypo 3D Printed letters. tct 20/6
27
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 28
28 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 29
Streamlining
Bureau Quoting Operations
This edition of TCT marks the launch of Asiga’s new cloud computing software QuoteServer, which brings web-based quoting automation, document generation and part tracking to any 3D printing bureau. Asiga’s CTO, Ray Ericsson, explains the motivation for QuoteServer and presents strategies for quoting 3D printed parts efficiently. Where does your time go? One of the most time consuming activities in a 3D printing bureau is accurately quoting jobs. A typical day runs something like this: You’re trying to get production happening. But there’s an ever increasing queue of quotes backing up and clients calling to find out their status. Meanwhile, your production staff are chasing other clients for more information because job details haven’t been specified correctly or the files have errors. Suddenly, the day is over, and you’re working late. Again. Why does this happen? 3D printing bureaus receive a large number of parts every day that require quoting. Every job needs to be quoted – even the ones you don’t win! Each part takes a few minutes to quote. You have to open the CAD file, acquire the relevant parameters, enter the parameters into a
spreadsheet, and reply to the customer with an email or perhaps a formal quote document. All this takes time. CAD packages don’t provide all the necessary parameters to quote 3D printing processes properly. For example, how do you calculate the amount of support material required to print a part correctly? You need specialist software. As a result, quotes are typically inaccurate guesstimates of your real costs.
QuoteServer is a completely web-based tool that can be configured and branded to your business in a matter of hours. QuoteServer gives a bureau the scalability and online presence of the world’s biggest prototyping bureaux with zero up-front investment.
ASIGA QUOTESERVER
WORDS | RAY ERICSSON @ ASIGA
Quoting delays result in slower turn-around time for the client – typically the loss of a day or more. This diminishes the value of “rapid” prototyping and reduces client satisfaction. Is there a solution? Asiga has developed a new cloud computing platform called QuoteServer. QuoteServer is designed for 3D printing bureaux to automate quoting, ordering and production management. tct 20/6
29
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 30
Here’s some of what QuoteServer does: n Creates a powerful website that allows clients to upload STL and SLC files for instant quoting and ordering n Receives online payments with credit cards and PayPal n Automatically generates professional documentation including order confirmations, invoices and delivery notes n Manages accounts and payments and can interface to your existing accounting software or stand alone n Keeps clients informed with automatic email notifications on their order’s progress n Communicates with web services of couriers like FedEx and UPS to generate real shipping quotes and airway bills automatically n Allows fully customisable pricing strategies. QuoteServer therefore automates the mundane aspects of running a 3D printing bureau. It’s a tool that frees up your time and resources for growth. Here’s what the quoting page of a bureau’s QuoteServer might look like in action:
The Key Elements of Great Online Parts Quoting In the remainder of this article I’ll describe the key elements required for a successful online quoting system. I believe this is instructive for any 3D printing bureau manager to understand so that they can specify a quoting system that will meet their internal needs and the expectations of their clients.
30
Element 1: Cloud Architecture A web browser is a powerful tool for delivering services over the Internet and interacting with databases. QuoteServer uses a cloud architecture to enable the delivery of quotes to clients and allow your staff to interact with the database. As a result, you don’t need any special software in-house. Any Internet connected device with a web browser can become a
processing node for your bureau. This gives your bureau infinite scalability. You can seamlessly expand operations at your site or over multiple sites by simply connecting more computers. Element 2: Automated Graphical Document Generation Every one of your documents – from the order confirmation to the delivery note and final invoice – should include thumbnail images of the parts. Graphical documentation has so many benefits they seem almost too obvious to mention. It eliminates confusion for you and your client over what has been ordered. It saves you a lot of time referring to CAD files on a computer screen. Parts are easily matched to paperwork which reduces the chance of sending the wrong part to the wrong customer. Unfortunately, standard accounting packages don’t allow you to tag line items with unique images, and it would be a laborious task to grab screen shots yourself and paste them into your bespoke invoices. Automatic generation of graphical documentation for every order is taken care of by QuoteServer. Element 3: Barcode Tracking Imagine working on a supermarket checkout in the days before barcode scanners! I did and it was terrible. Every item leaving the store needed data entry. This would be unacceptable in any modern retail store. And despite this powerful technology being so readily accessible now, so many small businesses don’t use it and wonder why they can’t seem to break into the big time… If your bureau is ever to achieve scalable efficiency, tag every part with a unique barcode. This allows you to access and update part information without using a keyboard or trolling through a computer file system. It also gives customers a clear part identifier when communicating with you. Element 4: Spoken Word Feedback Whenever you scan a QuoteServer barcode, the server streams spoken word feedback to your web browser for playback through your computer’s speakers. This confirms your actions or alerts you to critical information about a job, all without having to touch a keyboard or look up at a screen. Every time you divert your eyes away
tct 20/6
from the task at hand you lose valuable time, which ultimately costs your business money. Element 5: Part Geometry Analyser Pricing 3D printed parts require specific geometry parameters. In addition to part dimensions, the most important parameters are part volume, shadow volume and surface area. Part volume is necessary for calculating the amount of material used to build the part. Shadow volume is the volume in shadow when the part is illuminated from overhead. It is required to calculate the amount of support material used to fabricate the part. This parameter is not standard in normal CAD packages because it is specific to 3D printing processes. Surface area is a very useful parameter. It may not be required for calculating the price of 3D printing a part, but is necessary for pricing post-processing actions. For example, polishing, painting and vacuum metalising processes will all scale in price according to the surface area of the part. QuoteServer calculates the above parameters for every part and makes them available to your pricing formulae. Element 6: Error Checking You will often have to chase clients because they have sent you STL files with holes or other errors. If the client is aware of the errors they can often fix them. However, if you’re doing things the traditional way, you won’t realise the errors until the end of the day when you’re setting up the machines and everyone else has gone home. QuoteServer checks all uploaded files for errors and notifies the client. This gives your client an opportunity to repair the file themselves, or at least know that there may be an additional delay while their file is repaired and that it is their fault not yours. Element 7: Flexible Pricing Specification Your bureau’s pricing strategies may be unique. For example, you may want to price small parts differently to large parts, or have fixed pricing for jobs fitting in specific bin sizes. You need the flexibility to be able to express this in your quoting system. Furthermore, multiple processes may be linked together to specify complex offerings. For example, castings production may involve a combination of wax printing, investment casting and various finishing processes, priced separately and applied sequentially to a part. QuoteServer’s pricing database allows infinitely customisable pricing formulas and process linkages to be specified, allowing complex production offerings to be defined in a simple and maintainable format.
ASIGA QUOTESERVER
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 31
31 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 32
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 33
Element 8: File Format Conversions STL and SLC file formats are the standard inputs to most 3D printers. The problem is, not all CAD packages can generate both reliably, and not all 3D printers can accept both. Thus, a 3D printing technician will often have the need to convert files.
Right: Each document contains thumbnailed images making visual tracking easier.
QuoteServer allows bureaux to specify a preferred file type for each 3D printing process. QuoteServer incorporates a robust slicer to convert STL files to SLC, and an integrator to convert SLC files to STL, automatically, if specified. This saves time at the end of the day when you are setting up your prints. Element 9: Real-Time Commodity and Currency Data Some 3D printing bureaux are exposed to commodity price fluctuation risk. These include jewellery prototyping companies and dental laboratories that produce precious metal castings. If the price of gold rises 10% overnight, you need to make sure your online quoting changes accordingly, otherwise you may be losing money on the job! Many bureaux are also exposed to currency exchange risk. If your 3D printer consumables are priced in US dollars and you bill your clients in Euro, you may need to incorporate this into your pricing formula.
Element 10: Automatic Email Notifications How often do customers call you asking for updates on the status of their parts? The entire reason they are using your service is because they want something fast! If you present them with a black hole after taking their order they will become increasingly agitated and crave feedback. When you update the production status of part with QuoteServer barcodes, your customers immediately receive an automatic email telling them their job’s new status. Keeping customers informed and managing their expectations will keep them happy, and keep them off your phone when you both could be doing more effective activities. Element 11: Shipping Tools Making a part is only half the job. The other half is getting it to your customer on time. You should give your customer several shipping options. For example, if they are local, the fastest way may be to use a local courier service for same-day delivery. If they are interstate or international, you would probably use a tracked courier like FedEx or UPS. If you don’t have a tracking number you can’t ever be sure of delivery, so it’s worth the effort.
QuoteServer has a powerful shipping tools section that allows specification of arbitrary courier services and seamless integration with the Web Services of FedEx and UPS. This means you can present your customers with a range of shipping options, all priced in real-time, to their specified address. QuoteServer generates the shipping labels automatically. Your customer will be informed of the dispatch time and tracking number by automatic email notification. It sounds too good to be true – what’s the catch? There is no catch. QuoteServer costs nothing to set-up and nothing to maintain. Any orders you receive through QuoteServer attract a small commission, less than a credit card fee. That means you can instantly reap the benefits of a professional quoting system and be cash-flow positive. If you don’t use it or don’t win the job, there’s no cost, therefore nothing to lose and everything to gain.
Conclusions Summing up, here’s my overall analysis of why any 3D printing bureau seeking to improve customer service and profitability should investigate the benefits of an automated online quoting and ordering system: n Your most mundane and repetitive bureau operations – quoting, document generation and accounting, are eliminated. n Staff can be deployed more efficiently. n Customers are served faster and are kept better informed so are happier as a result. n Job turn-around is faster. n Reduced risk of dispatch mistakes. n No quoting errors eroding margin. n Fewer and less qualified staff required for high-quality service delivery.
ASIGA QUOTESERVER
Left: A standard invoice could delay picking, packing and lead to errors.
QuoteServer obtains real-time commodity pricing for metals and currency exchange rates on a daily basis and makes them available to your calculations in a simple format. This allows your pricing to be accurate and minimise exposure to market fluctuations.
Automation may mean the difference between thriving or just surviving in the ever expanding world of 3D printing. Asiga will be demonstrating QuoteServer at Euromold in Frankfurt, Germany this month at Stand E58.
33 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 34
TCT 20-6 progress_Layout 1 07/11/2012 12:00 Page 35
Additive Manufacturing and Industrial 3D Printing Matrix One of the frequently relayed pieces of feedback from this year’s TCT Live exhibitors was that on the whole visitors to the stands were much better educated about the processes and their capabilities than even 12 months ago. Of the established AM / RP companies of old, only 3D Systems seems to be pursuing the consumer market with any real determination — meaning a vast majority of companies must still see the professional user as the future of their business. It is also interesting to see the likes of Brooklynbased Makerbot starting to move away from the
Manufacturer
consumer and towards what has been dubbed the ‘prosumer’ with its Replicator 2 machine. This convergence of offerings from above and below the ‘prosumer’ line gives us an interesting insight into the potential of the $5k machine in future. This matrix concentrates on the machines available to the professional user, including for the first time a Makerbot machine.
around since EuroMold 2011 and make the list for the first time with a machine that appeals to jewellers and designers of small, detailed parts. Matsuura makes the list with the LUMEX Avance-25 — the only additive and subtractive hybrid machine — for the first time; see the last issue for further details of mould making appilcations of this technology.
According to the 2012 Wohlers’ Report, 31 manufacturers from around the world produced and sold professional AM systems (down from 35 in 2009), nine of which sold more than 100 systems each; ten of which sold fewer than 10 systems each.
Most of the rest of the list is generally well known, though many have updates and upgrades across systems and materials for 2012, including: Objet’s 123 materials (digital and cartridge ready) for the Connex500; conductive metals and polymers for Optomec’s Aerosol Jet series; 3D Systems ProJet 5000 printer with increased build size and speed; and Realizer’s SLM 300 machine.
Another new addition to the list, Blueprinter A.p.S, had the commercial launch of its eponymous machine during TCT Live 2012. Asiga, makers of the Freeform Pico has been
Build Materials
Layer Thickness
Price (Euro)
298 x 185 x 203
VisiJet Crystal, VisiJet Proplast, VisiJet Navy, VisiJet Techplast - Acrylic Plastics
32 µm
51,900
749 x 1207 x 1543
Up to 298 x 185 x 203
VisiJet Crystal, VisiJet Proplast, VisiJet Navy, VisiJet Techplast, VisiJet Procast - Acrylic Plastics
16 to 32 µm
From €69,200
ProJet CP 3500 Professional 3D Printer
749 x 1207 x 1543
298 x 185 x 203
VisiJet Prowax - Wax material
33 µm
63,600
ProJet CPX 3500 & CPX 3500Plus Professional 3D Printers
749 x 1207 x 1543
Up to 298 x 185 x 203
VisiJet Hi-Cast - Wax material
16 to 33 µm
From €75,200
ProJet MP 3500 Professional 3D Printer
749 x 1207 x 1543
298 x 185 x 203
VisiJet Stoneplast - Dental acrylic plastic
32 µm
62,500
749 x 1207 x 1543
Up to 298 x 185 x 203
VisiJet Dentcast - Dental acrylic plastic
29 to 32 µm
79,800
Machine Size
Build Envelope
(w x d x h mm)
(w x d x h mm)
ProJet SD 3500 Professional 3D Printer
749 x 1207 x 1543
ProJet HD 3500 & HD 3500Plus Professional 3D Printers
Machine Name/Number
ProJet DP 3500 Professional 3D Printer ZPrinter 350 Professional 3D Printer
1220 x 790 x 1400
203 x 254 x 203
High performance composite
0.09 – 0.1 mm
21,800
ZPrinter 450 Professional 3D Printer
1220 x 790 x 1400
203 x 254 x 203
High performance composite
0.09 – 0.1 mm
33,300
ZPrinter 650 Professional 3D Printer
1880 x 740 x 1450
254 x 381 x 203
High performance composite
0.09 – 0.1 mm
50,460
ZPrinter 850 Professional 3D Printer
1190 x 1160 x 1620
508 x 381 x 229
High performance composite
0.09 – 0.1 mm
83,200
ProJet 5000 Professional 3D Printer
1531 x 908 x 1450
550 x 393 x 300
VisiJet MX - Acrylic plastic
29 to 64 µm
not disclosed
ProJet 6000 Professional 3D Printer
787 x 737 x 1829
Up to 250 x 250 x 250
VisiJet Flex, Tough, Clear, Black, HiTemp, e-Stone (for MP), Jewel
0.05 to 0.125 mm
not disclosed
ProJet 7000 Professional 3D Printer
984 x 854 x 1829
Up to 380 x 380 x 250
VisiJet Flex, Tough, Clear, Black, HiTemp, e-Stone (for MP), Jewel
0.05 to 0.125 mm
not disclosed
iPro 8000 SLA Production 3D Printer
1260 x 2200 x 2280
Up to 650 x 750 x 550
Accura plastics and composites (wide-range, simulating ABS, PP and PC, high temp., for casting patterns...)
0.05–0.15 mm
not disclosed
iPro 9000 SLA Production 3D Printers
2120 x 2200 x 2280
Up to 1500 x 750 x 550
Accura plastics and composites (wide-range, simulating ABS, PP and PC, high temp., for casting patterns...)
0.05–0.15 mm
not disclosed
sPro 60 SLS Production 3D Printers
2077 x 1429 x 2040
381 x 330 x 457
DuraForm plastics and composites, CastForm PS (powders)
0.08 to 0.15 mm
not disclosed
sPro 140 SLS Production 3D Printers
1840 x 1850 x 1970
550 x 550 x 460
DuraForm plastics and composites, CastForm PS (powders)
0.08 to 0.15 mm
not disclosed
sPro 230 SLS Production 3D Printers
1840 x 1850 x 2200
550 x 550 x 750
DuraForm plastics and composites, CastForm PS (powders)
0.08 to 0.15 mm
not disclosed
Arcam A1
1850 x 900 x 2200
200 x 200 x 180
Titanium alloys; CoCr and other high-end metals
10–100 µm
not disclosed
Arcam A2
1850 x 900 x 2200
200 x 200 x 350; 300 x 200 (Ø / H)
Titanium alloys; CoCr and other high-end metals
10–100 µm
not disclosed
3D Systems www.3dsystems.com
Arcam AB
2013 MATRIX
As Additive Manufacturing and Industrial 3D Printing continue to see unprecedented growth across the consumer-focused end of the spectrum, it can be easy to forget that the technologies are still just breaking the surface of what is possible in the industrial space.
Sponsored by
www.arcam.com
tct 20/6
35
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 36
Manufacturer
Asiga
Build Materials
Layer Thickness
Price (Euro)
40 x 30 x 75
Photopolymers (general purpose & investment casting)
0.001 to 0.150 mm
5420
220 x 225 x 505
50 x 31.2 x 75
Photopolymers (general purpose & investment casting)
0.001 to 0.150 mm
6970
Freeform PicoPlus33
220 x 225 x 505
42.5 x 26.5 x 75
Photopolymers (general purpose & investment casting)
0.001 to 0.150 mm
6970
Freeform PicoPlus27
220 x 225 x 505
35 x 21.8 x 75
Photopolymers (general purpose & investment casting)
0.001 to 0.150 mm
6970
EasyCLAD VC LF300
1500 x 1400 x 2000
400 x 350 x 200
SS 316L, CpTi, TA6V, Ti6242, INCO 718, INCO 625, Stellite 6-12-21-25, WC + Ni/Co base, H13, D7, T15, Tool steel CPM 10V, M2, Waspalloy, SS 410, 440, Hatfield steel, Cu base
0.1 to 0.3 mm
300-600 k€ (3 to 5 axes, controlled atmosphere, CLAD software, set of nozzles,...)
EasyCLAD MAGIC
4370 x 3936 x 3500
1400 x 800 x 800
SS 316L, CpTi, TA6V, Ti6242, INCO 718, INCO 625, Stellite 6-12-21-25, WC + Ni/Co base, H13, D7, T15, Tool steel CPM 10V, M2, Waspalloy, SS 410, 440, Hatfield steel, Cu base
0.2 to 0.8 mm
1000-1200 k€ (depends on options : controlled atmosphere, set of nozzles, …)
0.1 to 0.3 / 0.5 to 1.2 mm
Machine Size
Build Envelope
(w x d x h mm)
(w x d x h mm)
Freeform Pico
220 x 225 x 505
Freeform PicoPlus39
Machine Name/Number
www.asiga.com
BeAM www.beam-machines.com
600-1000 k€ (depends on options : 4 or 5 axes, controlled atmosphere, CLAD software, set of nozzles, …) 600-1000 k€ (depends on options : 4 or 5 axes, controlled atmosphere, CLAD software, set of nozzles, …)
EasyCLAD VH LF4000
4480 x 3590 x 3500
650 x 700 x 500
SS 316L, CpTi, TA6V, Ti6242, INCO 718, INCO 625, Stellite 6-12-21-25, WC + Ni/Co base, H13, D7, T15, Tool steel CPM 10V, M2, Waspalloy, SS 410, 440, Hatfield steel, Cu base
EasyCLAD VI LF4000
2090 x 1860 x 2720
950 x 900 x 500
SS 316L, CpTi, TA6V, Ti6242, INCO 718, INCO 625, Stellite 6-12-21-25, WC + Ni/Co base, H13, D7, T15, Tool steel CPM 10V, M2, Waspalloy, SS 410, 440, Hatfield steel, Cu base
0.1 to 0.3 / 0.5 to 1.2 mm
Blueprinter
1220 x 500 x 570
160 x 200 x 140
Nylon Compound
0.1 mm
12,500
DigitalWax 008J
380 x 515 x 560
65 x 65 x 90
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
17,000
DigitalWax 028J
380 x 515 x 733
65 x 65 x 90
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
45,000
DigitalWax 028J+
380 x 495 x 670
90 x 90 x 90
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
55,000
DigitalWax 029J
544 x 767 x 1350
110 x 110 x 100
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
89,000
DigitalWax 029J+
545 x 800 x 1350
150 x 150 x 100
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
99,000
DigitalWax 008D
380 x 515 x 560
65 x 65 x 90
Direct Casting Resin (RF series)
0.01-0.10 mm
17,000
DigitalWax 028D
380 x 495 x 670
90 x 90 x 90
Direct Casting Resin (RF series), Digital Impression Resin (RD series)
0.01-0.10 mm
55,000
DigitalWax 029D
545 x 800 x 1350
150 x 150 x 100
Direct Casting Resin (RF series), Digital Impression Resin (RD series)
0.01-0.10 mm
99,000
DigitalWax 029X
545 x 800 x 1350
150 x 150 x 200
Direct Casting Resin (DC series), Moulding Resin (DM and DL series)
0.01-0.10 mm
109,000
Perfactory Xtreme
1803 x 1803 x 2286
368 x 229 x 356
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
25 - 150 µm
Call for pricing
Perfactory Xede
1803 x 1803 x 2286
25 - 150 µm
Call for pricing
Perfactory 3 Mini Multi W/ERM
730 x 480 x 1350
Multiple options available
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
15 - 150 µm
Call for pricing
Perfactory 4 Mini XL W/ERM
730 x 480 x 1350
115 x 72 x 160
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
15 - 150 µm
Call for pricing
Perfactory 4 Mini W/ERM
730 x 480 x 1350
84 x 52.5 x 230
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
15 - 150 µm
Call for pricing
Perfactory 4 Standard XL W/ERM
730 x 480 x 1350
192 x 120 x 160
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
25 - 150 µm
Call for pricing
Perfactory 4 Standard W/ERM
730 x 480 x 1350
160 x 100 x 160
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
25 - 150 µm
Call for pricing
Perfactory Micro
230 x 180 x 580
40 x 30 x 100
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
25 - 35 µm
Call for pricing
ULTRA HR UV
740 x 760 x 1170
160 x 100 x 200 to 203 x 127 x 203
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
20 - 100 µm
Call for pricing
ULTRA HR
740 x 760 x 1170
229 x 140 x 203
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
15 - 100 µm
Call for pricing
ULTRA
740 x 760 x 1170
267 x 165 x 203
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
25 - 150 µm
Call for pricing
ULTRA2
704 x 760 x 1170
241 x 149 x 293 to 267 x 165 x 203
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300, HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC 100, R5 Gray, R5/R11, RC25, RC31, SI500
15 - 100 µm
Call for pricing
Blueprinter www.blueprinter.dk
DWS S.R.L. www.dwssystems.com
ABStuff, Abflex, EC500, E-Shell 200, E-Shell 300,
EnvisionTEC, Inc.
444.5 x 355.6 x 500 HTM140, HTM140IV, Iflex 500, LS600, Photosilver, PIC or 330 x 266 x 500 100, R5 Gray, R5/R11, RC25, RC31, SI500
www.envisiontec.com
36
tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 16:40 Page 37
Manufacturer
Machine Name/Number FORMIGA P110
Machine Size
Build Envelope
(w x d x h mm)
(w x d x h mm)
1320 x 1067 x 2204
200 x 250 x 330
Build Materials
Layer Thickness
Price (Euro)
0.10 mm
not disclosed
PA 2200: 0.06/0.10/0.12/0.15/0.18; all other materials: 0.15
not disclosed
PA 2200: 0.06/0.10/0.12/0.15/0.18; PA 3200 GF, PA 2201, Alumide, PrimePart: 0.12; PA 220 FR, PrimeCast 101: 0.15
not disclosed
ESOINT P 760
2250 x 1550 x 2100
730 x 380 x 580
Polyamide 12 (PA 2200, PA 2201, PA 2202 black, PrimePart PLUS) Polyamide 12 filled (PA 3200 GF, Alumide, CarbonMide) Polyamide 11( PA 1101) Polystyrene (PrimeCast 101) TPE (Sintaflex 201, PrimePart ST)
EOSINT P 800
2250 x 1500 x 2100
700 x 380 x 580
EOS PEEK HP 3
0.12 mm
not disclosed
EOSINT M 280
2200 x 1070 x 2290
250 x 250 x 325
Maraging and Stainless steel, nickel alloy, cobalt chrome, titanium, aluminium
0.20-0.80 depending on material
not disclosed
EOSINT S 750
1420 x 1400 x 2150
720 x 380 x 380
resin-coated sand materials
0.20 mm
not disclosed
Replicator 2 Desktop 3D Printer
18.4" x 12.6" x 15"
285 x 153 x 155
MakerBot PLA filament
0.1 mm
not disclosed
www.matsuura.co.jp
LUMEX Avance-25
3200 x 4650 x 2050
250 x 250 x 185
Titanium, Steel, Maraging, Ti-6AI-7Nb, Ti-6AI-4V, SUS630, SUS316l
Call for information
Call for information
Mcor Technologies Ltd
Matrix 300+
900 x 700 x 800
256 x 169 x 150mm
A4 Paper (80gsm & 160gsm) - letter sized version also available
0.1 mm & 0.19 mm
From as low as €8,333 per year
Mcor IRIS
900 x 700 x 800
256 x 169 x 150mm
A4 Paper (80gsm) - letter sized version also available
0.1 mm
Pricing for the Iris to be announced
Objet Connex500
1420 x 1120 x 1130
500 x 400 x 200
Objet Connex350
1420 x 1120 x 1130
350 x 350 x 200
Objet260 Connex
870 x 735 x 1200
260 x 260 x 200
Objet Eden500V
1320 x 990 x 1200
500 x 400 x 200
Objet Eden350V
1320 x 990 x 1200
350 x 350 x 200
Objet Eden350
1320 x 990 x 1200
350 x 350 x 200
Objet Eden260V
870 x 735 x 1200
260 x 260 x 200
Objet Eden250
870 x 735 x 1200
250 x 250 x 200
Aerosol Jet 300 Series
1.5 m x 1.5 m x 2.2 m
300 mm x 300 mm
Aerosol Jet Display Lab
1.5 m x 1.5 m x 2.2 m
370 mm x 470mm
Aerosol Jet Solar Lab
1.5 m x 1.5 m x 2.2 m
300 mm x 300 mm
EOSINT P 395
EOS GmbH Electro Optical Systems
1840 x 1175 x 2100
340 x 340 x 620
www.eos.info
MakerBot Industries www.makerbot.com
www.mcortechnologies.com
Objet Ltd. www.objet.com
Optomec, Inc. www.optomec.com
LENS MR7
1 m x 1.5 m x 2.0 m
300 x 300 x 300 mm
LENS 850-R
2.7 m x 2.7 m x 2.7 m
900mm x 1500mm x 900mm
PXS
770 x 1200 x 1950
100 x 100 x 80
123 materials of varying physical and mechanical properties, including 17 cartridge-ready materials and 106 Digital Materials (composite materials comprising two cartridge-ready materials). Includes: ABS-like Digital Material, rigid bio-compatible material MED610, rigid transparent materials VeroClear and FullCure720, polypropylene-like DurusWhite, the Tango family of rubber-like materials comprising: TangoBlack, TangoGray, TangoPlus, TangoBlackPlus and the rigid opaque materials: VeroBlackPlus, VeroBlue, VeroGray, VeroWhitePlus. 17 cartridge-ready materials. Includes: rigid bio-compatible material MED610, rigid transparent materials VeroClear and FullCure720, polypropylene-like DurusWhite, the Tango family of rubber-like materials comprising: TangoBlack, TangoGray, TangoPlus, TangoBlackPlus and the rigid opaque materials: VeroBlackPlus, VeroBlue, VeroGray, VeroWhitePlus. 10 cartridge-ready materials. Includes: rigid bio-compatible material MED610, rigid transparent materials VeroClear and FullCure720, polypropylenelike DurusWhite and the rigid opaque materials: VeroBlackPlus, VeroBlue, VeroGray, VeroWhitePlus. Conductive metals, conductive polymers, semiconductors, resistors, dieltectrics Conductive metals, conductive polymers, semiconductors, resistors, dieltectrics Conductive metals, conductive polymers, semiconductors, resistors, dieltectrics Titanium, inconel, steel, cobalt, aluminum, stellite, composites Titanium, inconel, steel, cobalt, aluminum, stellite, composites
16–30 µm
16–30 µm
16–30 µm
16–30 µm
Upon request
16–30 µm 16 µm 16–30 µm
16 µm
100 nanometers to 2+ µm 100 nanometers to 2+ µm 100 nanometers to 2+ µm
not disclosed not disclosed not disclosed
0.3 mm
not disclosed
0.3 mm
not disclosed
2013 MATRIX
Matsuura Machinery Corporation
Phenix Systems www.phenix-system.com
6.1 x 6.1 x 3.1 m; 44R 5.1 x 3.0 x 3.2 m; 5-axis 4.4 x 6.9 x 4.1 m; 5-axis
0.8m Reach (6 axis robot) 2m – 3m Reach (6 axis robot) 0.3 x 0.3 x 0.3 m; (3/5 axis) 1.2 x 1.2 x 0.6 m; (5 axis)
SYNERGY5 (Deposition-subtraction by DryµEDM)
3.4 x 8.6 x 3.2 m; 5-axis
0.3 x 0.3 x 0.3 m; (3/5 axis)
Realizer SLM 50
800 x 700 x 500
Ø 70 x 40
Realizer SLM 100
900 x 800 x 2400
Realizer SLM 250
Realizer SLM 300
DMD IC 106
The POM Group, Inc. www.pomgroup.com
DMD 44R/66R DMD103/105D DMD505D
Realizer GmbH
1.5 x 1.2 x 1.3 m;
Stainless and tooling steels, inconels, non ferrous Adjustable alloys, ceramics… 0.00020 to 0.00070
147000
0.1–0.5 mm
USD 350 k - 450 k
0.5–1.8 mm
USD 600 k - 800 k
0.25–0.7 mm
USD 650 k - 800 k
0.1–1.5 mm
USD 870 k - 1M
0.4–1.5 mm
USD 1.4M - 1.7M
Tool steel, titanium, titanium V4, aluminium, cobalt chrome, stainless steel, Inconel, gold alloys others on request
20–50 µm
on request
125 x 120 x 100
Tool steel, titanium, titanium V4, aluminium, cobalt chrome, stainless steel, Inconel, ceramic materials under development others on request
20–100 µm
on request
1800 x 1000 x 2200
250 x 250 x 300
Tool steel, titanium , titanium V4, aluminium, cobalt chrome, stainless steel, Inconel others on request
20–100 mm
on request
1800 x 1000 x 2200
300 x 300 x 300
Tool steel, titanium , titanium V4, aluminium, cobalt chrome, stainless steel, Inconel others on request
20–100 mm
on request
www.realizer.com
tct 20/6
H13, S7, 420SS, 316SS, CPM1V, CPM10V, Cermets, C250, C276, In625, In718, Wasp alloy, Invar, Stellite6, Stellite21, Stellite31, Ti, Ti6AL4V
37
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 38
38 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 39
Machine Size
Build Envelope
(w x d x h mm)
(w x d x h mm)
AM 250
1700 x 800 x 2025
245 x 245 x 300 (optional 360 mm h)
AM 125
1350 x 800 x 1900
120 x 120 x 125
Manufacturer
Machine Name/Number
Renishaw plc www.renishaw.com/additive
Build Materials OPEN SYSTEM Standard materials include: Stainless Steel, Tool Steel, Aluminium Titanium Cobalt-Chrome Inconel, plus others in development
Layer Thickness
Price (Euro)
20 µm to 100 µm
not disclosed
20 µm to 100 µm
not disclosed
0.006350 mm* *User selectable through €35,200** **We publish US MRSP: variable slider $45,650. 0.006350 mm to 0.076200mm
3Z PRO
558 x 495 x 419
152.4 x 152.4 x 101.6
3ZModel, 3Z Support
3Z STUDIO
558 x 495 x 419
152.4 x 152.4 x 50.8
3ZModel, 3Z Support, 3Z Studio Pack
0.006350 mm*** ***User selectable through variable slider 0.006350 mm to 0.025400mm
€19,000**** ****We publish US MRSP: $24,650.
12.7 x 12.7 x 12.7 cm
ABSplus
0.178 mm
€7800 (includes local shipping within EU)
203 x 152 x 152 mm
ABSplus
0.254 mm
€11,342 (includes local shipping within EU)
Solidscape, Inc. www.solid-scape.com
Mojo 3D Printer: 63 x 45 x 53 cm
Mojo 3D Printer
uPrint SE
WaveWash 55 Support Cleaning System: 33.5 x 33.5 x 33.5 cm uPrint SE / SE Plus and one material bay: 635 x 660 x 787 mm uPrint SE / SE Plus and two material bays: 635 x 660 x 940 mm
uPrint SE plus
WaveWash Support Cleaning System: 48.33 x 43.18 x 43.85 cm
203 x 203 x 152 mm
ABSplus
0.254 mm or 0.330 mm
€15,423 (includes local shipping within EU)
Dimension Elite 3D Printer
838 x 737 x 1143 mm
203 x 203 x 305 mm
ABSplus
0.178 mm, or 0.254 mm
€23,479 (includes local shipping within EU)
Dimension SST 1200es 3D Printer
838 x 737 x 1143 mm
254 x 254 x 305 mm
ABSplus
0.254 mm, or 0.33 mm
€25,833 (includes local shipping within EU)
ABSplus
Multiple build speed options for fine feature detail and smoother surface finish: 0.330 mm; 0.254 mm; 0.178 mm
Prices available upon request
Stratasys www.stratasys.com
FORTUS 360mc System Production System
Fortus 400mc Production System
Fortus 900 mc Production System
838 x 737 x 1143 mm
254 x 254 x 305 mm
Base envelope: 355 x 254 x 254 mm; 1281 x 896 x 1962 mm Optional upgrade: 406 x 355 x 406 mm
2772 x 1683 x 2027 mm 914 x 610 x 914 mm
ABS-M30;PC-ABS;PC
ABSi; PC-ISO;ABS-M30 PC;ABS-M30i; ULTEM 9085; ABS-ESD7; PPSF; PC-ABS
Multiple build speed options for fine feature detail and smoother surface finish: 0.330 mm; 0.254 mm; 0.178 mm; 0.127 mm
Prices available upon request
Prices available upon request
ABS-M30; ABS-M30i;ABSi;ABS-ESD7; PC-ABS;PC-ISO;PC;ULTEM 9085;PPSF/PPSU
0.330 mm; 0.254 mm; 0.178 mm
Prices available upon request
VX200
2.000 x 900 x 1.600
300 x 200 x 150
PolyPor-PMMA/ Sand
0.08 - 0.15 / 0.2- 0.4
120 k
VX500
1.790 x 1.852 x 1.660
500 x 400 x 300
PolyPor-PMMA/ Sand
0.08 - 0.15 / 0.2- 0.4
350 k
VXC800
4.000 x 2.800 x 2.200
850 x 500 x 2.000
PolyPor-PMMA/ Sand
0.08 - 0.15 / 0.2- 0.4
600 k
VX1000
2.375 x 2.800 x 1.980
1.060 x 600 x 500
PolyPor-PMMA/ Sand
0.08 - 0.15 / 0.2- 0.4
680 - 820 k
VX4000
19.500 x 3.800 x 7.000 4.000 x 2.000 x 1.000
PolyPor-PMMA/ Sand
0.08 - 0.15 / 0.2- 0.4
1600 k
voxeljet www.voxeljet.de
2013 MATRIX
FORTUS 250mc 3D Production System
39 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 40
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 41
Through the doors at...
Technologies are seldom powerful enough to become standalone solutions for anything but the simplest of tasks. And so it is that to solve complex problems, a vast array of processes must be deployed intelligently. Whether in automotive, consumer goods, medical devices or any other industry, companies like Pro2Pro must use the whole gamut of technologies at its disposal to solve the problems of prototyping and production. Jim Woodcock took a trip to Telford to find out exactly what this entails. Pro2Pro (standing for Prototype to Production if you didn’t know) are located just outside Telford in the West Midlands, UK. Headed up by David Piper (left), the company has a no-nonsense approach to getting stuff done — a reflection of David’s personal approach. When I visited the company last month, I deployed the ‘Prince Philip Opener’, which is to say: “And what is it that you do?” You might think this odd, as presumably I already have good idea of what the company does beforehand — but the response to this simple question is one of the most telling. For starters, most people don’t expect it and therefore answer instinctively. This gives you a good idea of the way they think! When I asked Dave, the answer was succinct and focussed and lacking in buzzwords: “We help to get a product to market more quickly, or to prove a concept design with the shortest lead time possible. We also specialise in short-production run manufacturing.” No room for complication there then!
Dave himself comes from a model making background in the automotive, entertainment and architecture industries. He has the benefit of having run stereolithography and selective laser sintering machines, alongside traditional technologies such as vacuum casting, RIM, and CNC machining. This broad experience really shows through in the company’s range of technologies, and the way in which they are deployed.
THROUGH THE DOORS
Pro2Pro
As Dave explained: “All manufacturing service providers should be able to deliver parts quickly and to spec — if they can’t, they shouldn’t be in this game. Where Pro2Pro set ourselves apart is in the way we can deploy different technologies to work together so as to shave valuable time and cost from the project. With so many technologies in-house, we are able to follow a process right from initial design validation to 1-off, 100-off right up to 20,000-off part production.” Whilst touring the Telford site (Pro2Pro are in the process of expanding in to the unit next door creating a capacity floor space of over 12,000 sq feet with some
tct 20/6
41
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 42
42 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 43
Right: A soft-touch dashboard representative of the final production part — large parts such as full dash boards are a speciality of Pro2Pro new CNC kit, including Dugard Eco 1500 and Eco 2000 CNC machines, as well as a Resin Transfer Moulding Cell) it was obvious that the company has invested significantly to bring all these technologies in house. With 16 staff currently at the company, the workshop was buzzing with activity and crammed with kit — not helped by the fact that one of the specialities of Pro2Pro is very large parts, usually produced by reaction-injection-moulding (RIM) in huge, coffin-like cases. These parts can theoretically be as large as required as each mould and supporting box is bespoke to the project, with injection of a two-part reactive mix at multiple points Alongside the RIM and Structural Reaction Injection Moulding (SRIM) gear lies a range of foam handling equipment including an SAIP production polyurethane machine as well as a station for hand mixed foam mouldings; a large CNC milling machine occupies part of the new unit, with another due to join it soon; vacuum casting equipment; an Objet Eden 500V 3D printer; a specialist silicone dosing unit to cope with the company’s larger projects; and even a cement mixer — some of the moulds are so large they have to be backed up with cement — this is just a small selection of the onsite equipment used for the company’s in-house processes. The company has a strong focus on research and development in a production environment, which is one of the reasons that so many of the processes were brought in-house. The team is currently looking into tct 20/6
composite production and is looking to acquire an autoclave for the new unit next door, which will again increase the scope of projects Pro2Pro can undertake. Investment has also been made in business process as well as equipment, with the company gaining ISO 9001:2008 accreditation. Having undertaken so much automotive work over the years, the company is used to working to very high specifications and very tight deadlines — experience that is highly transferable to other industries such as medical, where equally high standards apply, to consumer product development, which often has tight timeframes.
THROUGH THE DOORS
Left: The Objet Eden 500V in the process of manufacturing a series of automotive air registers that will be taken from the machines already fully assembled
As is so often the case, I am bound by the unspoken (but very much written) laws of secrecy, so I can’t tell you about the specific parts I saw being produced, suffice to say that there were large parts for cars, smaller parts for consumer goods and highly specialised parts for medical devices. So, how could you get to see all of this capability for yourself without leaving your office? Easy: Pro2Pro bring their technologies to you in the form of a ‘travelling roadshow’ van decked out with parts from all the technologies on offer with some excellent examples of how the technologies have been used in tandem to produce otherwise impossible parts. From speaker covers (notoriously difficult to prototype because of the fine detail of the meshes) produced on the Objet machine to large PU moulds and even metalised parts. Pro2Pro Ltd www.pro2proltd.co.uk
43
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 44
44 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 45
Design for Selective Laser Melting:
No rules or new rules?
DESIGN FOR AM
The excitement surrounding Additive Manufacturing (AM) processes is undeniably justified, but the idea that these techniques are almost entirely free of production constraints is something of a myth. The myth is based on the fact that building a part layer by layer means that product designers don’t need to worry about things like draft angles and undercuts, so any geometry is possible. Mike Ayre, Managing Director of Crucible Industrial Design, looks at the design limitations of AM processes and introduces the new Design Guidelines for Selective Laser Melting (SLM) produced as part of the Technology Strategy Board’s SAVING project.
WORDS | MIKE AYRE @ CRUCIBLE INDUSTRIAL DESIGN the way in which parts are laid out on the build platform, and the number of parts that can made in one build, is critical to the economics of a project. Designers should therefore consider the size of the build platform and the way in which parts can be ‘nested’ as part of the design process.
Additive Layer Manufacturing. 3D printing. Rapid prototyping — call them what you like, AM processes offer tremendous opportunities to designers, engineers and artists. But as the AM bandwagon gathers pace, the perception that these processes are free from any production constraints has remained largely unchallenged. The reality however, is that – as production, as opposed to prototyping processes — additive manufacturing methods DO have design constraints. This is particularly true of one of the most exciting of the processes, Selective Laser Melting (SLM). What design limitations? Because SLM parts are built with molten metal, geometry that cannot support itself during the build process, such as downward facing horizontal surfaces, needs to be supported by structures built into the part. These then have to be removed post production, involving additional processing and wasted material. To minimise cost and waste, designers need to consider the orientation and geometry of the part at the outset to avoid unnecessary production time and post processing. The completed parts are removed from the build platform using wire erosion — a time consuming and energy intensive process. This means that
These are just two of the considerations that need to be made when designing parts for production using SLM. The operative word here is production — very few limits exist when AM processes are used for prototyping, and it is the assumption that one is simply an extension of the other that has led to the myth that design rules do not apply to AM processes. As one of Crucible Industrial Design’s main contributions to the Technology Strategy Board’s SAVING project, Crucible examined the SLM process in detail and developed a set of design guidelines which are aimed at promoting ‘best practice’ in terms of energy efficient manufacture. Most of the guidelines focus on making designers aware of the basic facts regarding design with SLM. If followed, the guidelines will minimise the need for post production processes and expense, and result in parts that are quicker to build, less prone to stresses (another side effect of supports), cheaper and less wasteful.
tct 20/6
45
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 46
TCT 20-6 progress_Layout 1 07/11/2012 12:01 Page 47
The SAVING project The SAVING project was a consortium formed from several UK-based companies and research bodies. Using funding from the Technology Strategy Board, over a three year period, SAVING investigated how processes like SLM can be applied to reduce energy use. The research focussed on two main issues: improving the efficiency of the production process; and investigating how SLM parts can be used to help save energy, for example, by reducing weight.
The design team at Crucible produced several versions which were subjected to FEA testing and then built from titanium, which is particularly suitable for the SLM process. The final model looks different from a conventional buckle, but it is just as strong and 40% lighter. With over 800 seats in a single configuration A380 plane, this adds up to quite a weight saving. Calculations showed that, even after taking the increased production costs of the new design into account, fuel and cost savings over the life of a plane would be substantial.
As part of the project Crucible Industrial Design worked on the design guidelines which are available on the SAVING website (www.manufac turingthefuture.com). The guidelines also include a number of example projects to illustrate the best practice principles of designing for SLM, including a redesigned version of the ubiquitous airline seat buckle. This project focused on designing a part that could save energy as a result of its use, but was also as efficient to build as possible using the SLM process.
In addition to these savings, Crucible’s buckle design also illustrated the best ways to orient a part during SLM to take advantage of the process and minimise the energy required for building and finishing the parts. These methods are illustrated in the design guidelines on the SAVING website.
The airline buckle project The aerospace industry is under tremendous pressure to reduce its carbon footprint. Ambitious targets have been set for the industry; new aircraft entering service need to emit 50% less carbon dioxide than they did 20 years ago. Carbon dioxide emissions are directly related to the amount of fuel burned, so Crucible set out to help reduce the weight of an aircraft by designing an airline buckle that was considerably lighter than current versions.
DESIGN FOR AM
the same as the standard product. Crucible then optimised the design to suit the SLM process, with each part orientated to use the minimum of support structures during the build process. This was eventually reduced to just one support structure.
Conclusion The development and improvement of these new rules are just the beginning of a process that will see AM techniques mature from prototyping tools and the hype of the ‘third industrial revolution’ into a series of effective production technologies. If designers can learn to work with their unique limits, as well as their unique abilities, the reality will be even more impressive than the hype. Crucible Industrial Design www.crucibleid.com
The objectives set by Crucible were to design a buckle that was at least as functional as its conventional counterpart; design it to be as efficient as possible to make using SLM; and to ensure that the final part weighed considerably less than a conventional airline buckle.
The SAVING Project www.manufacturingthefuture.com
These objectives meant that the buckle had to be based on conventional engineering design, with the pivots, latches and other mechanisms exactly
47 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:02 Page 48
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 49
Reverse Engineering and AM for Military Mechanical Parts Replacement Although modern military hardware bristles with advanced technology that gives it capabilities that seem, to the general public at least, to verge on the impossible, it takes several years for the latest technology to be put into regular service. As a result, the fact is that a large proportion of the aircraft and military vehicles — from tanks to trucks — that are in use today by armed forces around the world can be anything up to 20 or 30 years old. That presents a major logistical challenge when these aircraft and vehicles are deployed to conflict areas, especially if those conflict areas are on the other side of the world. When vehicle breakdowns occur, during a conflict or in peacetime, replacement parts must be available where they are needed, without delay.
Operating the EADS corporate Research & Technology (R&T) laboratories around the world, the mission of EADS Innovation Works is to identify new value-creating technologies and to develop technological skills and resources that can be of benefit to any or all of these EADS business units — or indeed, to organisations outside the EADS community.
That means either that appropriate spares must be stored where the vehicles are deployed so that they are readily available should they be needed, or they must be flown out as and when required. That logistical requirement is complex and costly enough on its own. On top of that is the fact that, because of the age of many of the vehicles still in daily use by armed forces, the procurement or supply of spare parts for these ageing vehicles and equipment is becoming more difficult as time goes by. So in many cases, replacement mechanical parts have to be made from scratch, either on demand or for storage for possible future use. Even with today’s 3D CAD software and CNC machining technologies, this again adds to the complexity and cost of replacement parts provision. However, EADS Innovation Works has come up with a possible solution to this growing logistical problem. It involves the use of a FARO ScanArm 3D laser scanner, Geomagic Studio 3D imaging/reverse engineering software and an Arcam A2 EBM (electron beam melting) additive manufacturing (AM) direct manufacturing system.
Advanced research and technology EADS Innovation Works comprises a global network of Technical Capability Centres and serves all of the business units of EADS (European Aeronautic, Defence & Space Company). These business units are passenger, freight, military and corporate aircraft maker, Airbus; military and civil helicopter manufacturer, Eurocopter; space transport and satellite systems developer, Astrium; and defence and security systems specialist, Cassidian.
EADS & GEOMAGIC
EADS Innovation Works has used Geomagic Studio 3D imaging/reverse engineering software together with Additive Manufacturing technology to demonstrate a quicker, more cost-effective way to provide replacement parts for military vehicles and equipment in the field.
The project to develop a quicker, more cost-effective way to provide the required replacement parts for aircraft and military vehicles is one example of the type of work undertaken by Innovation Works. Jon Meyer, research team leader in the Metallic Technologies & Surface Engineering group at EADS Innovation Works’ facility at Filton, near Bristol, UK, outlined the aim of the project. “This was a proof-of-concept project,” he explained. “The whole idea behind it was to demonstrate that additive manufacturing technology could cut the time and the cost involved in providing replacement parts for ageing aircraft and vehicles. Instead of needing to store parts locally or have them flown out, the failed original part could be scanned, digitally modelled and then produced, on demand, at the same location as the vehicle for which it is required. In practice, each location would be equipped with a 3D scanner, the necessary software and an additive manufacturing machine.”
tct 20/6
49
TCT 20-6 progress_Layout 1 07/11/2012 12:02 Page 50
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 51
The first step in the process was to scan the calliper with the FARO ScanArm laser scanner. This can record data at a rate of nearly 20,000 points per second to an accuracy of 0.035 mm. The individual scans required to capture the whole calliper were saved as a series of point cloud files that were then read into Geomagic Studio 3D imaging/reverse engineering software. The second and crucial step in the process was to then use the tools in Geomagic Studio to convert this ‘dumb’ point cloud data into a watertight 3D digital polygon surface model that accurately replicated the shape of the original calliper and that could be used in the final manufacturing process. As the calliper comprised a combination of complex and simple shapes and required several separate scans to capture it fully, once the individual scans had been registered with each other and combined to produce a single point cloud model of the calliper, the resulting file contained several tens of millions of 3D coordinate points. The software’s ‘curvature sampling’ tool was therefore used to reduce the points count in flat or low curvature areas while retaining it where there was high curvature. This reduced the overall file size to a more manageable size without losing any of the detail. This would speed up subsequent processing. The data was also ‘cleaned’ to remove any scanner noise and ‘outliers’ that had been picked up during the scanning process. Other tools within the software enabled the team to fill in areas that the scanner couldn’t capture fully, such as holes for fixing bolts, which extend from one surface, through the calliper to the opposite surface. The scanner was only able to capture their location and circumference, not their full depth. So with Geomagic Studio, the team first created a model of the entire calliper without the holes, then used the software’s tools to clean and sharpen the surface edges of the holes as captured by the scanner. These were then ‘pushed’ through the model from one side to the other to create the bolt holes.
Realising the benefits While the replica calliper was geometrically accurate, in practice parts produced using this process would also need to meet international standards and certification requirements. This is especially so in the case of aircraft parts, where meeting internationally agreed certification requirements is essential before parts can be put into use. In the case of land-going vehicles, however, the process as demonstrated by EADS Innovation Works already has the potential to bring real benefits in terms of providing spare parts in a timely, cost-efficient manner. The process also brings a number of more general benefits. For example, AM technology is more resources efficient — and therefore less costly and more environmentally friendly — than traditional machining in terms of material usage because it doesn’t start with a billet of expensive material, most of which is then machined away to produce the part. AM uses only the amount of material required to make the part, irrespective of its complexity. Further, parts can be produced with AM technology on an as-needed basis, where they are needed, so there is the potential for reduced parts storage and transport costs and reduced delays in delivery. There’s also a benefit from the user’s perspective, because it can remove one of the steps required in the more traditional process. There’s no need for a CAD model. It’s 3D scan, to 3D digital model, to 3D printed part.
EADS & GEOMAGIC
Three-step process The item selected by the project team for use as an example was a brake calliper from a car — for no other reason, really, than that it was available.
The process demonstrated by EADS Innovation Works shows clearly that the combination of 3D scanning, Geomagic Studio 3D imaging/reverse engineering software and additive layer manufacturing technology has the potential to cut the time and cost involved in providing replacement mechanical parts for ageing aircraft and military vehicles on deployment – or indeed, for any type of equipment in any situation when parts are needed now but are hard to source. EADS Innovation Works http://www.eads.com/eads/int/en/our-innovation/innovationworks.html
Other tools in the software enabled them to smooth areas of the model and to refine it using digital ‘sandpaper’.
Geomagic www.geomagic.com
Once the 3D polygon surface model was complete it was saved as an STL file and exported to the Magics additive manufacturing build preparation software from Materialise. From here, the third and final step, the production of a replica calliper in titanium, could begin on the Arcam A2 EBM additive layer manufacturing system.
FARO www.faro.com Materialise www.materialise.com
tct 20/6
51
TCT 20-6 progress_Layout 1 07/11/2012 12:02 Page 52
TCT 20-6 progress_Layout 1 07/11/2012 12:02 Page 53
SpaceClaim Engineer 2012+
– Just Do It
WORDS | DR. CHARLES CLARKE
When remodeling parts from a mesh, it is often convenient to create curves through the mesh. SpaceClaim 2012+ automatically fits curves through any arbitrary cross section, fitting lines, arcs, and splines as desired to the desired level of granularity.
SpaceClaim has been credited with introducing us to Direct Modelling, but because all other wannabe Direct Modellers have been bolting on Direct Editing tools onto existing monolithic CAD systems the industry hasn’t credited SpaceClaim properly for starting this new modelling paradigm. With SpaceClaim it’s Direct Modelling and Editing, with everything else it’s just Direct Editing.
CHARLES CLARKE
Have you ever wished you could apply the Nike slogan, Just Do It, to CAD? Have you ever been given a modelling job and your first reaction is “you want me to do WHAT and by WHEN?” Well with traditional CAD you could be forgiven for tearing your hair out and cancelling all leave. But not with SpaceClaim – they are going into their second decade and their software is more robust than ever, so says Dr. Charles Clarke
About 4 years ago I introduced my 10 year old daughter to a Beta version of SpaceClaim, I showed her round the screen architecture and came back an hour later and she had created nine models. So using it IS child’s play and even the Beta version didn’t crash once, in the hands of a totally inexperienced user.
Yes it’s nice to use direct editing sometimes on imported geometry in the likes of NX and Creo, but this is only a fraction of the benefit of what SpaceClaim Direct Modelling does for you. Also because SpaceClaim was built from the ground up for Direct Modelling it is not carrying around explicit or parametric geometric baggage that it needs to resolve at every turn, so it’s breathtaking fast in comparison to the direct editing in other systems.
It would seem unkind to say that SpaceClaim Engineer 2012+ is more of the same, but ‘the same’ in SpaceClaim terms is always accompanied by real innovation and a level of productivity, performance and usability that we are not accustomed to in our industry. This release introduces significant new capabilities for manufacturing, simulation, concept development, and mesh remodeling. These enhancements will help all engineers work more effectively in 3D, without the high cost and complexity of traditional CAD.
53 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:02 Page 54
54 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 55
SpaceClaim 2012+ includes practical new mesh remodelling capabilities, such as the ability to compare a solid to a scan. This technology is useful when recreating models from scan and STL data, as well as to compare scans of produced parts to as-designed parts.
SpaceClaim has really established a footing in the simulation market. In general the simulation community spends about three-quarters of the simulation task setting up the geometry. Model preparation for simulation represents a huge opportunity for SpaceClaim. Also in Manufacturing, sales engineering, concept modelling, advanced engineering — in all these areas traditional CAD is not a good fit. Although there are a lot of traditional CAD tools being used for it today because there was nothing better, SpaceClaim is a much better tool for the job.
SpaceClaim is an extremely fast and easy-to-use tool. Once you know SpaceClaim you can do things very quickly which are unfathomably complicated with modern feature based modelers. Things that takes minutes in other modellers you can do in seconds in SpaceClaim and sometimes things you can do in SpaceClaim you haven't a hope in hell of doing in any feature-based modeller.
SpaceClaim is changing the way people use 3D and in a lot of cases they're taking seats away from traditional 3D CAD vendors, but they are doing this by getting access to users for whom they have a much better product. SpaceClaim has revolutionised modern mechanical design by providing an easy-to-use and affordable way for engineers and product teams to create, modify, repair, and enhance 3D CAD geometry, without compromising existing processes and methods. Users can exploit existing 2D and 3D designs, including customer and supplier models, analysis and simulation results, mesh and STL data, and surface models, along with PMI and tolerance data, in all their work.
SpaceClaim ‘clean up’ of dirty geometry is spellchecker robust. The suspect areas are highlighted, you click on them and they get fixed, it's that simple. You could even say ‘fix all’ in the same way you would say ‘replace all’ in Microsoft Word.
SpaceClaim also helps to eliminate the waste and rework caused by incompatible file formats. In stark contrast to traditional history-based modellers, SpaceClaim works with foreign CAD data as easily as it does its own. It opens and edits all leading 2D and 3D CAD file formats directly, as well as neutral file formats, link JT (with PMI), STEP, and 3D PDF. It’s as easy as double clicking on filenames. SpaceClaim has great interoperability with NX through JT — in some ways SpaceClaim has better support for JT than Siemens does. It supports Semantic PMI which is what the non-Siemens automotive companies use to be compatible. The idea that you can never have a rebuild error like you tend to get with feature-based modellers, is a very compelling situation for the SpaceClaim user community.
SpaceClaim needs good geometry for their direct modelling algorithms to work, which is why their translation facilities are so robust. So the geometry clean up is a critical part of the SpaceClaim process. Typically geometry clean up tools have been expensive and difficult to use — SpaceClaim has made the process a lot more affordable and pushbutton simple. There was a huge amount of pent-up demand for effective geometry healing software and SpaceClaim has just taken advantage of that.
CHARLES CLARKE
This is especially important if you frequently do live design reviews in front of your peers and your customers. SpaceClaim is the only modern solid modelling tool that can do this with impunity. “The amazing thing is that we can do all this with just one simple tool,” says Blake Courter, Co-founder of SpaceClaim. “We can work with any data as if it's our own. We have focused on 3D solid modelling, but we can work with 2D data, we can work with scan data, we can work with all sorts of data and you can just drag and drop it into SpaceClaim and make good use of it.”
Because of its performance and robust direct geometric manipulation SpaceClaim Engineer 2012+ allows manufacturers of all sizes to get the job done faster, finish projects on budget and ahead of schedule, and win more business. It makes it easy for companies specialising in CNC machining, tool and fixture design, injection moulding, sheet metal, and production automation to communicate more efficiently with their customers, focus on value-added work, and increase production rates.
55 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 56
56 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 57
Numerous enhancements for manufacturing workflows, including connections to Mastercam and Esprit, new annotation types like weld symbols and semantic datums, machinist-friendly measuring and positioning, broken and broken out section views, and advanced sheet metal capabilities such as formed bends.
As well as appealing to a wider range of end-users with this release, SpaceClaim is continuing to expand its partner and OEM channels. SpaceClaim’s direct modelling technology is more appropriate for independent software vendors, as its technology is easily adapted to specialised and proprietary tools and processes.
SpaceClaim fully integrated into MasterCAM and Esprit so the buttons to control SpaceClaim actually appear in the GUI of the CAM software. SpaceClaim don't regard their software as the centre of the universe, it is an enabling technology that helps you get your job done. For a lot of manufacturing customers CAM is the centre of their universe so it makes sense to have SpaceClaim directly embedded into the CAM system. They can launch SpaceClaim from MasterCAM to do geometry editing if required and the software is identified as SpaceClaim in the MasterCAM GUI.
In addition, SpaceClaim’s modern and extensive API makes it the most flexible 3D platform for third-party customisation, and the fastest route to market for ISVs. New Solution Partners include fluid simulation experts Simerics, EDM provider First Trace, and 2D drafting provider SofTech. AMC Bridge is a new Software Development Partner offering services to develop SpaceClaim customisations for end-user customers and partners.
New tools to work with mesh and STL data, such as the ability to compare a mesh to a solid, improved section curve fitting, plane and cylinder fitting, mesh splitting, and improved selection and colouring.
SpaceClaim retains its leadership position in direct modelling by providing a series of tools that users want and providing very robust software that does exactly what you expected it to do in a very timely fashion. These may appear to be simple tools and because the modelling and manipulation seems so effortless it's very easy to overlook the complexity of what’s being achieved here. This is how SpaceClaim really delivers value to their customers. And this is why they are making such a difference in the markets they serve.
Major improvements to core modelling, including significant performance improvements, radial move, curve filling, structure search, section properties, and XYZ-based move. SpaceClaim 2012+ is certified for Windows 8. New language support for Polish, Czech, and Portuguese, bringing the total number of languages supported to 12, including English, German, French, Italian, Spanish, Japanese, Korean, as well as Traditional and Simplified Chinese. The production release of version 10 of the SpaceClaim API, including mesh support, animation handlers, custom window support, the ability to replace panels, asynchronous threading to update custom objects in the background, and the ability to add custom items to the structure tree. As previously announced, built-in, free PDM using Microsoft SharePoint.
CHARLES CLARKE
SpaceClaim 2012+ makes SpaceClaim faster than ever. This imported assembly contains a hole pattern with bolts. One simple selection is all that’s needed to move the location of the holes radially, along with each instance of bolt.
There are a lot of very complex calculations happening in the background. SpaceClaim has a dedicated team of mathematicians in China working on topological exception cases — which's why the software is so robust. “We've had to refine direct modelling not only to be easy to use but to be more powerful under the hood,” says Courter. “This is a big part of our development process.” In many cases you would not even attempt to some of the geometric manipulations in traditional modellers that SpaceClaim takes for granted, it would be much more effective to delete the geometry and start again. In SpaceClaim you just do it, as they say at Nike.
57 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 58
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 59
Wohlers Report
Executive Summary This executive summary provides a sampling of the information published in Wohlers Report 2012, a 287-page industry study. The publication provides a global review and analysis of the technologies and applications of additive manufacturing (AM) and 3D printing.
Right: No. of AM for direct part production 2003 - 2011
Industry growth The market for additive manufacturing, consisting of all products and services worldwide, grew 29.4% (CAGR) to $1.714 billion in 2011. This is up from $1.325 billion in 2010 when it grew 24.1%. It declined 9.8% in 2009, largely due to the Great Recession. The AM industry has grown in the double digits for 15 of its 24 years.
Asia’s adoption of AM for modeling and prototyping applications has caught up to the rest of the world, for the most part. However, far fewer organizations in this region are applying AM to the production of parts for final products. Most machines are bought by product development companies to assist in accelerating the labor-intensive early stages of product development.
Unit sales of professional-grade, industrial systems were relatively soft in 2011, compared to very strong unit sales in 2010. However, revenues from system sales were exceptionally strong. The average selling price of these systems increased substantially, which accounts for this difference.
AM processes In January 2012, ASTM International Committee F42 on Additive Manufacturing Technologies voted on a list of AM process category names and definitions. The committee approved the work, titled “Standard Terminology for Additive Manufacturing Technologies.” The system of process categorization is presented in the following bulleted list. Inevitably, new processes will be invented that do not fit nicely into this system of categorization, and the standard will be revised as necessary to accommodate these new technologies.
Meanwhile, the industry experienced staggering growth in low-cost “personal” 3D printers. These are products that typically sell for about $1,000 to $2,000 and are available as a kit or assembled machine. The majority originated from the RepRap open-source machine development at Bath University in the UK. Personal 3D printer unit sales grew 289% in 2011, with an astonishing 23,265 units believed to have been placed, as shown in the following chart. However, personal 3D printers represent just $26.1 million of the total market for AM systems sales in 2011. If the personal systems category continues to grow at its current pace, it will quickly become an interesting market segment for system developers and investors. AM around the world An estimated 26.3% of all industrial AM systems installed worldwide are in the Asia/Pacific region. Meanwhile, 29.1% are in Europe and 40.2% are in North America. The remaining 4.4% are in Central America, South America, the Middle East, and Africa. With the exception of Japan, the growth of additive manufacturing in Asia started much later than in the U.S. and Europe. Companies were mostly experimenting with the technology in the late 1990s, with most machine installations in Asia occurring at technology transfer centers, universities, and training centers.
Direct part production The use of AM for the direct production of parts that end up in final products continues to grow, as shown in the following graph. In just nine years, it has gone from virtually nothing to 24% of the total product and service revenues from additive manufacturing.
WOHLERS REPORT
Left: Personal 3D Printer sales from 2007 - 2011
Trends and the future Many trends in additive manufacturing have come into focus over the past 12–18 months. Among them are advances in metals, the availability of new design tools, the expiration of key patents, and potentially explosive growth in the launching of new businesses related to additive manufacturing. Recent trends are impacting the current research, development, use, education, and strategies associated with AM technology. These trends, coupled with recent growth estimates, provide a sense of where the industry is headed and how organizations and individuals might contribute to the future of the technology. Wohlers Associates, Inc www.wohlersassociates.com tct 20/6
59
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 60
Sponsored by
Preview Objet Showcases Latest 3D Printing Innovations at EuroMold 2012 Objet Ltd., once again takes to the floors of EuroMold to reveal its latest technology developments. An action-packed year has seen Objet launch the world’s only professional desktop 3D printer offering up to 7 different materials, the Objet30 Pro, along with the release of a further 39 digital materials. According to Andy Middleton, Objet General Manager EMEA, EuroMold can expect to see Objet continue its drive for innovation within 3D printing:
combinations enabled Oxman to convey the true artistic nature of her designs with extremely fine detail and accuracy.
“As the year draws to a close, our ethos of leading innovation within 3D printing has never been stronger and we see EuroMold as the ideal platform to demonstrate this, by bringing our latest developments to the fore. Visitors can expect to see an expanded 3D printing portfolio. 2012 has already been a very significant year for Objet— not only have we
New to EuroMold and in the spotlight on the Objet stand is the widely-acclaimed work of leading artist and designer Neri Oxman from MIT’s Media Lab (see front cover for another example!), including a selection of stunning 3D printed models printed using Objet’s unique Connex multi-material 3D printing technology. Objet and Oxman collaborated earlier this year in a convergence of art and 3D printing, with the finished models showcasing Objet 3D printing and how Connex multi-material technology can help push the boundaries of creative design. The unique ability to print different rigid and flexible material
Premiere for the World’s First Continuous 3D Printer
Prototyping and Machine Sales in the 4th Dimension
Automotive, Aerospace and Medial Metal Parts from Poly-Shape
Following a reportedly excellent reception at GIFA 2011, Augsburg-based voxeljet is presenting the brand new VXC800, a 3D continuous printer that has been developed to series production readiness. The machine will celebrate its premiere at EuroMold 2012.
4D Concept’s service portfolio offers complete solutions from CAD design up to small series production of plastic parts. The company offers 3D CAD design; 3D Scanning; the use of intuitive force-feedback systems for 3D data creation; additive manufacturing utilising core technologies like 3DP, MJM, SLA, SLS; as well as milling for large scale prototypes and moulds. For small series production of plastic parts the company offers vacuum casting and RIM.
POLY-SHAPE produces, with no shape constraints, technical parts for the aeronautical, automotive and medical industries.
The company currently resells ZPrinters as well as ProJet high definition 3D Printers for applications with highest demand in details and resolution. Based on the customers demand 4D guides its prospects through an effective evaluation to specify the right 3D printer followed by a first class service and support during installation and operation.
ISO 9001 and 13485 certified, POLY-SHAPE offers the application of this procedure in particular for titanium, aluminum and nickelbased alloys products. 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 major manufacturers in the aeronautical sectors.
Hall 11, Stand D112 4D Concepts GmbH www.4dconcepts.de
Hall 11, Stand A54 Poly-Shape www.poly-shape.com
“Our presentation of the concept study was so well received that we decided on a rapid implementation of the project. Our development team worked at full speed for an entire year. The result is the VXC800 — the world's first continuous 3D printer that lays the foundation for a completely new generation of equipment. The building and unpacking process steps now run in parallel, without a need to interrupt the operations of the system — an absolute novelty for the industry,” said Dr. Ingo Ederer, CEO of voxeljet technology.
60
launched the most versatile 3D printer in the professional desktop market — but we have also invested heavily in developing further digital materials taking the Objet range of 3D printing materials to a record-breaking 107.”
Hall 11, Stand E62 voxeljet technology GmbH www.voxeljet.com
tct 20/6
Also featuring at the show are prototypes, demonstrating real applications from Objet customers across a variety of industries ranging from automotive to defence, aerospace to education, consumer good and electronics, animation and film, right through to the highly-specialised world of digital dentistry and medical devices. Hall 11, Stand D90 Objet Ltd www.objet.com
During Euromold, POLY-SHAPE will announce the purchase of a brand new “off-specs” machine which will allow a huge improvement of the productivity and the sizes of the built parts, that means the possibility to really compete against metal casting technology.
EUROMOLD PREVIEW
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 61
61 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 62
62 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 63
Breuckmann’s 3D scanners accompany projects in the tooling and mould making industry from the first draft to the production of the prototype all the way to serial production. This not only results in a reported reduction of the development time and serial production start-up time as well as the optimisation towards a most effective labour input, but also helps to ensure a consistently high level of productivity. In the context of customised product design, the contact-free scanning process generates high-precision digital data even of fragile or deformable objects within a matter of seconds for further online processing. In addition, the systems are used in such cases of quality inspection applications, in which most minute structures or minimal deviations have to be measured at the highest level of accuracy. Hall 8, Stand C90 Breuckmann GmbH www.breuckmann.com
Steinbichler Optotechnik Presents the Laser Scanner T-SCAN CS and Tracker T-TRACK CS Steinbichler Optotechnik GmbH is presenting its new, hand-held laser scanner T-SCAN CS as well as the optical tracker T-TRACK CS at Euromold. With the tracker T-TRACK CS, the company presents a new optical tracking system with universal application capabilities. Thanks to its favourable price/performance ratio, the unit provides this innovative technology to a large variety of applications also in the entry-level sector and enables a combination of surface and point measurement. The compact size of the tracker and controller box as well as the manageable central cabling make the system suitable for mobile use. Besides performance and user friendliness, the T-SCAN CS is reportedly well priced. The new laser scanner generation has user-oriented design and technical features, such as its good dynamic range for data acquisition on various object surfaces, and a hitherto unseen data rate. The user therefore benefits from a unique scanning speed and precise measurement results. Hall 8, Stand L68 Steinbichler Optotechnik GmbH www.steinbichler.de
SLM Solutions Showcase Range at Euromold 2012
EGS Innovation DENTAL SUITE 3.0 to be Launched EUROMOLD 2012
SLM Solutions GmbH will display several new machines at Euromold this year. The SLM 125 HL selective laser melting machine for metals with a new design and 125 mm build volume. The saying ‘There is life in the old dog yet’ will apply to the new inhouse design and production of the VCM 04 PU-vacuum casting machine with Nylon module option. Although in the market since the 1980’s the vacuum casting technology has recently seen a renaissance due to fast, economical and individual low volume production. Due to the huge success of the SLM 280 HL selective laser melting machine during Euromold last year, we hear from a trusted source that SLM Solutions has planned for a big surprise at their booth on the first show day morning to make future success of the Selective Laser Melting technology even “bigger”. As known already by frequent visitors to Euromold a good draft of German beer is always offered at the SLM Solutions booth to demonstrate the Northern German hospitality and “(gr)ease” the technical discussions during the show.
EGS, company leader in 3D scanners and CAD/CAM software solutions, will launch major upgrades of its DENTAL SUITE for the dental restorations. EGS DENTAL SUITE 3.0 continues to adopt the “open” systems in which manufacturers can combine any type of equipment and software. Upgrades of DentalCAD software are designed for use in dental CAD/CAM systems to manufacture copings, bridges, crowns, abutments and bars. It can accept data from all leading dental scanning systems and output designs to any machining software. Hall 11, Stand A143 EGS www.egsolutions.com
EUROMOLD PREVIEW
Powerful 3D Scanners for Versatile Applications in Design and Mould Making
Hall 11, Stand C80 SLM Solutions GmbH www.slm-solutions.com
63 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 64
Profile: INITIAL How did INITIAL begin? In 1990, three engineers left the R&D department of Salomon Sports in order to create their own company, INITIAL, based in the French Alps, between Lyons and Geneva. Yvon Gallet, one of the founders, is still CEO of the company. Bertrand Besnier is now Technical Director and Alain Berthet is in charge of long-term R&D projects. In the beginning, the company was focused on engineering services. Shortly after that, they extended their offerings, investing in SLA machines then SLS facilities, as well as 3D Digitising equipment. The goal was to be able to offer a full service supply to the customer, for all the services linked with product development. How does the company look now? Almost 60 people are part of the Initial team in the headquarters in the French Alps. The company also has a distributor established in Spain (Valencia). Currently, turnover ratio is 75% in France and 25% abroad. INITIAL’s first 3D Digitising system dates back to 1996. An ATOS optical scanner and photogrammetry system from GOM were added in 2007. The company first started with AM in 1997 with its first SLA system. Today the company runs five SLA machines. In 1998 the company invested in SLS and FDM technologies and now has 6 EOSint SLS systems. Selective Laser Melting (SLM) technology were then added in with a DMLS system, with capability in this area growing to three EOSint M270 and one M280 machines providing significant capacity.
The first EOSint M250 DMLS machine was bought in 2002 originally for mould cavities, then in 2007 an M270 was necessary to respond to a new market (stainless steel, cobalt chrome, maraging steel) and finally in 2009, INITIAL bought an M270 Xtended which enables the production of Aluminium, Inconel and Titanium, to comply with the requests of its customers.
Which materials are on offer? INITIAL has a wide range of materials including: n Stainless steel n Maraging steel n Aluminium n Cobalt Chrome n Inconel (nickel alloy) n Titanium
Just this year the company acquired an Objet Connex system for 3D printing in multimaterials, as well as the EOS M280 with a 250 x 250 x 325 mm build chamber.
Maraging Steel (MS1) accounts for almost 90 % of the company’s SLM production, the remaining 10 % is split between Aluminium and more specific alloys such as Inconel for aeronautical applications or Cobalt Chrome and Titanium for Medical or Luxury applications. The company also offers polishing, machining, welding, heat or surface treatment.
What was the driver for getting SLM technology? The company began with DMLS in 2002 for mould cavities, however the technology was not really adequate because parts were still porous. The novelty of a technology allowing complete homogeneity of the parts was the driver for the company investing in the M270. Focus then increasingly changed towards more on direct parts rather than mould cavities. What are the benefits of using SLM technology for Initial? 1) To build parts that were previously impossible to produce 2) Creation of complex internal and external geometries, e.g. the conformal cooling in addition to our offer in tooling injection. 3) Directly manufactured whole assemblies 4) Ramp up of productivity through improvements in cost, quality and lead time 5) Flexibility: INITIAL machines operate 24/7 6) Replacement technology for parts traditionally machined or cast 7) Economical and ecological with 98% of unused material recycled.
Where are the technologies being employed? A manufacturer of hot runner for injection had a project of a metal pipe with some complex internal ducts. It was not possible to build them by CNC or Machining, therefore Initial decided to propose a DMLS alternative enabling the production of the parts directly with the internal geometry. The customer was so satisfied with the parts produced due both to the technology and INITIAL’s expertise that they decided to entrust them with a complete programme of yearly additive manufacturing production, which includes 100 parts per month. Parts are built in MS1 (Maraging steel) because the material can be hardened through heat treatment. Initial also offers mirror polishing of the outer surface for some specific applications. INITIAL www.initial.fr/en
64 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 65
!tct directory
TCT DIRECTORY
To advertise here call Carol Hardy on 01829 770037 or email carol@rapidnews.com
TA K I N G D E S I G N T O P R O D U C T I O N STEREOLITHOGRAPHY (SLA) 3D PRINTING (OBJET) SELECTIVE LASER SINTERING (SLS) DIRECT METAL LASER SINTERING (DMLS) FUSED DEPOSITION MODELLING (FDM) VACUUM CASTING CNC PRECISION MACHINING (3,4 & 5 AXIS) PROFESSIONAL PAINT /FINISHING FACILITY t. 01786 464434 e. sales@camodels.co.uk
www.camodels.co.uk
65 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 15:57 Page 66
!tct directory To advertise here call Carol Hardy on 01829 770037 or email carol@rapidnews.com
66 tct 20/6
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 67
TCT 20-6 progress_Layout 1 07/11/2012 12:03 Page 68