TCT Europe 22.5 by TCT Magazine

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SEPTEMBER 14

3D PRINTING | ADDITIVE MANUFACTURING | PRODUCT DEVELOPMENT

CHANGING THE GAME IN HEALTHCARE

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3D PRINTING, ADDITIVE MANUFACTURING AND PRODUCT DEVELOPMENT

ISSN 1751-0333

GROUP EDITOR James Woodcock | james@rapidnews.com

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

EDITORIAL ASSISTANT Laura Griffiths | laura.griffiths@rapidnews.com

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

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DESIGN Sam Hamlyn Tracey Roberts

C.O.O. / PUBLISHER Duncan Wood

C.E.O. Mark Blezard

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September 2014

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THE EDITOR

Levelling the playing field Choice is nearly always a good thing. As consumers I believe that TCT Show represents the best we demand choice and vote with our feet when we opportunity for users, potential users or interested get it. Choice usually improves service, creates better parties to assess the entire landscape for themselves products, and reduces cost. But choice is only useful while surrounded with all the information needed. when comparing like with like and across the world The stands will be staffed with experts, the stage will of AM and 3D printing that’s not easy to do. host some of the thought-leaders of the industry and For those considering additive manufacturing / 3D — perhaps equally as importantly — the user printing solutions things are made a little easier by community will be in the same place at the same the availability of technical data pertaining to the time. That is a powerful set of decision making tools. processes. Often however two quite different Whether you receive this issue in the post, on your processes (from the same or different vendors) are tablet or whether you’ve just picked a copy up at the competing for the same business. For desktop 3D show, there’s plenty to keep you going before and printing the picture is less clear, and only by seeing after the event. From the future of your service systems in provider to action and I believe that TCT Show represents the best some advances monitoring in 3D printing opportunity for users, potential users or the real-world for medical interested parties to assess the entire output, armed applications; with up-tolandscape for themselves while surrounded from news from date facts and the industrial with all the information needed. figures, can a product design decision be made. space to Q&As with the TCT Show Keynote TCT Show + Personalize is your opportunity to see speakers. more than 50 3D printing machines in one place, As ever, if you have comments, questions or would levelling the decision making playing field and like to contribute, drop an email to me on putting ‘choice’ at the heart of the discussion. james@rapidnews.com Whether you’re seeking a high-end system for series production of metal components or you’re looking for a cost-effective way to produce first plastic prototypes the system you need will be represented on the show floor. Jim Woodcock Group Editor & Conference Director

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

www.renishaw.com September 2014

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CONTENTS tct + personalize | September 2014

01 COVER STAR

The talk of 3D printing as a technology without the right application is overlooking the significant impact it is already having on the practice of medicine. 3D Systems have positioned themselves at the cutting edge of this fascinating world, as this issue’s cover story by Andy Christensen explores.

REGULARS

07 FROM THE EDITOR’S DESK 17

JORIS PEELS COLUMN

82 TODD GRIMM COLUMN

08 13 21 29 33

35 39

FEATURES

CHANGING THE GAME IN HEALTHCARE

3D Systems’ Andy Christensen explores the role 3D printing is having in healthcare and where the relationship could lead.

BACK TO SCHOOL

DRIVE AND PRECISION

Educating business is as important educating students when it comes to AM, says CALM.

Inside Fenner Group’s 3D printing ops.

THINK SMART

NEWS UPDATE

MATERIALS ROUNDUP

AT-HOME-HEROES

WHO NEEDS KICKSTARTER?

A look at the 3D technology that is impacting how products are developed.

Some of the most pertinent news from the materials arena, including a profile of DSM Somos.

NEW BUSINESS MODELS FROM 3D PRINTING

Daniel O’Connor explores how 3D printing is changing the entrepreneurial landscape.

STRATASYS TCT SHOW NEWS

News of Stratasys’ exclusive unveiling at TCT Show + Personalize

SALOMON SPORTSWEAR

Jim Woodcock explores how 3D printing is impacting the France-based sportswear brand.

DRIVING INNOVATION

3D printing is helping amputee golfers try to reach the Olympics.

September 2014

71 |

Connecting 3D printing with AstroPrint.

UNIVERSITY CHALLENGE

Laura Griffiths explores the importance of 3D printing to the modern curriculum.

Could increased access to 3D printers spell the end for service providers?

Kora prove you can still launch the old way.

ORGANIC DESIGN

Wacom open up 3D design to everyone.

ERASTEEL

Metals materials for AM progress.

END OF AN ERA

Changes afoot at MakerBot.

PRECISION CASTING

Medical and product design opportunities.

KEYNOTE Q&A

TCT Show Keynotes 60-second interviews.

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HEALTHCARE APPLICATIONS

Changing the Game in

HEALTHCARE words | Andy Christensen, VP of Personalised Surgery & Medical Devices, 3D Systems

printing medical breakthroughs are driven by enabling technologies and developments in other, typically unrelated, disciplines.

Medical applications of 3D printing technology date back to the earliest days of stereolithography and, if you can believe it, even earlier. Just recently, I sat with an engineer who recounted times during the early 1980s, after the advent of computed tomography (CT) in the late 1970s, when they would create crude anatomical models through an “additive” process. CT scans are akin to x-ray slices of an object. In the ‘old days’, one would take a sheet of plastic and cut out, by hand, the cross sectional image from a piece of x-ray film. Stacking successive sheets one on top of each other would form a crude 3D model of an anatomic object, and this is exactly how it was done before 3D printing was invented.

These models help surgeons better prepare for surgery, make better decisions during surgery and, most importantly, help improve patient outcomes while reducing surgical time.

Chuck Hull, the inventor of stereolithography and founder and Chief Technology Officer of 3D Systems, probably didn’t imagine Stereolithography as a game-changing tool for the medical industry, but it has had a tremendous impact on healthcare and promises even greater benefits in the future. Achieving these greater gains, however, will require utilising further technologies—I call them “enabling technologies.” Yet, to identify the enabling technologies that will propel us into the future, we must look to the past. With the benefit of hindsight, we can identify the supporting technological advances that first enabled medical applications of 3D printing, and start to recognise the puzzle pieces still missing.

The key enabling technologies that have brought us to our current medical applications include: n n n

n n n n n

The advent of volumetric medical imaging (CT in the 1970s, MRI in the 1980s), The advent of 3D printing (also known as “additive manufacturing”), The advent of biocompatible materials (circa 1996, Stereocol by Astra Zeneca in the UK, later Huntsman and 3D Systems) as well as laser sintering in nylon, The advent of haptic-enabled design tools, The advent of cone-beam computed tomography (for head and neck use, circa 2000), The widespread use of virtual surgical planning combined with personalised instrumentation The advent of 3D printing in biocompatible metals, and The bioprinting of living cells for replacing human parts with human parts.

Volumetric imaging and 3D printing are obviously the foundational technologies in enabling current medical applications of 3D printing. Combining these two revolutionary technologies together places life-size, physical 3D replica models into surgeons’ hands before major reconstructive surgeries. These models help surgeons better prepare for surgery, make better decisions during surgery and, most importantly, help improve patient outcomes while reducing surgical time. These anatomical models also became the basis for the design of personalised implants for areas ranging from the skull to the ankle. 3D Systems Medical Modeling is used by more surgeons worldwide in this area than any other for “tactile” surgical guidance. Biocompatible materials emerged in the mid-1990s and opened up the feasibility of taking these tools into the operating theatre, transforming outputs of 3D printing from mere diagnostic and planning tools to surgical guides. Haptic-enabled design tools were commercialised in the early 2000s, making the hugely labourious process of designing organic shapes simple and intuitive. Overnight, designers discovered new applications in haptic-enabled medical design, creating freeform designs that were impossible to imagine before.

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| September 2014

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HEALTHCARE APPLICATIONS

Cone-Beam Computed Tomography (CBCT) Virtual surgical planning combines accurate, In the head and neck surgical specialties, no bigger invention computer-based planning for surgical procedures in has impacted the use of 3D printing than Cone-Beam the computer with custom-designed, disposable Computed Tomography (CBCT). instruments meant to carry the virtual plan from This is a smaller version of a hospital CT scanner, designed the computer to the operating room. and priced to fit within a doctor’s office. Quick, affordable and with much less radiation than a typical CT scan, these devices have Centre for Applied Reconstructive Technologies transformed diagnostic imaging for specialties like orthodontics, CARTIS, the Center for Applied Reconstructive Technologies in oral and maxillofacial surgery and are now impacting general Surgery, in Cardiff, Wales, has been particularly successful in dentistry. The explosion of volumetric medical image data has delivering 3D printed surgical guides and implants customised to a enabled broader access to medical tools like 3D printed dental patient’s data. By having designers and surgeons work together, they implant drill guides, invisible orthodontic devices and 3D printed have proved that complex surgeries can be less invasive, and with occlusal wafers used in orthognathic surgery. faster, more successful outcomes than before. Additive manufacturing of implantable metals emerged in the midThat same usable 3D data from the patient has allowed major 2000s, made possible by both electron beam-based and laser-based advances in virtual surgery planning. NYU’s Langone Center uses technologies. Today, the production of titanium, titanium alloy and 3D technology on cobalt-chromium implants, focussed mostly around porous many procedures, geometries, represents only a small percentage of the overall 3D notably one that printing medical market, but is rising quickly. At the same time, they call ‘Jaw in a throughput of 3D printers is going up, quality of the parts is going Day’ that allows up and cost of the components in production is going down. This trend means that metals printing is poised to make major impacts in manufacturing of off-the-shelf joint replacement and trauma devices over the next ten years. Virtual surgical planning combines accurate, computer-based planning for surgical procedures in the computer with customdesigned, disposable instruments meant to carry the virtual plan from the computer to the operating room. Consider surgeons who cut bone for relocation or replacement with another piece of bone or an implant. Using virtual surgical planning, surgeons can use instruments for cutting a bone that fits along the patient’s bone structure and guides a saw-blade in a precise place, thus cutting the bone exactly as it was done digitally. Bioprinting is typically used as a term today to describe either scaffold-based printing or true 3D biologic structure printing, using living cells as print materials. These emergent capabilities open up a new world of possibilities, allowing for the deposit of cells into infinitely complex and “living” 3D structures. Researchers at Cornell University, for example, are using live cells to 3D print ears. Researchers at Wake Forest University are looking at how to develop replacement organs using a patient’s cells, with the overall goal of reducing demand for donated organs and the rejection rates of transplanted organs. The market for 3D-printed medical devices is larger than most people realise and growing rapidly. Dentistry, orthodontics and the hearing aid industries all rely on 3D printing to produce millions of patient-specific pieces every year. In orthopedics, these technologies are impacting surgery in many ways, most notably in the use of custom implants and custom instruments for personalised surgical procedures, as well as the production of off-the-shelf implants. All combined in just orthopedic surgery 3D printing touches more than 150,000 patients per year.

Virtual surgical planning and surgical simulators help make surgery safer and more effective

the planning of critical jaw surgeries using a combination of 3D Systems’ VSP (Virtual Surgical Planning) and Stereolithography. ‘Jaw in a Day’ allows patients with large tumours of the mandible or maxilla to check into the hospital with a serious problem and check out the next day with a new tumour-free, functional jaw— complete with teeth. This process combines cutting-edge technology with virtual surgical planning to create disposable, personalised surgical tools and even custom-designed teeth—all meant to reconstruct the patient in a single procedure versus what’s typically taken several surgeries to accomplish in the past. Continued on page 11

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HEALTHCARE APPLICATIONS

Use of 3D data has also fuelled breakthroughs in touch-based simulation for surgeons—not unlike flight simulations for pilots. Simbionix’s Procedure Rehearsal Studio (PRS), for example, utilises an individual’s medical image data to create an immersive, virtual simulation for a medical procedure. Combining this technology with existing virtual surgical planning technology creates an entirely digital workflow for preparing and conducting a surgery. In a day not so far away, surgeons will be able to take a CT scan, import it into a surgical planning software, simulate the procedure in a very realistic way and then quickly output 3D printed instruments or templates to enable a seamless transfer of the digital plan to the surgical theater. Farfetched? I don’t think so. Future vision So what is ahead? What are the enabling technologies of tomorrow that will drive further innovation in 3Dprinted medicine and how will they impact the space? I believe a number of developments will play a key role. First, I expect to see 3D printing move from today’s uses for hard-tissue (bone) reconstructive procedures to more work in organs and other soft tissues. In fact, work in soft-tissue 3D printing is already becoming a topic of conversation. At Tulane University in New Orleans, professors are working out how to recreate realistic human organs for practice models. This means developing materials that resemble the softer feel of, say, a kidney, so that surgeons can practice their surgeries before performing them. Many of these procedures are starting to use robotic surgical assistance. The rise of robotics will bring greater automation and control to surgical procedures—an important factor considering our rapid shift from traditional to digital surgical workflows and further compelling the need for accurate surgical planning.

Formerly conjoined Filipino twins benefitted from digital surgical advances at CHAM Second, as these technologies become more sophisticated, and price points continue to decline, we’re going to witness a large-scale localisation of medical 3D printing. Within one decade, expect to see push-button 3D printing capabilities used with increasing frequency at hospital facilities and even your local surgeons’ office. Already, surgeons and medical schools are beginning to reimagine the surgeon’s desktop, understanding that no practitioner’s workspace will be complete without 3D printing, haptic modeling for intuitive design and virtual surgical planning tools. Finally, I believe design to mimic nature is the next frontier. In ten to fifteen years from now, we will view today’s chunky, nonanatomic-looking hip, knee, ankle and shoulder replacements as primitive. We are in the process of developing a new, more eloquent design methodology—a design language powered by the body and its needs. This will give rise to a new genre of implants, designed with the stress and strain of adjacent tissues in mind and optimised for both functional and mechanical properties. Until now the healthcare applications for 3D printing have been exciting, but they pale in comparison to what’s to come. When we combine the incredible technologies available to us in the near tomorrow and apply them to the medical field, we will unleash new, powerful and life-altering capabilities. Of all the incredible applications of 3D printing, healthcare is the most “human” of all. And in the next decade, we will see this “human” technology touch the lives of millions of our fellow humans.

A 3D printed mandible— is this just the first step to an exciting future for surgery?

i| www.3dsystems.com

September 2014

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PUSHING THE ENVELOPE FOR ADDITIVE MANUFACTURING

The Arcam Q20 represents the 3rd generation EBM technology. It is a manufacturing equipment specifically designed for production of components for the aerospace industry.

Key Features: • Arcam LayerQam™ for build verification • Latest generation EB gun • Closed powder handling

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NEWS UPDATE

NEWS UPDATE: Product design and manufacturing

From the garage to outer space, additive manufacturing touches all aspects of product design and manufacturing. With promising figures showing the growth of the metal additive manufacturing industry and the development of new materials providing manufacturers with the opportunity to make more flexible and sustainable products, it’s set to have a significant impact on the way products are conceived in the next decade. For these stories in full, click to www.tctmagazine.com/topics/automotive.

SCIAKY TO RELEASE WORLD’S LARGEST AM SYSTEM

NASA SET TO PRODUCE FIRST 3D PRINTED CAMERAS NASA is set to produce its first space cameras to be made entirely from 3D printed parts by the end of September. Engineered by Jason Budinoff, the cameras are set to be fully functional, 50 mm instruments made from optical mounts and tubes all produced exclusively from 3D manufactured components. Funded by Goddard’s Internal Research and Development programme, the pathfinder project is being developed to show the benefit of additive manufacturing in industrial components.

INDUSTRIAL AND MANUFACTURING OPERATIONS IN 3D PRINTING 5 TO 10 YEARS AWAY Industrial 3D printing is predicted to have its biggest impact in the next five to 10 years according to Gartner’s latest Hype Cycle. The chart, which pinpoints the maturity and adoption of new technologies, suggests that 3D printing in manufacturing operations will also be fully adopted in that time frame whilst maturation of medical devices will arrive in the next two to five years.

Chicago based pioneer in additive manufacturing welding solutions Sciaky, has announced the commercial launch of one of the world’s largest 3D printers. Their large-scale electron beam additive manufacturing systems have been at the forefront of the industry producing metal prototypes up to 19 feet in length and will be available for purchase this September.

MTI LEADS WAY IN ADDITIVE MANUFACTURING OF C-103 SPACE ALLOY

DIAMOND PLASTICS LAUNCHES NEW REUSABLE POWDER Diamond Plastics GmbH, has introduced a new 100% reusable powder for laser sintering. HDPE HX 17, based on bulkproduced polymer HDPE, can easily be processed on all state of the art laser sinter equipment and can be cross-linked with other materials. Due to its smooth surface, the material will be of particular interest to designers producing master forms for vacuum casting and can be easily painted to make unique finished products.

Metal Technology Albany has successfully produced a key alloy required in propulsion industries and space travel. Until now, C-103 a niobium based alloy, containing about 10% Hafnium and 1% Titanium, had not been sintered from powder form and makes MTI the first to use a powder-bed laser, additive manufacturing system to produce solids from the material. The powder sintering process of C-103 will allow more reliable production of the alloy, known for its excellent formability, cost and weight characteristics in space development.

September 2014

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NEWS UPDATE: Product design and manufactur-

GE AVIATION ADVANCES AM TECHNOLOGY IN AUBURN World-leading jet engine provider, GE Aviation is set to be the first company of its kind to mass-produce additive components for the jet propulsion industry. The company will invest $50M in its existing facility in Auburn, AL, which has undergone a huge development project since 2011. GE will continue to grow with its partnership with the Aviation Technology Centre in Cincinnati, which is predicted to increase by 300% in size this year.

ARRK ADDS NEW SINTERED ELASTOMER POWDER FOR MOTOR VEHICLES ARRKâ&#x20AC;&#x2122;s prototyping division in Gloucester has added a new sintered Elastomer powder to its range of SLS materials. The Elastomer material offers high performance component flexibility and elongation, which makes it an ideal solution for engineers and designers seeking gaiter type components such as those found on motor vehicles, gaskets or rubber seals.

NEWS UPDATE

3D SYSTEMS EXPANDS INFLUENCE ON AEROSPACE INDUSTRY 3D Systems extends its reach into the aerospace industry with the acquisition of American Precision Prototyping and its sister company American Precision Machining. With over 24 years of experience, the companies are both expert providers of rapid prototyping and advanced manufacturing, product development and engineering services and could help 3D Systems gain a significant aerospace presence.

For these stories in full, click to www.tctmagazine.com/ topics/automotive

TOOLCRAFT AND GRAPHITE DEVELOP RAPID INJECTION MOULDING TOOLS Toolcraft Plastics partnered with rapid prototyping specialists Graphite Additive Manufacturing to develop a quick turnaround injection-moulding tool. Toolcraft wanted cost effective way of producing only a small amount of mouldings with a rapid completion time. Graphite got to work and in a single day, helped Toolcraft produce its supermarket trolley coin which was 3D printed using ceramic-filled plastic using a stereolithography process to build a twopart mould.

METAL ADDITIVE MANUFACTURING INDUSTRY GROWS BY NEARLY 76% Wohlers Associates has been tracking the market for machines that produce metal parts for 14 years. In 2013 348 of these machines were sold, compared to 198 in 2012â&#x20AC;&#x201D;growth of an impressive 75.8%. Companies such as Airbus, General Electric, and Lima Corporate are using these machines to produce complex metal parts for nextgeneration aerospace and medical products.

September 2014

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JORIS PEELS

In a change from the normal run of things, this issue sees Joris Peels spend some time talking with Scott Crump, the inventor of FDM and, with his wife, co-founder of Stratasys. Joris finds out how and why he came to invent this enduring 3D printing technology.

Joris Peels in conversation with I

Scott

CRUMP

t was telling that Scott wasn’t immediately able to say which of his family members has the most patents. Scott’s family is filled with inventors and innovators. His parents were active in building ten innovative companies and these companies either had IPOs or were sold to industry giants such as GE. His father Ralph Crump was an innovator that brought to market soft contact lenses, reverse osmosis technology and medical instruments. His brother Craig Crump has a number patents to his name and now runs his own 3D Scanning firm.

Scott had co founded a company with his wife Lisa where they were making semiconductor devices. One of the major issues they had was in product development. They had “serious problems getting prototypes, getting new products to market took too long.” In the semiconductor industry, slow product development is potentially lethal and Scott spent many hours thinking about how to solve this problem.

3D Modler Scott Crump

Scott Crump in his garage

FDM 1600

FDM Genesis Machine

But, it was during playtime with his daughter that Scott hit on the inspiration that would lead to the invention of FDM. He was working on creating a little frog for her, using a glue gun. This is when the spark hit him. He drew the frog using the glue gun. “Once I saw the froggy and her impression of it, I saw how someone could output a part and use it and like it.” Looking at the glue gun, he realised the potential of “using low temperature thermoplastic to make.” Continued on page 19

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JORIS PEELS

Scott set to work on weekends and evenings at his house and in his garage. He “went through the development process as a hobby.” He bought an XY plotter, attached a glue gun and a motion stage. In the late 1980s there was no 3D CAD and computers were developing from “mainframe to PC.” But, he went on trying to invent FDM “in the hope that there would be 3D CAD in the future.” With this prototype Scott went to his board asking them to devote more time to this new way of making things. Scott says “The board members said I was crazy” and wouldn’t fund the idea. Scott went on working at night through 1988 and 1989. His hobby had now cost him over $10,000 dollars as well as countless hours.

“I sat down with my wife to make the decision to either stop this hobby or incorporate it. And we decided to incorporate Stratasys and turn it from a expensive hobby into a business.”

“I sat down with my wife to make the decision to either stop this hobby or incorporate it. And we decided to incorporate Stratasys and turn it from a expensive hobby into a business.” While Scott went on developing prototypes, Lisa built the externally facing parts of the business. She found resellers, did trade shows, set up sales and marketing and the supply chain.

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

3D printing does have to improve in order to fulfil all customers manufacturing needs and be used at scale for “mission critical parts.” Scott says, “Ease of use, strengths of materials, speeds of machines and part quality” will need to improve as will companies understanding of “customer’s needs and specifications.”

It took Scott, “3 months to make a first part, weeks to build the Gcode and one What about the future of 3D Printing, and what is Scott working on year to convert from CAM software to as Stratasys’ Chief Innovation Officer? Scott is really interested in slicing.” At this point Scott was “big giant parts”, “higher throughput 3D printing competing with working on a wax form of the injection moulding” and “new emerging verticals of the mass technology for investment casting. He customisation of parts at scale.” made a detailed wax part, “a turbine blade for a Saab turbocharger What did Scott learn along the with very high surface quality.” way? What made him so After showing it to friends he went to the VC firm Battery As an inventor I successful? “As an inventor I Ventures and obtained $1.5 million to make his first machine. learned not to use the word fail. learned not to use They sold their first 3D Modeler system to Biomet. Fear of public ridicule, not a the word fail. Fear of monetary fear is the thing Other launch customers were GM, GE, Pittsburg State public ridicule, not a holding many people back from College and Pratt and Whitney. They “tried to find good launch customers in all the promising verticals from medical, monetary fear is the innovating. Fear of public ridicule from people who don’t automotive, education and aerospace.” After selling “50 wax thing holding many understand iterating. Set goals, systems, we improved the technology in 1992 and were able keep an eye on success and people back from to retrofit the first systems to work with FDM filament that iterate. It’s 2000 iterations not could make pretty good strength and quality parts.” innovating. Fear of 2000 failures.” This was the birth of FDM which is now the technology that public ridicule from “Fall on your face and get up.” He powers more 3D printers than any other. As a mechanical people who don’t also thinks its “good to take risks, engineer and having parents who took six companies public, Scott knew that “Stratasys would be a good opportunity.” understand iterating. not crazy risks but the highest risk you can possibly find and “At that time it was hard to imagine,” says Scott. “It took a stomach.” long time to learn CAD and you had to work with each individual Scott thinks it would be good to “teach kids early to iterate a lot.” CAD package to stay current.” Using “Unix workstations to create Introducing 3D printers in education could play a role especially if 3D content was also very difficult.” Over the years Scott has seen, “there was a structured curriculum for grade schools, high schools “an S-Curve emerge in the content creation space.” and colleges.” He’s also a big believer in the “fundamentals of “Current generation tools such as Solidworks are easy to get going learning and using math.” on and files are becoming much more accessible as is the ability to “Now we are teaching our kids to be consumers, not makers. By modify those files.” With “3D scanners and other content creation moving manufacturing systems closer to where people live we can tools improving 3D printing is becoming a wonderful tool. Now teach them to be innovators and creators.” This is why he and his that 3D CAD is standard in the manufacturing world and 3D wife love to support INSciTE which organises the First Lego League. printing is becoming the norm in product development we are He thinks its “amazing watching kids code, design things, iterate seeing direct digital manufacturing of fixtures, tooling and end use right on the League floor immediately before a match.” parts.” So this weekend when you sit in your garage working on a maker project, and something should go wrong, do remember, “Fall on your face and get up.”

September 2014

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SPONSORED BY

MATERIALS ROUNDUP

Perennial bugbears of the AM/3D Printing industry, materials, have been appearing with gratifying regularity of late — at both ends of the industry scale. From exciting new possibilities for industrial applications to some much-needed desktop choice, there are more materials in which to create than ever before. Here are some of the most interesting:

Materials

roundup

GRAPHENE Back in April TCT reported that Canadian business Grafoid signed an agreement with advanced materials manufacturing consultancy Altamat to construct an atomisation facility to produce MesoGrafgraphene (MesoGraf )-based filaments and powders for additive manufacturing. The MesoGraf process transforms graphite ore into graphene, which has led to the creation of a suite of economically scalable graphene products for both industrial and commercial applications.

BALSA WOOD? Scientists at the Harvard School of Engineering and Applied Sciences (SEAS) and the Wyss Institute for Biological Inspired Engineering have developed a cellular composite material of never-before-seen light-weight and rigidity. Researchers say this new material mimics and improves on balsa and even the best commercial 3D-printed polymers and polymer composites on the market. Wind turbine blades are getting larger, with some near to meeting the wingspan of an Airbus A380, and so they must be engineered to operate with practically no maintenance for decades, which is why scientists have been working towards an improved sandwich construction material.

More recently Graphene 3D Lab took the next step and submitted a provisional application for a patent in the US for 3D printed battery technology. “The application filed by Graphene 3D has the potential to play an important role in achieving the ability to print electronic devices due to the necessity of providing a power source,” explained Daniel Stolyarov, CEO of Graphene 3D. “A 3D printed battery can be incorporated into a 3D printed object during the building process. In addition, 3D printed batteries have several advantages over traditional batteries. Their shape, size and specifications can be freely adjusted to fit the particular design of the device.” New materials like graphene could help to propel 3D printing into exciting new areas — or they could further muddy the water, leading to further confusion about what’s possible today, what will be possible next year and in 2024. i| www.graphenelabs.com If you’re not quite ready for graphene but would like some more options for your 3D printing, check out Dan O’Connor’s roundup of new materials on tctmagazine.com: http://mytct.co/new3dpmats

In a paper published in Advanced Materials, principal investigator Jennifer Lewism Hansjörg Wyss Professor of Biologically Inspired Engineering at Harvard SEAS, explained: "By moving into new classes of materials like epoxies, we open up new avenues for using 3D printing to construct lightweight architectures. Essentially, we are broadening the materials palette for 3D printing. i| www.seas.harvard.edu

APPROVALS New materials are all well and good, but for most meaningful applications there will be years (decades?) of further work needed after a material becomes viable for processing. Medical approvals are some of the toughest to come by, especially when you’re putting parts inside humans. I think we can all sleep sounder knowing that the regulatory authorities don’t take this process lightly, but it can prove a frustration for those pioneering applications. It was with great pride therefore that Oxford Performance Materials, Inc. announced the FDA approval of its revolutionary 3D printed

OsteoFab Patient Specific Facial Device. The approval marked the first and only 3D polymeric implant to be cleared by the FDA for use with facial reconstruction. OPM’s CEO, Scott DeFelice commented: “This is a classic example of a paradigm shift in which technology advances to meet both the patient’s needs and the cost realities of the overall healthcare system.” With the rise and rise of 3D printing in medical applications, it’s heartening to see that this is very much on the radar of developers and the powers that be in regulatory roles.

September 2014

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DSM SOMOS: PROFILE

The proverb of this story’s headline has been accepted wisdom since Geoffrey Chaucer first penned the following quote in his distinctive Middle English vernacular for the poem Troilus and Criseyde:

He which that no-thing under-taketh, No-thing one achieveth, be him looth or dere... He that nought n'assayeth, nought n'acheveth.

Nothing Ventured, Nothing Gained WORDS | Daniel O’Connor

n the year before the turn of this millennia DSM decided to under-taketh a venture into a field they’d once briefly dipped their toe into before, the field of this little known technology of Solid Imaging. In 1999 DSM Desotech purchased Somos from DuPont and for the next decade Somos continued to quietly go about their business. Back in the 1999 press release that accompanied the acquisition DuPont’s VP at the time, John Hodgson, said: "Although the Somos business has grown over the last few years, long term it is a better strategic fit for DSM Desotech.” That ‘strategic fit’ is, 15 years later as Solid Imagining/3D Printing is beyond burgeoning, coming to fruition.

“It is interesting now, because four or five years ago when we approached companies the reply was often ‘you don’t have a turn key package, you’re not into the equipment’,” explains Hayes. “Now they’re asking us to come to talk to their engineers about what kind of materials we could develop and what kind The Somos of applications they could be used for. The conversations with those companies have changed and the same goes portfolio now for the equipment companies. Now that the focus is on includes 13 selling more machines they need more materials to offer materials that so they’re coming to materials scientists like us, it is great to have all this interest.”

cover a wide

The Somos portfolio now includes 13 materials that “Previously, Somos was this niche business range of cover a wide range of industries from dental to bought from DuPont and was treated much more applications automotive. A recent case study published by Somos like a venture,” says Hayes, “but now it is seen as very strategic to have a materials company in the from dental to details how NFL offensive guard for the Philadelphia Eagles, Todd Herremans, is using Somos NanoTool 3D printing market. The Somos team feels so automotive. material to gain a competitive edge. excited because they are backed by DSM, DSM wants to know how we can expand from what Herremans found by squeezing softballs he was Somos is today and be a stronger player in this industry.”” developing different muscles in his arm so wondered about implementing these softballs to weightlifting bars. With a roughly Expanding through application patched together prototype he noticed that this was a highly The path to expansion is clear for Somos - it has been set out by effective way of gaining muscle mass. So he turned to a design their history, the bridges they’ve already built and the breakthroughs company back home in Michigan for a more permanent solution. they’ve already made. The fruits of the labour in the decade and a Eagle Design determined that the best solution would be half since acquisition are ripening and Somos is in prime position stereolithography combined with injection moulding and, having to pluck them and taste the sweet taste of success. used the material on another project, the team decided on Somos NanoTool. Continued on page 25

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DSM SOMOS: PROFILE

“A lot of time was saved using Somos NanoTool. Traditionally, we would have had to create the inserts with our 5-axis CNC machine which would have taken twice as long,” says Don Portenga, Engineer at Eagle Design. “We were even able to injection mould 50 sets on our 200 ton Niigata Press from just one mould of Somos NanoTool.” So impressed with the silicone prototypes was Herremans that he ordered 50 more sets of what are now known as Spyder Grips and are commonplace amongst the NFL players’ gyms - all aiming to gain this competitive edge using Somos material. This isn’t the only sporting context were Somos is proving a hit as Melissa Hayes explains: “In spring we launched a new material, Somos PerFORM, and one of the biggest benefits of that particular material is that it processed faster on an older generation of stereolithography machines. Toyota Motorsport, whose stereolithography machines are almost exclusively older generations, was able to increase their production So impressed efficiency 30 to 35%. This enables with the silicone them to get more out of the prototypes was machines and more out of the significant investment they made in Herremans that the first place.”

he ordered 50 more sets of what are now known as Spyder Grips and commonplace amongst the NFL players’ gyms, all aiming to gain this competitive edge using Somos material.

Knowing your place One feature of Somos as a company is their well-balanced approach to product development. Although there are plenty of emerging markets, particularly in the form of desktop machines, Somos knows that the majority of their market lies in the industrial world were many companies still operate machines they purchased 10-20 years ago. ‘We have several different buckets of development so we continue to

Somos has materials for everything from aerospace to toymaking

put a lot of effort into advancing the traditional stereolithography materials, improving their properties; their strengths, their durability, improving clarity, improving temperature resistance...” says Hayes. “One of the biggest tests is trying to maintain properties over time. As we’ve seen this shift coming from prototyping to manufacturing where products are being used over and over they need those properties to last. So we’re looking to not just improve properties but maintain them too. The more we perfect the stereolithography materials , the more applications we hope to unlock.” With eyes firmly on the world of stereolithography, irons in DLP fires - Somos recently announced that their Somos ProtoGen line would include ProtoGen 365nm, which polymerizes at wavelengths used on DLP machines – and two feet planted firmly in the growing industrial applications for medical, aerospace and automotive, that venture back in 1999 is starting to gain significant ground and as for that strategic placement? “There’s a lot of large materials science companies talking about how they’re going to enter the 3D printing market but where Somos and DSM are very unique is that we’ve been in the industry since the very beginning. We have this long history with SOMOS originally having a machine – our roots are in equipment technology - and with DMS, they installed some of the first commercial vats into the early 3D Systems prototypes machines. So we’ve got this integrated understanding of machines and their materials, whereas companies entering the market now with materials may not understand the rest of the technology,” said Ms. Hayes. “We are happy that this ‘venture’ became an established brand and are looking forward to all the new developments that the future brings.”

NFL’s Todd Herreman’s Spyder Grips

i| www.dsm.com

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HIGH TECH INDUSTRIES

AEROSPACE

Metal 3D Printing High End AM for High End Applications

ORTHOPEDICS

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

www.layerwise.com

+32 16 94 64 00

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WORLDWIDE SUBSIDIARIES Cologne , DE

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MATERIALS ROUNDUP TITANIUM & TUNGSTEN The last 12 months have seen some interesting stories relating to the apple of the of the AM materials world’s eye, titanium. Titanium’s properties make it desirable in applications as diverse as jewellery and space explorations, but for every pro there must be a con and in titanium’s case that is the cost and effort of extracting and processing the material. The challenge of extracting titanium from it’s naturally found oxide, rutile, and converting it into a useful form for further processing has been tackled by Cambridge University spinout, Metalysis. The Rotherham-based company has, along with researchers from the University of Sheffield’s Mercury Centre have developed a new method for extracting titanium from its ore using electrolysis, vastly reducing the number of steps, and thus cost, of processing. Then in August the focussed turned to tungsten, a heavy, high-melting-point metal found naturally only within chemical compounds. Interest in tungsten revolces around the fact that it has the highest melting point of any pure metal, a staggering 3,422°C. When Smit Röntgen, a Philips brand, announced that it was able to additively manufacture pure tungsten parts a great number of interests were piqued. Smit Röntgen’s Sales and Marketing specialist Pieter Nuijts explained: “When talking to major players in medical and non-medical fields, it becomes evident that being able to 3D print pure Tungsten parts does attract global attention. By mastering this technique, the possibilities for creating new innovative products and niche markets are endless.”

i| www.metalysis.com i| www.smitroentgen.com

SPACE 3D printed parts have been launched into space on the KySat-2 satellite, a 1U CubeSat, built and tested by students of the University of Kentucky and Morehead University together with Kentucky Space acting as mission manager and coordinator. CRP USA has announced the successful launch of Windform as part of the project. The team launched the KySat-2 into orbit as part of the NASA ElaNa IV mission from the Wallops Flight Facility in Virginia. Just 35 minutes after lift off, the satellite began to send down its telemetry data, which was almost instantly picked up by amateur radio operators. Ever since, Ky-SAT-2 has been performing system checks for each of the many subsystems that make up this sophisticated piece of hardware, which is tasked with being both an educational and demonstration tool for students. CRP USA's 3D printing material Windform XT 2.0 was used to make several of the components on the satellite. Project manager of Kentucky Space Twyman Clements said: "One of the subsystems, is the

camera systems that acts as an attitude determination system called Stellar Gyro. The 3D-printed parts were produced using the additive manufacturing technology selective laser sintering and Windform XT 2.0 material. The additive manufactured process 3D printed the mounting hardware for the camera system, extensions for the separation switches, clips for holding the antennas in their stowed position and the mounting bracket for the on board batteries. The process and the material were critical to achieve the right components for KySat-2." i| www.crptechnology.eu

GROWTH It’s easy to see when a topic has reached the consciousness of the investment communities and those that serve them — all of a sudden, there are ‘reports’. These generally optimistic pieces will assess the likely growth and opportunities within a field and generate through much fiscal fiddling a number, usually an impressive one, which is sure to get investors rushing to throw money into the pit. One such report delivered by RnR Market Research predicts 20% yearly growth for 3D printing materials from now until 2018. With the market only just opening up and so many systems locked to OEM materials, it will be interesting to see what the opportunities to exploit the predicted growth are.

365 nm Higher-wavelengths are being used in 3D printing systems, in the 365nm range, to speed up processing and reduce costs. DSM Somos launched Somos ProtoGen Clear 365 nm, the next material to be released in the 365 nm product portfolio. The company explained that the material can be used for a wide variety of applications requiring transparency, accuracy and high temperature resistance including electronics, consumer products, automotive and aerospace. “We are delighted to announce the latest addition to the Somos 365 nm product portfolio,” said Melissa Hayes, Business Director Somos. “We are committed to innovation and will continue to expand our portfolio for 365 nm photopolymer-based 3D printers while providing customers with the high quality products that they have come to rely on Somos for at this new wavelength.” As an increasing number of ‘desktop’ systems based on light- and laser-polymerisation technologies emerge it will be interesting to see how the historically industry-focussed suppliers will react. i| www.dsm.com

For constantly updated news on the materials sector, visit tctmagazine.com/material

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September 2014

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Color and material combinations that make you say “Wow!”

Visit u s a t TCT Sh ow, NEC , Birm in gh a m 30.09. – 02.10.2014 Ha ll 3A, St a n d E18

[COLOR + RUBBER +TRANSPARENT + RIGID] !"#$%&'()"*+#,-+./0-#122+3%""-45+6$%7+8#$9#9:;:< the world’s only full-color and multi-material 3D printer. Select from incomparably brilliant and consistent colors, plus a full palette of transparent colors — the only 3D printer to offer such a wide array. And it’s the only 3D printer that prints flexible materials in a broad range of shore values. All with ultra-fine detail creating the most true-to-life modeling possible. Stratasys is the proven leader in multi-material 3D printing. =%$+ >,9#-?-$+ ;%'$+ 7) "&+ (9 "+ ) 79 * ) " -<+ ?) :) #+:# $9 # 9 :;: @ (% 7A. /0 -#1 2 2 3% " " -45+% $+(% " # 9 (#+' :+ 9 #+- 7-9 B:# $9 # 9 :;: @ (% 7+% $+(9 C C+DEF+GHH F+GGG+H 2@

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NEW BUSINESS MODELS WITH 3DP

GIVING UP THE

DAY JOB 3

3D printing is sometimes feared as the bogeyman of manufacturing, here to take the jobs of those hard at work on assembly lines across the factories of the world’s biggest companies. WORDS | Daniel O’Connor

It is easy to see why technology is inherently seen as a threat to the workforce; nine times out of ten the introduction of technology into a corporation is designed to save cost on labour. You only have to take a look as far as your local supermarket when back in the days before barcodes, supermarket cashiers often had to be highly trained in acumen and have memories the size of an elephant, for this they were fairly handsomely rewarded. Then barcodes appeared and their jobs became minimum-wage roles requiring little more than an arm. Now take a look at any supermarket, six self-service tills are being operated by one human being; Technology 5 – Humans 1. Although additive manufacturing does have benefits for the likes of GE, who can reduce assembly costs of a fuel injector by printing complex components as one it is also responsible for a whole new set of business models set by entrepreneurs who are using the technology to become self-employed.

Model of success “What I find interesting is that we’ve always had the Business to Business (B2B) model and the Business to Consumer market (B2C) model but what you now see happening because of 3D printing is that the Consumer to Consumer (C2C) and even Consumer to Business (C2B) models are growing.” explained Onno Ponfoort, Senior Managing Consultant at Berenschot and author of a new book ‘Successful Business Models for 3D Printing’.

The idea is fairly simple with Shapeways, you do the creative side and they’ll do all the heavy lifting for a cut, Shapeways have previously stated that they’d like to see the first Shapeways millionaire by the end of this calendar year. The business model for shop owners is C2C. However, it is the increasing area of the previously unknown C2B market that intrigues Onno most. “Our whole society is coming round to the idea of that the maker community is a valid alternative to traditional industry manufacturing,” Claims “Our whole Poonfort. “Sometimes a design society is coming company may not need the maximum quality for an round to the idea iteration they just need it of that the maker quickly and the maker market community is a can fill that hole.”

valid alternative to traditional industry manufacturing.”

3D printing hubbubs of activity One platform thriving in the C2B market is 3D Hubs who have, at the time of writing, just announced a $4.5 million round of funding. Filemon Schöffer, Head of Community at 3D Hubs told TCT: “The bigger goal of 3D Hubs is for Hubs to run their own business, we want to give them the platform to grow a 3D printing business.” Continued on page 31

A recent report by Shapeways submitted to the US House of Representatives Committee on Small Business said that 84% of the 14,000 Shapeways Shop owners want the marketplace to be their full-time income and 94% of those spent less than $1,000 setting the shop up in the first place.

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NEW BUSINESS MODELS WITH 3DP

“A lot of people ask me ‘Will I get my investment on a 3D printer back on 3D Hubs?’ Of course you will get you money back eventually but the speed in which you do so relies on your own skills of selling.”

One man, who has certainly grown his 3D Hub into a sustainable business, is film producer Jan-Willem Wirtz. One of the first people on the 3D Hubs platform with his secondhand MakerBot Thing-O-Matic, JanWillem has steadily cultivated his Hub into a five-strong production facility.

“I am addicted to my normal job as a film producer but I can imagine that I only have to only take out the jobs I really love on that side and my basic income is coming through 3D Hubs.” Says Jan-Willem. “Last week I had a new record, I printed more than €1000 in a week, the material cost is only 10-20% maximum. If it continues to grow then I can see that you could give up your day job.” Jan-Williem

Though the idea behind 3D Hubs is fairly simple – you list a printer for those that need a local printer – Jan-Willem says that as the platform grows and more people list their printers, the more canny operators are the ones who have most success. “A lot of people ask me ‘Will I get my investment on a 3D printer back on 3D Hubs?’ Of course you will get you money back eventually but the speed in which you do so relies on your own skills of selling, for example one of the things I do is put an extra 3D Hubs mailbox in my garden so that people can collect their prints 24/7, I don’t have to be at home they can just come to the address and collect. Those are the kind of services you need to offer, you not only have to think creatively for the 3D print itself but the whole customer journey.”

Badge of Honour Jan-Willem says that around 40-50 per cent of his orders are for prototypes and another half are for fun one off products like iPhone cases often downloaded and customised from Thingiverse but there is another income source heading his way, certified badges. Badges signify a trusted manufacturing partner, a truly C2B service that allows for local production on machines tested for quality. Filemon Schöffer explains more:

Badges signify a trusted manufacturing partner, a truly C2B service that allows for local production on machines tested for quality.

“Ultimaker are outsourcing their whole sample programme to 3DHubs, they gets a lot of requests for samples from potential customers, which took up a great deal of energy but now they can order samples at all our Ultimaker badged Hubs. Hubs will be required to do a few tests and then they earn a badge. Ultimaker sample orders are placed directly through us, we deal with the customer order and support and the Hub prints the item. Ultimaker pays for the order but that outlay is minor in comparison to setting up a sample programme, the Hubs take the money and we take our commission, so everybody is happy.”

This form of local production of minor parts for larger companies is a business area that Onno Ponfoort completely believes in and has already seen the wheels in motion at one unnamed corporation: “A company I am working with classifies parts in three categories ; Category 1 was the most important part to the brand value, for those parts they only have a monitored, completely controlled minimal set of production partners; Category 2 tends to be aesthetics that don’t matter so much to the end result, for those items they have a much larger ring of suppliers they are able to use, which means a more competitive price; Category 3 are parts that as long as they perform the function, it’s fine to 3D print them, we just do test sampling to make sure that the producers are getting to the quality required. This opens up the door for manufacturing on your doorstep.” If the likes of Shapeways and 3D Hubs continue to grow these new business models then it is likely that 3D printing will go from zero to hero, seeing people cast-off their dwindling factory jobs in order to design some jewellery or make hooks for Ikea curtain rails, and thus the balance of the universe is restored.

i| www.berenschot.com i| www.3dhubs.com

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STRATASYS

TCT SHOW EXCLUSIVE:

Stratasys presents expanded range of Connex multi-material printers Stratasys has unveiled the Objet500 Connex1 and Objet500 Connex2 Multimaterial 3D Printers featuring the company’s unique triplejetting technology — both of which will be available to see for the first time at TCT Show + Personalize (www.tctshow.com).

Objet500 Connex1 Equipped with a large build envelope, the Objet500 Connex1 Multimaterial 3D Printer can produce parts from three diverse materials in a single production run. This allows users to create assemblies with components formed from three different materials, or it can produce components that contain both rigid and flexible materials, such as rubber-like Tango and rigid Vero material. The 3D printer can build a part up to 490 mm x 390 mm x 200 mm or a mixed tray of small parts. A larger material cabinet contains eight cartridges, resulting in more unattended run time and fewer material changeovers than previous models. Hot swapping – or reloading material and support cartridges while the 3D printer is operating – allows for continuous part production. Multi-material 3D printing achieves in a single, automated build what would be either impossible to achieve with conventional single-material 3D printers or would require hand assembly from multiple print jobs. Objet500 Connex2 The Objet500 Connex2 Multi-material 3D Printer enables users to combine transparency, durability and flexibility in one part. It has all the capabilities of the Objet500 Connex1 plus the ability to combine droplets from two base materials to produce new materials or “Digital Materials.” Digital ABS, for example, is the most durable material available for the Stratasys PolyJet process and is often used to produce mold cores and cavities for short-run injection molding. With more than 100 material options, Connex2 users can produce a variety of Shore A values in the same part with rigid or clear components, or can combine Digital ABS with pure Tango for for strong over-molded handles and grips. The versatility of the Objet500 Connex2 also makes it ideal for creating custom manufacturing tools such as jigs and fixtures.

“Following the launch of the Objet500 Connex3 earlier this year, we saw the demand for additional multi-material 3D printers that can address a variety of applications in prototyping and manufacturing, such as tooling and molding,” explains Stratasys’ Senior Product Marketing Manager Ron Ellenbogen. “We were able to build on the success of our triple-jetting technology and expand the Objet500 Connex family with two 3D production systems that we believe set new standards for 3D printing price performance.”

i| www.stratasys.com

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SALOMON

Apparel companies operate in exceptionally competitive environments, with any perceived improvement aped by the competition extremely quickly. Combined with the fickle nature of consumers and the constant march of fashion it pays to be one step ahead. TCT took a visit to Annecy in eastern France to see how 3D printing is helping one sportswear brand.

3D PRINTING IN

Sportswear Development S

alomon is part of the global Amer Sports Group, a Finlandheadquartered multinational sportswear company with 2013 revenues in excess of €2.1bn. Many of the design teams for Amer Sports subsidiaries — including Salomon, Wilson, Mavic and Atomic — are housed at the Annecy Design Centre in the Rhônes-Alpes region in south-eastern France. Salomon started making ski wear back in 1947, growing to a €650 million turnover in 2013, of which some €340 million comes from the Footwear division. Salomon alone undertakes some 75–80 new footwear projects each season including entirely new designs and updates to existing product. Emilien Arbez, Footwear Product Manager at Salomon explained: “Traditionally all of the prototypes we required would have been made by hand — and many still are — but 3D printing became a viable solution for prototyping of certain parts of our footwear range, specifically the soles. “Like many companies we first integrated 3D printing into our workflows by using third-party external bureaux. We would prepare designs in house, send the files over and wait for the prints to come back. This would sometimes take just a few days, but other times over

a week. The process was still faster than creating iterations by hand, but we soon saw the opportunity to streamline. “We started to look at the 3D printers available to us ‘in-house’ considering purchase cost, materials costs and any special requirements for housing the machine.” Between 15 and 20 new soles (outer sole and midsole) are designed, prototyped and produced for each season’s new range. Of those 15–20 new soles each season, only five or so will be 3D printed as part of the prototyping process. Of these five, a standard product will require around two or three iterations with special projects often requiring upwards of 15 3D printed parts. However, the 3D printer doesn’t sit idle as seven brands or sub-brands housed within the Annecy Design Centre (FOOTwear – Alpine bindings/boots – Nordic bindings/boots – Mavic - Snowboard - Gear) use the in-house 3D printer in the development of their products. After researching the 3D printers available to them, the team decided on the Stratasys Dimension 1200es, which is housed in the corner of an existing print room alongside 2D printers, large format plotters and photocopiers. A casual observer would be hard pressed to identify it as anything other than another piece of generic office white goods. Continued on page 37

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SALOMON

3D printed, prototyped and production soles A 3d printed sole for Wilson tennis shoes

Over 2012/2013 the Stratasys 1200es FDM machine was used for 3,740 hours, printing around 1,100 parts using nearly 26,000 cm3 of ABS and 13,000 cm3 of support material.

Emilien explained how the choice was made: “For the type of prototypes we are making the ABS plastic is perfect. The resolution is good enough for the scale we are working at and the parts are robust enough to withstand spirited design meetings.” As can be seen by the amount of time the printer is in use, the stability of the FDM process is also a boon when there are multiple nonspecialist users.

Emilien continued: “The workflow we have established for the system allows designers to send files to the printer and obtain prototypes without a significant amount of training — and prints almost never fail so the printer rarely requires human intervention in either the running or servicing.” Any company looking to complete a limited amount of printing will look for a system that causes the least disruption, but with that comes compromise. “For a lot of work we could do with a 3D printer there are simply not the materials choices. Ideally for designs of the midsole we require a foam-like material — something that is not currently available from any system. We have had parts printed with the Connex multimaterial 3D printers, and while the ability to create parts that closely mimic the rubber of a training shoe sole is useful, the inability to manage the density through the part is a drawback.” Downstairs from Salomon, Mavic — the cycling technology company — also use the 3D printer, but in a very different way. Here the printer is used to create bespoke vacuum parts to remove dust from the CNC

3D printed ducts for one of Mavic’s CNC machines manufacturing process. The ABS parts are resilient enough to be used in the relatively harsh environment in the high-speed machining systems that make cycle parts. Such uses are difficult to predict when making the case for an in-house 3D printer but can make all the difference to the rate of return on investment. It is often the case that different departments will have no use for a 3D printer… until one appears next door. Elsewhere the printer is used by the Nordic service and ‘gear’ teams for making small functional parts for testing, such as bindings for ski boots. Emilien: “The guys will sometimes print a part and take to the mountains to test it out, usually until it breaks. The printed parts won’t be as as strong as the final parts, but they’re useful for initial testing and a lot of good data can be gathered at this relatively early stage.” Around 40 per cent of the 3D printing undertaken is at the behest of the footwear division, with the alpine boots, Mavic and ‘gear’ running at just over 10 per cent each. Over 2012/2013 the Stratasys 1200es FDM machine was used for 3,740 hours, printing around 1,100 parts using nearly 26,000 cm3 of ABS and 13,000 cm3 of support material. The cost of 3D printing using the in-house machine across the brands was calculated at €11,970, which equates to a saving of nearly €12,000 per year when compared with using external service providers. The team expects to complete some 300 prints through 2014. i| www.salomon.com September 2014

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DRIVING INNOVATION

ParaLong Drive Championships in Mesquite

In this world of instant gratification some more long haul sports and pastimes are seeing attendance and participation of younger generations decrease. In order to keep up with this ondemand world many have attempted to introduce shortform versions. Cricket, for instance, has Twenty20, snooker has Power Snooker and now the shortened version of golf ‘Long Drive’ is starting to draw a significant crowd.

DRIVING INNOVATION T

he RE/MAX World Long Drive Championship, which involves golfers smashing six balls down a golf course inside 2 minutes 45 seconds hoping to achieve the furthest in-bounds shot, has taken close to 20 years to break into the mainstream by appearing on NBC’s Golf Channel in 2013. The Amputee Long Drive Championship (ALDC) has taken just one year to gain enough popularity for it to appear on the very same channel. The Director of the ALDC, Dean Jarvis set up the event after learning that though Golf is to be included in the 2016 Rio Olympics there would be no Paralympic golf event due to challenges around measurable impairment. Jarvis decided that best solution for getting golf into the Paralympics would be to combine it with the sport of Long Drive.

WORDS | Daniel O’Connor

At the age of 14 Easton decided to build a robotic arm using Lego, at the age of 17 he was presenting a brain powered, 3D printed, robotic, prosthetic arm to President Obama as well as working at NASA.

Although the primary aim for the ALDC is to put on a truly competitive event, thrilling for spectators and participants Jarvis also sees the tournament as an opportunity to promote innovation that improves the lives of amputees and paralysed people. This is where Stratasys come in, as lead sponsors of the event and a company dedicated to innovation in medical applications they introduced Jarvis to one of the most pioneering individuals working in prosthesis today, Easton LaChappelle. At the age of 14 Easton decided to build a robotic arm using Lego, at the age of 17 he was presenting a brain powered, 3D printed, robotic, prosthetic arm to President Obama as well as working at NASA. In the meantime was the leading speaker at a recent ALDC event.

“I’m left handed and I like to try use that as an excuse for why my golf game is pretty bad but when you see these guys hit a golf ball close to 400 yards it kind of puts you to shame.” Easton told TCT. Dean Jarvis recognises Easton as one of the people that is doing most at improving lives of amputees across the globe, for this reason Jarvis felt it was essential to get Easton involved, yet it is Easton who feels like he gets more out of it than he has to put in. “Getting to talk several amputees that have already tried multiple technologies was really fascinating to me. I don’t live very close to many amputees, there’s maybe two or three within a hundred miles of here, to have a platform to talk to some of the world’s best sporting amputees to find out what works and what doesn’t work is amazing for me.” Explained Easton.

Easton and Jarvis will team up once more for Mesquite Innovation and Technology Summit, which runs concurrently to the Mesquite ParaLong Drive WORLDS Competition in October. At the inaugural summit LaChappelle will be demonstrating the final iteration of his robotic arm that he has been working on for so long. “It will be complete, open-source robotic arm from fingertip to shoulder. An amputee can buy a 3D printer for $300, print these designs, buy some small motors, install the custom software tuneable to my own needs and then use it as a prosthetic you can do the dishes with and then play golf with later on.” i| www.amputeelongdrivechampionship.com September 2014

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CALM

or the past few years, there has been a real buzz around additive layer manufacturing (ALM) — known in other circles as AM and more still as 3D Printing — and the rise of the technology, hailed by many as the “next industrial revolution”, has been widely documented in the media. AM has much lauded advantages over traditional processes in a number of industry applications, and has been used to create everything from fuel nozzles for civil aircraft to hip replacements. However, despite the extensive media coverage, there is relatively little knowledge about the capabilities of AM among sectors that are not currently using the technology, but could benefit from adopting it. On the flip side, there have been cases where businesses, influenced by the hype about AM, but unaware of its limitations, have ploughed ahead in purchasing equipment, only to find it has not been appropriate for their requirements. The conundrum of how to address this knowledge gap has been widely discussed and debated at AM conferences and roadshows. One solution is to engage young people and inspire the next generation of engineers and other users, which was the impetus behind TCT Magazine’s Bright Mind’s programme. In addition, a number of universities are incorporating the technology into their undergraduate courses and there has been a great deal of investment in PhDs. Another approach is to educate businesses and individuals, using knowledge exchange workshops, such as those run by the Centre for Additive Layer Manufacturing (CALM) at the University of Exeter. Originally funded for three years by the ERDF, RDA, University of Exeter, and EADS UK Ltd, CALM was primarily set up to deliver informative workshops to suppliers of the aerospace sector. Airbus teamed up with the centre as an industrial partner because it felt there was a knowledge gap among its extensive supply chain that needed to be addressed. As interest in AM continued to grow, CALM expanded its focus to increasing the knowledge and awareness of the technology and its capabilities among a wide variety of businesses, initially small and medium enterprises based in the South West. The continued fascination in the technology and ever growing desire in businesses to find out more enabled CALM to become self-supporting, and the centre has broadened its scope yet again to assist large national and international businesses. The centre’s intensive, day long workshops are designed to help businesses make an informed decision about whether AM is right for them, to enable them to focus their investments in the correct area, and help them to adopt the technology in a form that is appropriate to the businesses’ needs. Although tailored to suit a wide range of sectors, in general, the workshops have covered the advantages, challenges and limitations of the technology, as well as advising on how AM can be integrated into businesses to create new services. Topics have included design, types of process, materials, software, and examples of the diverse range of applications.

WORDS | Daniel O’Connor

The University of Exeter explains why educating established and startup businesses on the benefits of this technology of ours is just as important as the STEM programmes governments across the globe are embedding into the curriculum.

Continued on page 43

Back to School September 2014

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CALM

CASE STUDY

Award winning engineering firm J+S Ltd., based in Barnstaple, Devon, and Aberdeen, Scotland, incorporated AM into its business processes after attending a workshop run by CALM. J+S Ltd, which designs, develops and manufactures products for a range of sectors, from defence to oil and gas and marine renewables, has since used AM for a number of projects.

CALM has delivered the workshops to hundreds of people across a variety of sectors. Manufacturers, such as those involved with injection moulding, casting and machining, designers and end users from the aerospace, defence, automotive and space sectors, as well as the creative industry have benefitted. The events have helped businesses and inventors to utilise the technology for a seemingly endless range of applications, including the creation of bespoke, individual implants for the medical sector, the manufacture of crowns for the dental industry, and the production of low-volume, high-value components for defence.

As well as presentations and demonstrations of the technology delivered by CALM’s experts, the workshops, with their strong interactive and networking element, also encourage businesses to share their own knowledge and experiences of the technology. Following the workshops, CALM can offer a further service of helping individual companies to work out how they can utilise the technology within their own businesses.

Initially, J+S Ltd approached CALM to find out more about the potential of the technology for prototyping a towed or static underwater sensor providing both acoustic and non-acoustic measurements for use with a wave powered unmanned surface vehicle. The product, which is in the company’s NarcineArray range, was launched at Oceanology in London in March. The company has also utilised the technology for other products in the range. Chris Tucker, Electronics Engineer for J+S Ltd, said: “Since visiting CALM for the open day, and making use of the business support, J+S have used AM for a number of projects. AM is now considered whenever J+S are prototyping products, be it mechanical or electrical. AM has allowed engineers to produce space models of mechanical and electrical components for derisking at a low cost.” He added: “The training and support given by CALM has provided J+S with the knowledge and confidence to design for AM. Internally, we have regarded AM as a huge step forward in our capability to design new products and produce quick turnaround prototypes.”

During the three years of its funding, the centre delivered workshops at no cost to eligible companies. Although there is now a charge, the centre continues to be inundated with interest from businesses, which see the workshops as a worthwhile investment and as a vital part of the process in learning to use the technology. The continued interest has no doubt been driven in part by the promotion of AM in the media, which has inspired businesses to become more creative and innovative. Furthermore, seeing that some businesses are ahead of the game, there are many forward thinking companies that do not wish to be left behind. As awareness of AM and its potential continues to grow, the workshops run by CALM have evolved from transferring basic knowledge to informing businesses about how to take the plunge and apply the technology in the appropriate manner. The centre will continue to promote this to current and future users, and there are signs that a number of companies are now following suit and starting to offer knowledge transfer workshops. No doubt, in the future, education, both of young people and of businesses, will continue to play an important role in the growing adoption of the technology. i| http://emps.exeter.ac.uk September 2014

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PROFILE: FENNER GROUP

The Fenner Group is a company that has been providing engineering solutions for over 150 years; the group has grown from Joseph Henry Fenner producing leather belting systems out of a rented room at 211/2 Bishop Lane in Hull, England into a multinational with major operations on six continents and over 5,000 employees.

DRIVE AND PRECISION, the formula for success? WORDS | Daniel O’Connor

ou do not do this as a company by standing still; you grow through innovation and spotting new revenue streams earlier than most. In this past year the Fenner Group has seen two of its subsidiaries - Fenner Precision and Fenner Drives – spot new a cash cow in the form of the 3D printing industry. As Divisional Managing Director for both Fenner Precision and Fenner Drives, Allen Cubell explained to TCT the paths to entry for Drives and Precision were entirely different. “Fenner Precision got into the market as a logical progression from their 2D printing business, Precision makes timing belts by the tensof-millions for consumer inkjet printers. We’ve probably made a billion of these things and we thought ‘we’re already moving the inkjet around on a 2D printer why not add another dimension?’ We’ve made some alterations and made a fantastically smooth, quiet and precise belt for 3D printers.” For Fenner Precision the move into the third dimension is a logical, a strategic decision based on their current supply to OEMs but for Fenner Drives the move was more coincidence than business sense. “Fenner Drives is in the power transmission systems business; they basically make high-end niche products to move things around factories.” Explained Cubell. “One of their product development engineers happened to be one of these 3D printing enthusiasts, he had a MakerBot in his garage and he would go on forums to read up on 3D printing. He saw that a bunch of people like him were looking for more filament solutions, after a few conversations it turned out that somebody had gone to the Fenner Drives website, bought some of our Eagle Polyurethane Belting and tried to run it through their 3D printer, to their surprise it, for the most part, worked. “Like any good product development engineer our guy started playing around, he realised that the Eagle belting wasn’t even the best of our products he could use. With a little development and a few tweaks to some formulas we could use a very similar manufacturing process to one we currently use and produce these filaments. We make conveyor belting that has to be very flexible, very strong and very reliable; those properties make for this really good filament that hits a sweet spot for the market. We got the marketers involved and they came up with the name, NinjaFlex, and we launched the first four colours in October, we launched five more colours in February and it is continuing to grow.” Flexing muscles In less than a year, NinjaFlex has become one of the most recognisable 3D printing filament brands and for good reason. TCT recently interviewed Mike Garey, who shot to fame by designing a 3D printed prosthetic foot for Buttercup, a one-legged duck he had rescued.

Buttercup the duck now swims happily thanks to a prosthetic foot made using Fenner Drives’ NinjaFlex filament

“The key factor for me being able to actually print a foot for Buttercup was finding NinjaFlex,” explained Garey. “Having a hard plastic foot was never going to work, it need to have bend to it, it needs to be comfortable for him when he’s lying down and PLAs and ABSs weren’t suitable. From the various filaments I’ve tried so far NinjaFlex is the best solution.” Cubell added: “We have heard stories like Buttercup, there was a story of a doctor in Kentucky who used NinjaFlex to make a model of an infant’s defective heart before operating and then we saw that it was being used as a the material for a helmet at the World Cup for the paraplegic guy who was able to kick a ball for the first time thanks to an exoskeleton powered by his brain. We have really been shocked by its uses, when we first launched it we thought, ‘this is great for flexible iPhone cases’ so to see those kind of applications really blows us away.” if you follow TCT online you’ll read about other uses of NinjaFlex in medical applications showing that it is increasingly becoming the filament of choice in perhaps the industry’s most lucrative sector. Though that could be very lucrative perhaps the real potential for growth comes through the more mundane story of the belts that Fenner Precision is now producing for 3D printers. The industry is now firmly in the gaze of huge computing and inkjet companies, many are waiting to pounce on their prey and when they do, to whom will they turn for help? Allen Cubell thinks he knows whom thanks to some strategic positioning. “We provide millions of timing belts to the likes of HP and their competitors so if these companies do enter the 3D printing market we’re already making 2D belts for them and we make 3D belts you’d hope they’d come to us.” i| www.fennerprecision.com

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ASTROPRINT

THINK SMART WORDS | Daniel O’Connor 3D Printing is considered bleeding-edge technology, a tech that could usher in a new industrial revolution they say, a tech that will have us all manufacturing on our desktops apparently. But take a look at about 85% of the desktop 3D printers on the market there’s an interesting anomaly, one that leaves them in a sort of limbo in-between antiquated and ultramodern: connectivity.

ecently, leading market research firm International Data Corporation published a report that claimed by 2017 87% of all connected devices will be either smartphones or tablets yet only 1.5% of the printers listed on 3D Hubs’ latest trend report are capable of out-of-the-box smartphone connectivity. The majority of 3D printers sold to date require a connection to a PC, a system consumers are eschewing in favour of their Android and iOS devices. Though the likes of 3D Systems and MakerBot have addressed this gap for their latest models this doesn’t account for the 60,000 printers sold and a large share of un-connected printers on the market right now. There is, however, a solution and a reasonably priced one at that. A software/hardware combo that can turn pretty much any 3D printer into and all singing, all dancing, smart-phone connected one-touch personal manufacturing plant. The project is AstroPrint, the company is 3DaGoGo and their CEO is Drew Taylor. “3D printing is too technical and too complex for end-users and that is why it is not crossing over to mass consumerisation.” Explained Taylor. “AstroPrint focusses on this gap between 3D printing

AstroBox can be installed into most printers to make them smart

AstroPrint will be smartphone and tablet enabled technology and the smartphone technology that we’re so used to. We’re automating the whole process.”

“We’re now serving the retrofit market, printers that are not WiFi enabled, they don’t have smartphone capabilities..”

The solution comes in the form of AstroBox and AstroPrint, a seamlessly integrated hardware and software system that connects to your printer offering wireless printing, global access, cloud slicing, camera monitoring support, cloud file storage and other features that can turn that investment you made on a 3D printer into a futureproof smart printer.

“We’re now serving the retrofit market now, printers that are not WiFi enabled, they don’t have smartphone capabilities and their users don’t want to tinker with them, that’s what the AstroBox is for; it upgrades a printer to be cloud aware and work with our software,” says Taylor. Retrofitting is not a sustainable market, with an estimated 60,000 desktop printers out there today this solution may well be out of date by the time the next TCT Show rolls around but Taylor and his team are savvy enough to be fully aware of AstroBox’s shelf life. “When coming up with our company vision we asked ourselves, ‘who has money and who needs something done?’ The printer manufacturers, and we have a solution that could help them out. As we move forward our big focus will be on the manufacturers, our platform can be embedded in the printer, that might be white labelled, co-branded or not depending on what the manufacturer wants.” With a truly innovative and merchandisable product, a Kickstarter campaign that was funded in a single day and a clear vision for the future of their revenue streams AstroPrint are smart thinkers in a smart world. i| www.astroprint.com September 2014

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3D TECHNOLOGY IN EDUCATION

When personal computers were first introduced to schools, education leaders were given the task of coming up with a way of integrating them into the curriculum. By the mid 1990s, this usually meant a single machine in every classroom, used once a year by each student to word-process a handwritten essay for a wall display. Who would have thought it would advance so immensely that schools are now using touchscreen tablets to teach their pupils?

University challenge:

GETTING 3D PRINTING INTO EDUCATION WORDS | Laura Griffiths

ow the latest piece of technology to be treated in the same fashion is 3D printing. The process has been around for years but only recently, due to mainstream media interest, has the world been able to make room for the technology in its everyday vocabulary. To put the technology into motion the UK government last year decided it was going to make 3D printing part of the school curriculum to enrich the teaching of STEM and design subjects. But how much of this has actually been implemented? Have 3D printers replaced the old PC in the corner of the classroom? 3D printing in schools has a good case. A key benefit is that universities, the next stepping stone for almost half of school leavers, have begun to adopt the process into their teaching over the last few years. Design students from fashion to furniture have been taking advantage of the possibilities with 3D printing by experimenting with new methods and prototyping their designs using desktop machines. If A Levels are supposed to prepare students for university, then surely they should be well versed in the practical side too? Ravensbourne College in London was one of the first in the UK to really embrace 3D printing in its teaching practices thanks to former lecturer and Modla founder, Jon Fidler. Jon, whose company provides specialist 3D design and consultation solutions, says that the motivation arose from his own experience as an unengaged design student working within the prototyping area at Bournemouth University. “They had just put in a new 3D prototyping unit back in 2004 and when I fell across this I was just totally sold,” says Jon. “It gave me Continued on page 51

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Triumph is looking for a CAD/PLM Support Engineer – Is this you? Triumph Motorcycles Ltd is a global business based in Leicestershire which designs, manufactures and distributes over 50,000 motorcycles per annum. Triumph has annual sales of over £300m and employs over 2,000 people worldwide. The business has enjoyed continuous success since the start of production in 1990 due to massive investment into innovative new manufacturing processes, close interaction amongst dealers and distributors on a world-wide basis and most importantly of all, Triumph’s empathy with its customers and enthusiasts. Triumph Motorcycles Ltd is currently seeking a CAD PLM Support Engineer to help support the Design Department.

Based within the CAD support team, the successful applicant will be responsible for a variety of CAD support duties. You will support our 3D CAD and data management systems such as CREO, Windchill, PDMLink, FEA Packages and A class surfacing. You will also mentor our 250+ Design Engineers in the use of Creo. For further information about the company and this role, or to apply on line, please visit our website: http://careers.triumph.co.uk Applications can only be accepted from candidates who have the unrestricted right to work in the EU. No agencies please.

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3D TECHNOLOGY IN EDUCATION

“I have it from day to day,” explains Jon. “A lot of people hear ‘3D printing’ and instantly think you can make anything whereas we know you are limited to sizes, dimensions and shapes. There’s a big gap and people need to be educated much more about the technology.”

“I don’t understand why so many fashion schools have not adopted the technology yet – it’s the way everything works now.” — Francis Bitonti

“These tool sets are not just teaching students how to design clothing, they are preparing them for a whole new language that has been brought about with 3D printing.”

the ability to create something with the software and within a day have something I could hold and touch and it really inspired me to push on.” After working on projects with the likes of Formula 1 and JCB, Jon progressed to working at Ravensbourne College, an institution known for its forward thinking and industry focused teaching, where he introduced the use of 3D Printing, 3D software and digital fabrication. The university recently installed four Makerbot machines, and Jon says students have taken to the technology with an encouraging level of enthusiasm.

“You see not just engineers using it but also graphic designers, fashion students, architects and it’s really interesting go see what that’s enabling them to do and allowing them to visualise and realise their ideas a lot quicker.” 3D printing has also changed the structure of the university’s teaching. Gone are the days when students would have to be assisted in using prototyping technology and replaced with simple 3D printing machines that make designing and implementing ideas a much more hands on experience.

If 3D printing in further education is proving to be such a turning point for changing the way practical design skills are taught, it seems logical to introduce the technology as early as possible starting with schools. Jon is confident that young pupils would benefit from the technology and thinks the UK should be much more active in its approach to 3D printing. “I think every school should be given one of these machines by the government,” says Jon. “It ‘s definitely something that needs to be addressed. I think it’s important for the UK because the UK built itself on engineering and it’s a way to get people back into that and inspire the talent to be involved in these technologies. I think 3D printing is the key to be able to do this because it’s one machine that doesn’t need a massive workshop and with the software being taught properly, it could really open a lot for inspiring the talent of tomorrow.” Institutions in the UK are gradually increasing their additive manufacturing portfolio with the University of Sheffield investing in its Centre for Advanced Manufacturing and the University of Nottingham carrying out research in the field additive manufacturing since the mid 1990s.

“I think every school should be given one of these machines by the government.”

“The workshop engineers were completely done away with as was the entire workshop area,” says Jon. “Actually having that hands on experience is great. You can go down there now and you’ve got a big queue of people waiting to use the printers. It also spurs them on to go and use the software more because it plays such a massive part within product development.” Yet there is still a substantial gap between the preconceived ideas people have about 3D printing and the right knowledge. Although the understanding is slowly improving, there is still a high concentration of people who assume the technology is as simple as choosing your object and clicking print without any knowledge of limitations.

Over in the US, 3D printing in universities is also on the rise. One man who has worked alongside students on both sides of the pond is architect turned fashion designer Francis Bitonti, a name made famous for the 3D printed dress, designed for Dita Von Teese, in 2013.

Francis Bitonti Studios has played a major part in teaching the technology with a series of workshops for budding designers providing them with hands on experience working with 3D printed textiles. From Brooklyn to Greenwich, he has taken his New Skins project to universities and design workshops, engaging students with the possibilities of 3D printing in fashion.

“The program started because there wasn’t really any opportunity in the design schools to learn 3D models,” explains Francis. “Computing is not part of the curriculum at all so there wasn’t any way for me to be teaching the designs and methodologies that we’re working with in the studio.” Francis visited Ravensbourne earlier this year to give students the opportunity to work on the New Skins: Deus ex Machina project. The 10-day workshop focused on learning the tools and theory of

Continued on page 53

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3D TECHNOLOGY IN EDUCATION Francis Bitonti

Although the technology and the teaching is getting there, Francis, like Jon, believes that there still needs to be more of an awareness about what 3D printing actually is. On a large scale, 3D printing is still in its infancy and Francis is optimistic that gradually, the fashion world will catch up. “I think there’s probably a lot of people out there, especially in the fashion industry that don’t know what it is,” said Francis. “I’ve had a lot of people ask me ‘do you need 3d glasses to see it?’ There’s not a lot of awareness yet. It’s still a new technology and it’s gotten so much press and media attention that people forget how new it is.”

“It’s very frustrating for them in the beginning but in that frustration is where you find the creativity and your own way of working with it.”

computation design processes for fashion design. “It’s very frustrating for them in the beginning but in that frustration is where you find the creativity and your own way of working with it,” says Francis. “It starts with them modelling not a dress but an actual little component – it’s a completely opposite way of thinking, they think from the component up to the form.”

The future looks to be filled with jobs in the 3D printing market. From designers to manufacturers, it is set to change the supply chain and completely alter the way we work. As more colleges get involved and when schools inevitably decide to put that 3D printer in the corner of the classroom, making it an integral part of the curriculum, educators will have the opportunity to better equip the next generation of workers and innovators with the skills of the future. Francis adds: “I know we’ll get there but there’s still a lot of evolution that has to take place.” i| www.ravensbourne.ac.uk i| www.francisbitonti.com i| www.modla.co.uk

The work in universities has evolved significantly since the advent of 3D printing. It is no longer just a game for engineers and creative students have adapted to create pieces that may give us an insight into what the future holds for fashion and design. However, art schools have had to construct ways to introduce the technology just as any another creative material, be that clay or PLA. “We don’t spend time teaching interfaces or software,” says Francis. “We try to throw them into a project immediately – kind of like throwing them in to a pool – which I think for designers is much more effective because you’re not confronted with a set of rules or behaviours, you’re just given this empty pallet and given a way to navigate that.” These tool sets are not just teaching students how to design clothing, they are preparing them for a whole new language that has been brought about with 3D printing. It is not just about thinking of a solution for creating a dress but imagining a way of engaging with the world through a design that can be digested and manipulated by the user. “I’m always amazed at the curriculums,” explains Francis. “We live in a time where I don’t really think you can participate in culture if you can’t code or if you can’t really work digitally. I don’t understand why so many fashion schools have not adopted the technology yet – it’s the way everything works now. I think computer programing might not seem like a skill a fashion designer needs but I think just to be part of the world now you have to have that foundation.” September 2014

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FUTURE OF THE BUREAU MARKET

IS HOME TAPING

KILLING MUSIC? WORDS | Laura Griffiths Every new technology development is met with fears of obsolescence for all that has gone before it. The printing press killed storytelling. Video killed the radio star. Except, of course, they didn’t. So what of the rumours that increasingly accessible 3D printing will banish the draftsman, the model maker and the service bureaux to the scrap heap? Laura Griffiths asks those in the know.

Aleksandrina Rizova 3D Printed Table Legs (3DPrintUK)

‘Bureau’. It appears to be a bit of a negative word in the 3D printing lexicon and companies that reside under the umbrella of ‘print service providers’ tend to avoid attaching themselves to it. Yet for some time, bureaux and additive manufacturing services have bridged the gap between casual consumers and advanced 3D printing technology, providing facilities to customers who otherwise would not have access to the technology first hand.

However, that gap is gradually getting filled as businesses and individuals begin to try their hand at 3D printing solo. So where does that leave the bureaux, the folks that brought it to them in the first place? We spoke to some of the biggest 3D printing and additive manufacturing service providers in the UK to find out what their take on the future of the 3D printing industry looks like. General consensus? Some very confident bureaux and not a thing to worry about. “Business is good,” says Dave Bennett Director at 3D Creation Lab. “We work with small businesses to names like Ford. 95% of our business is for product design, verification models – that’s what we do. We give out between 50 to 100 quotes a day and produce about £10,000 of orders a week.” The scale of 3D printing services ranges from novelty products from as little as £2 to fully functioning end-parts manufactured for huge international companies. With talk of 3D printing being at an exciting high and everyone, so it seems, wanting a piece of the coloured PLA hype, it would be fair to assume that businesses are thriving off the recent public interest.

3D printed parts for quad copter at TCT Show (3DPrintUK)

“There has been an increase in interest but I wouldn’t say it’s in any form of use,” explains Dave. “The current interest is all media hype.” It is a fair point and a fellow bureau that echoes this sentiment is 3D Print UK, who after a successful year with 600% growth, claim the media hype holds limited traction for their business. “I think the hype around 3D printing is all based on the people who enjoy the hype and the people who enjoy 3D printing,” says Nick Allen, Founder of 3D Print UK. “The people who are getting very carried away are the people who like to fantasise and that’s probably only about 10% of the world, the other 90% don’t really care how things are made.” Yet interest has increased over the last few years and 3D printing at home has become more of a reality. Budget machines appear on crowd funding sites every week offering hobbyists the opportunity to get their hands on printers at a fraction of the original cost allowing people to create things that only a few years ago seemed impossible to do from the comfort of their own desk. Continued on page 57

September 2014

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FUTURE OF THE BUREAU MARKET

3D printer manufacturing giants 3D Systems famously remarked that in ten years time, they predict 3D printers will be in not just every household but in every room. We will soon trade a trip to the shops for downloading all of our products to a hard drive, making supply chains a thing of the past. Yet we know there are limitations to what we can currently do with 3D printing.

“It’s like saying “here’s a paintbrush set, why don’t you go and paint all of the art for your walls?”

It’s an interesting point and thankfully for “Usually people 3D print service providers, at the moment will have read looks to be true. The service providers are something in the “What we’re confident that ‘service’ is the key word that paper and then makes them the ideal option for people finding is that come up with a seeking 3D printed products. very unrealistic they have idea but it’s not Amalgam is another company that fairly quickly their fault its strongly believes in the quality of service what has been started to and with origins in traditional model said,” says Nick. making they have a rich history of realise the “We’re always Objet bottle with vacuum designing and prototyping for various getting these Daft limitations of cast lids (Amalgam) industries. Punk and Iron a 1000 “Amalgam takes pride in being different,” Man mask machine…” says Mike Harvey, Director at the company. “Where others provide requests very day. Then the cost comes a service, Amalgam engages with each individual clients projects, back and it’s going to be anything from working with — not for — our client to ensure that the end result is £500 to £1000 and actually that’s pretty the best that our joint efforts can achieve. good value for what they’re requesting. What they’re comparing it to is an off-the-shelf form when realty what we’re providing is a one“We are not the cheapest, or the quickest – and certainly not the off bespoke manufactured item.” most automated, but we always aim to offer the best value for Without better equipping the public with appropriate knowledge about what the technology can currently achieve, it is hardly a surprise to know that the public have been sold on the idea that it is a simple click and print process. “We have seen a massive wave of second hand consumer 3D printers coming out after Christmas when people find out it’s not just click and print,” says Nick. “Because you have the opportunity it doesn’t mean you will use it.” This sentiment rings true throughout additive manufacturing services. There is the firm belief that just because the technology is there it does not mean that people are going to go ahead and start producing products at home whether that be because they do not have the right knowledge or simply do not have that desire.

money, the best level of service and the highest possible overall results. After thirty years in the business we feel we are justified in thinking we are pretty hard to beat!” Consumer 3D printing is predicted to be widespread in our homes within the next 10 years. That seems a fair while away for huge 3D print providers to be concerned about the impact right now. For now the bureaux are confident that they will stay ahead of the curve even when consumer 3D printing is readily available for just a few hundred Pounds. High end processes like SLS, which 3D Creation Lab says “sets our business aside more than anything,” will keep customers seeking external services.

Continued on page 59

“It’s like saying “here’s a paintbrush set, why don’t you go and paint all of the art for your walls?”,” says Nick. “Well I would rather buy the art for my walls because the people who did the art are better.”

UTC Swindon (Amalgam)

September 2014

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Rapid Prototypes Artworks Scale Models CMA Moldform specialises in the development and manufacture of high quality rapid prototypes, optical art moulding and fine scale models. With wide experience in reverse engineering fitems and low volume production runs from 1 to 1001, CMA’s client base ranges from automotive, marine, medical, electronic and aerospace industries, to music, film & arts, and engineering sectors. Using a wide range of rigid and semi-rigid resins, flexible, “water-clear”, high impact and high temperature resistant resins, including self coloured resins, we can produce dimensionally accurate mouldings and castings from a few grams up to many kilos in weight. Production expertise includes: • 3D Scanning • SLA, SLS, CNC • Vacuum casting • RIM moulding • Pressure casting • Centrifugal casting • Reverse Engineering • Rotocasting • Low volume production • Assemblies • Component finishing

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CMA Moldform Limited Unit 17, Spitfire Road, Spitfire Park, Birmingham B24 9PR, United Kingdom

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FUTURE OF THE BUREAU MARKET

“We’re always getting these Daft Punk and Iron Man mask requests very day. Then the cost comes back and it’s going to be anything from 500 to 1000 and actually that’s pretty good value for what they’re requesting”

Prototyping SLS Medical (ARRK)

ARRK ELS New materials

“We are already 300 times the price of Shapeways,” explains Dave. “If people want a cheap option, they just have to use one of Shapeways or Imakr’s quote services and find it. It is a service. We don’t pool orders, every enquiry is priced and handled individually.” Craig Vickers, European RP Operations Director at ARRK, has a different approach to the situation. As with any business, if service providers are going to continue to thrive in the industry then they will have to be prepared to keep a close watch on trends within the market and evolve with it. ARRK claim they are ready to adapt and evolve by continuing to look into new processes and applications. “It is important for us to be very aware and know when it’s time for us to dive in,” explains Craig. “We keep an eye on them all of the time. It is our job to keep an eye on them so we know when it’s time to invest and will selectively invest when it suits our business.” For now, the domestic market is not such a concern for major service providers but there is another wave of interest from various businesses investing in their own 3D printing equipment meaning they can develop their own prototypes and eliminate the need to outsource. In order to do this successfully, businesses need to be able to carry out the whole process from 3D software to selecting the right hardware and materials. 3D Creation Lab reckons that most companies they deal with who have attempted the process themselves have actually reverted to coming back to them because they are not getting the same results. However, even success stories for a number of those small business have had a positive impact on 3D print services that can turn their prototypes into fully functioning parts with added value services. “If anything rather than detracting from or affecting our business negatively, its having an opposite effect,” says Craig. “What we’re finding is that they have fairly quickly started to realise the limitations of a £1000 machine for instance. So they find the prototype they have isn’t quite capable of giving them what they would really like it to do but they still have the hunger. Now they know that they would benefit from a prototype like that they come to us.”

The standard of desktop and consumer machines is improving massively as is the understanding that is essential to the progression of the technology. Yet the service providers are not so sure the understanding is quite there yet. 3D Creation Lab says that the hype is not a fair representation of what people actually know with even large international companies failing to research the technology properly. Without this, they reckon it will be difficult for the technology to progress. “Big names are looking into it but they don’t fully understand it,” says Dave. “When you can’t explain to big companies that there hasn’t actually been a 3D printed gun, it’s all a made up thing, it’s difficult.” Only time will tell if 3D printing will take of in the way it is supposed to. It’s predicted that medical applications will come first as well as other major industries before it impacts the home market and by that time the quality will have magnified. But has it reached a point where companies are now thinking they need a plan? “There isn’t one — so confident are we!’ says Dave. “Desktop printers are getting better and better but they will get more expensive and people will question if they need one. We’re not worried.” Craig adds: “Our plans for 2015 are significant. We have planned very significant growth within the UK and mainland Europe. That will involve investment as well as development in terms of materials, technologies and processes. There will be a lot to talk about in 2015, I have no doubt.” September 2014

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KORA

Launching a 3D printer without crowdfunding?

WORDS | Jim Woodcock New 3D printers pop up on crowdfunding sites such as Indiegogo and Kickstarter with alarming regularity at the moment. Some go the distance and deliver; others are vapourware that will never see the light of day. It may appear that this funding model is the only way to launch a new printer these days, but UK-base Kora have other ideas. And the new thinking doesn’t stop there…

f your interest has ever been piqued by a 3D printer launch, to the point that you actually start to do research with a view to making a purchase, you will likely have encountered the somewhat nebulous nature of many of the ‘companies’ behind them. All to often a slick website and some nifty renders are complemented by an info@ email address and little else. Want to call? No chance. Want to pop in to a physical address? There may not even be one. So it was pleasantly reassuring to be invited to a physical, UK address to see a pre-launch desktop 3D printer in the flesh. No renders, no crowdfunding, no vague shipping dates. Just a real, working printer in a real, established company. The company is Kora, part of a larger group of firms that are already renowned OE supplier to some of the largest luxury carmakers. The expertise in complex electronics, tight regulation and ultimate quality bodes well for the latest venture. Having been exposed to 3D printing through the other aspects of the business, MD Steve Burrows and Product Development Director John Hicken decided to establish Kora in 2013 to deploy the group’s considerable expertise in fixing some of the perceived problems with existing 3D printers. The result is the Alpha, the first — but, Steve assured, not the last — 3D printer to be developed at the Leeds HQ. The Alpha Standing at 470 mm high with a 400 mm by 420 mm footprint the Alpha packs an impressive 230 mm x 230 mm x 250 mm build volume for a moderate use of desktop real estate. On first sight there is little to distinguish the system from one of the dozens of other similar sized, similar shaped 3D printer — but the devil as always is the details.

For starters, the filament feed motor is located on the side of the machine, rather than on the top of the extruder a detail that at first seems a little incongruous. While it de-clutters the action-end of the printer, the reason isn’t entirely clear until one learns about the extruder swap-out system Kora has developed. Dubbed VariBLOCK, it allows users to quickly and easily swap out the hot end, greatly increasing the scope for materials — not to mention making servicing, upgrading and repairs much easier for less technical users. A lot of work has gone into ensuring that the printer is lowmaintenance and, to bastardise the old Formula 1 adage, if it looks simple it probably is. Gone are the bulky wiring looms to be replaced with PCB’s with integrated LED lighting running neatly up the back of the printer away from danger. The same can be said for the heated bed that has been developed to heat up quickly and evenly across the whole of the available build area while retaining an uncluttered look. In operation the quality of the components and assembly is evident through the quiet, wobble-free printing — this is a system that could sit at the end of your desk and be used without driving you and your colleagues to distraction. Back your products The quality is also backed up by an unprecedented 12-month warranty whereby the company will send you a replacement printer first and rectify any issues later. No back-to-base replacements here (especially annoying when you realise that ‘base’ is somehow an address in the Philippines and you’re based in Boston.) Steve Burrows explained: “If you’re confident in the quality of your components and engineering there’s no reason not to offer a comprehensive warranty. Although complex, the technologies that underpin extrusion-based 3D printing are well-proven and shouldn’t pose any problems. Our experience as OE supplier into some of the most demanding companies means we’re willing to put our reputation behind the quality of the Alpha.” Beyond the base specification there are a number of exciting options up for grabs including Wi-Fi connectivity, on-board webcam, dual extruder upgrade and — with the education sector in mind — a fully enclosed version with an automatic locking mechanism that seals the unit above 40°C. i| www.kora.co.uk

SPEC ROUNDUP: • • • • • • •

Nozzle temperature range: 160 – 300°C Layer resolution: 20 microns (0.02mm) to 400 microns (0.4mm) Position precision: X: 12.5 microns (0.125mm), Y: 12.5 microns (0.125mm), Z: 5 microns (0.005mm) Print speed: 30mm per second – 300mm per second Travel speed: 30mm per second – 350mm per second Filament diameter: 1.75mm Nozzle diameter: Standard 0.4mm (available 0.25, 0.3, 0.35, 0.6mm, 0.8mm)

September 2014

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ORGANIC 3D Design WACOM

WORDS | Laura Griffiths

Whatever you’re making, the chances are you will need a digital-physical workflow — and that’s not always the most intuitive route. Especially when it comes to bringing those first digital ideas to life. Could touchscreen technology deliver a solution? Striving to make the world a more creative place is quite an admirable ambition. Wacom, the world’s leading manufacturer of pen tablets, interactive pen displays and digital interface solutions, are set on achieving just that with a collection of creative hardware geared to make it easier for this generation of makers to get creative in a digital environment.

for an exhibition. Inspired by urban artwork like graffiti, Flatau was able to maintain his creative and mobile work style, which takes him from his studio in Munich and out into the snowcapped mountains. “Wacom tools can help bring creativity to life, making it easier and more intuitive to work on 3D models,” says Möller. “This is because it is so close to the “traditional” workflow and much more ergonomic than any other input device. Our tools are not limited to professionals. The Cintiq Companion is capable enough to support a mobile, intuitive creative workflow. We’ve had feedback from automotive designers saying that the Companion has changed the way they work, not only when it comes to mobility and travel.”

For anyone who has experienced touchscreen technology in the last Wacom specialises in developing platforms for digital innovation 20 years, be that interactive displays or tablets, you will recognise they from tablets to stylus’ that can be used on a broad range of devices for have come a long way from being the victims of accidental brushes professionals and doodlers alike. Perhaps one of the most exciting of whiteboard marker pens and non-responsive list makers. For over elements of Wacom’s products such as the Cintiq Companion is the 30 years, Wacom has been dedicated to developing breadth of opportunity 3D model designers. the most accurate interface solutions and devices “3D still has for creative individuals and organisations working Beyond professional massive in digital media. “3D still has massive potential, especially in the non-

potential, professional markets,” claims Möller. “With the prices “With our pen and touch tablets, we are offering of 3D printers going down making 3D printing especially in the tools that work in a very natural, intuitive and affordable and community sites like Thingiverse, this ergonomic way with a PC or MAC. A lot of non-professional market reaches the enthusiasts and hobbyist. As professional applications in the 3D creative space markets.” above, now there´s 3D creation software mentioned support Wacom tools including the pen pressure available, which is more affordable or even free (like Blender, sensitivity and pressure sensitive eraser etc.,” explains, Guido Möller, Autodesk 123 or Sculptris) Wacom is committed to providing Business Solutions Consultant at Wacom. “With our Cintiq intuitive tools at affordable prices as well.” Interactive Pen Display and Cintiq Companion Creative Tablet Computer, the creative artist can work directly on the screen, which This equipment can be used with sophisticated design software giving helps hand-eye coordination. Working with a Cintiq and applications users the freedom to create and manipulate designs with the highest like ZBrush, MODO or Mudbox means the user can sculpt and model level of precision. With Photoshop CC now offering full 3D support, and it’s almost like working on a real piece of clay.” designers can utilise the Wacom pen, pressure sensitive features in Wacom has played a significant role in making technology accessible on a universal scale in a natural and intuitive way. Creation on the go is becoming more of a possibility and sometimes a necessity for the professional designer, therefore Wacom’s products are focused on creating a flexible workflow so designs that may have started on a tablet, can be finished on a pc. Bring creativity to life Munich based artist and designer, Florian Flatau also known as the THESIGNER, recently utilised the Wacom Cintiq Companion to create designs for “FRGMNTZ”, a 12 day project in which the designer sketched and produced 3D printed and laser cut wood parts

the software. “I think it is safe to say that Wacom knows this market very well,” adds Möller. “We always strive to make our products better, more ergonomic, more intuitive. With 3D design becoming more important, it might also be possible to optimise our existing tools for 3D software or even come up with some interesting new devices. Wacom is also closely connected to the leading software manufactures to ensure that we have right tools for new features or have software support when launching new devices.” i| www.wacom.com September 2014

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ERA STEEL

Entering a new ERA: CUSTOMISED METAL POWDERS FOR AM

The interest surrounding metals AM has, in part, been driven by the investment community who, new to the industry are making a lot of noise about the possibilities. More quietly the development of metals AM processes has continued unabated since the early 2000s, recently companies like EOS, SLM Solutions, Concept Laser and Renishaw have been making great strides towards true production-ready technology. As ever, one of the bottlenecks is with materials — so the increase in interest from third party materials developers can only be welcomed.

ne such developer is France-based Erasteel, a major player in the high-speed steels market for tooling applications where tolerance to high temperatures and wear resistance are paramount, who also offer a unique portfolio of metal powders, for the manufacturing of complex net shape parts by processes such as AM, hot isostatic pressing and metal injection moulding. The company — which is a member of the Eramet mining and metallurgy group— has eight powder atomisation units located in Sweden, France and Spain, and is the world leading producer of spherical gas atomised powders. For additive manufacturing, Erasteel offer the range of Pearl Micro metal powders that include in particular: - Superalloys (nickel-base or cobalt-base)

Pearl mirco metal powders for additive manufacturing

- Special steels, including stainless steels - Other non-ferrous alloys such as copper or silver alloys. Erasteel VIM gas atomization process Vacuum chamber Induction furnace

Tundish gas jets

Atomization chamber

Powder collection

For the additive manufacturing market, Erasteel uses the VIM (vacuum induction melting) gas atomization process, where the metal is first molten in a vacuum chamber and then atomized in fine droplets by Nitrogen or Argon gas jets. The droplets spheroidise and cool down during their fall in the atomisation tower and they are collected at the bottom of the tower. The gas atomization process helps to ensure that the metal powders have a perfectly spherical shape which is required to ensure good powder flowability and spreadability in additive manufacturing machines. Erasteel’s VIM gas atomisation process also helps in reducing oxygen content, in the case of superalloys or alloys with reactive elements, and it ensures a higher powder cleanliness.

Pearl Micro powders are sieved and processed according to customer specification, so as to be used in the various types of additive manufacturing equipment such as selective laser melting (SLM), electron beam melting (EBM) or laser metal deposition (LMD). For AM applications Erasteel offers both standard and customised chemical compositions and particle size distribution, according to

users’ specifications. Markets include aerospace, energy (oil and gas, land turbines, nuclear etc.), automotive industry, as well as tooling applications. Batch sizes are suitable for Research & Development and serial production. Adeline Riou, Erasteel’s Powder Sales and Marketing Manager explained: “Erasteel has seen tremendous growth of the interest for metal-based additive manufacturing technologies over the last two years and we are working with end users to optimise metal powders for each application. Besides this, I personally strongly support the collective efforts from the European Powder Metallurgy Association (www.epma.com), where Erasteel has initiated the launch of a new working group named EAMG (European Additive Manufacturing Group), to help develop information exchanges, education and standardisation in metal-based additive manufacturing at European level, which are important to support the current shift from prototyping to series production.” i| www.erasteel.com

Standard Pearl Micro and customized chemical compositions powders: n Nickel-base and cobalt base superalloys: Ni 718, Ni 625, Hastelloy X, pure Ni etc. n Stainless steels: 316L, 17-4PH, 420, etc. and other steels n Copper-base alloys and customized metal powders containing Ag, Au, B, Be, Cu,Ga, Ge, Hf, Nb, Pt, Si, Sn, Y, Zn, Zr, etc. September 2014

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MAKERBOT

END

OF AN

ERA?

Though it may only seem like yesterday, half-a-decade ago this machine appeared out of a hackerspace in New York that shook up an entire industry. The man mainly responsible for that shaking is to step down from the day-to-day running as CEO of MakerBot. i| www.makerbot.com

Beard-free Bre and the Replicator 2 — the printer that signalled a shift in direction for the Brooklyn brand

‘S

tepping down’ may not be the correct term for Bre’s move away from the nitty-gritty of MakerBot, he is moving up to board level at MakerBot’s parent company Stratasys to head up a new venture, mysteriously called the “Innovation Lab”. Into Bre’s considerable shoes steps MakerBot President Jenny Lawton as new CEO. Bre was the only surviving member of the MakerBot trio that exploded out of NYC hackerspace Resistor with the MakerBot Cupcake, an FDM 3D printer for your desktop that worked. Sure it was a little rough around the edges; it had to be assembled and achieving the right results was more miss than hit but this was really the start of the first home 3D printing brand. Fab@Home and RepRap were doing similar things but with a more research-based focus, Bre Pettis knew that this Cupcake — named such because it could only build things the size of cupcakes — was the start of a brand that could be sold on for a nine-figure sum and they set the corporate tone with the name MakerBot Industries.

Some months before MakerBot Industries started trading, Bre was part of the team that set-up Thingiverse, the repository that would go on to establish MakerBot as the most notable brand in consumer 3D printing. MakerBot were the first 3D printer at International CES appearing at the IT/Wireless/Imaging zone in 2010. MakerBot’s pioneering led to a whole TCT-sponsored 3D Printing TechZone just four years later. Bre’s time at MakerBot has not been without its controversies, a falling out with fellow co-founder Zac Smith led to the latter leaving the company in 2012, his and the board’s decision to move the machine from open to closed-source for the Replicator 2 model saw an outcry in the very community the brand spawned to serve. The decision to sell to Stratasys last year was also criticised by some of that community but the cold-hard facts show that those difficult decisions, at least in the business sense, paid off. In the space of a single presedential term MakerBot has grown from one model made in a lockup in Brooklyn by three guys to five models and a scanner manufactured in a 55,000 square-foot facility, employing an excess of 400 people. One thing that can never be denied about Bre’s term as CEO of MakerBot is that it grew from nothing to, perhaps, the most recognisable brand in 3D printing today. His current role will still allow for Bre to sign off on important MakerBot decisions and under the stewardship of Jenny Lawton we’re sure MakerBot will continue its meteoric rise. September 2014

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PRECISION CASTING

PRECISION CASTING APPLICATIONS FOR

industrial product design

3D printed aneurysm model aids surgeons

3D printing has not only changed the way companies bring products to market, but it’s transforming the methods in which designers are able to bring their concepts to life. By using 3D printing, companies can create small batches of designs that are then tested and adjusted quickly. Not only does this make the entire production process more efficient, it also opens up a whole new realm of possibilities for designers.

aking that a step further, Solidscape offers designers microprecision 3D printing that — because of the accuracy and smooth surface finish — is 100% castable. The casting properties paired with improved material strength has allowed designers to incorporate even more intricate details, with thinner walls and lighter weight finished products. For example, Horbach GmbH, one of Europe’s premier casting services, put Solidscape’s precision printing to the test when they needed to create a finished silver object consisting of five nested, moveable spheres. With a wall thickness of 7 mm per sphere and distance between spheres measured at 5 mm, Horbach GmbH had to have the most accurate printing possible.

Horbach’s sliver piece is one of many examples where precision printing enables designers to cast and meet production demands in new ways. Solidscape is also working with ultra-model makers in automotive, trains and with fantasy figurines. Another industry that heavily leans on precision parts with precise finishes are medical device companies, such as the California Medical Company that manufactures vertebral body replacement implants. These titanium spinal implants were impossible for other pattern making technologies due to their complex lattice design. But with micro-precision printing and Solidscape’s proprietary build material, the California Medical Company was able to produce models with superior surface finishes, eliminating the need to hand finish the unreachable areas inside the lattice design. Additionally, the dissolvable support material helped to further speed up the process, resulting in a flawless titanium casted implant. Solidscape recently announced, the fully automated Solidscape MAX2 providing an easy-to-operate touch screen for any skill level to effectively produce high-precision wax patterns.

i| www.solid-scape.com

“We have cast from aluminum, brass, bronze, nickel and precious metals from the wax cores, all with excellent surface finish and accuracy,” states Christian Müller, CEO of Horbach GmbH. “We believe that the quality of the parts is now the best in the world. Successfully casting this is object was only possible with Solidscape.”

LEFT: Precision cast nested spheres RIGHT: Titanium vetebral implants

September 2014

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60 SECOND INTERVIEWS

60-second KEYNOTE INTERVIEWS For the second year running the TCT Show Keynotes represent a hand-picked selection of some of the most influential executives from the world of AM and 3D printing. Professional, consumer, prosumer, service, software, machines, applications — they’re all covered over three exhilarating opening sessions. DW opens the show

ay one sees Dr. Hans J. Langer and Wifried Vancraen — CEOs at EOS and Materialise respectively — take us through their businesses, their motivations and their dreams for the technology and the industry built around it. Both speakers are undisputed pioneers and have built up two of the most significant companies in the space over the last 25 years. Equally, both are seldom seen on stage so this is truly an unprecedented opportunity. The second day of the conference is opened by the inimitable Bre Pettis, CEO, and Jenny Lawton, President of MakerBot Industries. MakerBot’s meteoric rise from unknown to sector leader in less than a decade is one of the biggest stories in 3D printing. Bre and Jenny will lead us through the highs and lows of life at the heart of the 3D printing storm. The third and final day of the conference will be opened by Andy Christensen, now of 3D Systems and formally President of Medical Modelling Inc., a trailblazing organisation in the field of 3D printing in medicine. Andy holds an unparalleled level of expertise in 3D technologies for medical problem solving. The following pages contain a 60-second Q&A with the Keynotes, representing a sneak-peak into the minds of these ‘captains of industry’. Whether you’re coming to this before or after the talks have been made you’re sure to find something of interest. And lest we forget, all of the sessions from the Main Stage at TCT Show + Personalize are recorded and published on www.tctshow.com — so you can catch up with this essential viewing at any time. Continued on page 73

The empty arena the night before the event. Looks more like Wembley from the stage.

September 2014

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Q&A

TCT: It’s the September in the year 2024: What’s on the front cover of TCT magazine? DR HJL: AM is a standard and established manufacturing technology Digital factories worldwide are equipped with AM technology.

TCT: How has the increased coverage of 3D printing in the mainstream media affected your business / business model? DR HJL: In general, the broad mainstream media coverage of 3D printing has helped to increase general awareness for Additive Manufacturing solutions such as the one offered by EOS. On the other hand it also leads to inflated expectations on what these technologies can already deliver today as often they do not distinguish between consumer and industrial 3D Printing. As such, in the near future we won’t see it to happen that medical implants e.g. are being manufactured on home printers.

TCT: How can 3D printing have positive impact sustainable living models? DR HJL: Let’s take patient care based on additively manufactured implants as an example. Demographics show that people are getting older which makes the need for perfect patient care rise too. Ideally, implants must be tailor-fitted to every patient’s body. They should be quickly tolerated by the human body so that they can bring about a long-term improvement in the patient’s quality of life. Standardized and often too heavy implants are inadequate here. But additively manufactured implants can deliver exactly this: they are patient specific and lightweight and can be made available fast. EOS AM also ensures that production costs remain economically viable, even for highly individualized products. Compared to conventional implant production methods, EOS AM offers multiple benefits. Based on 3D CAD data, patient-specific parts can be generated without using tools, using high-quality, medically-compatible materials. Lattice structures can help to accelerate post-operative healing significantly. In addition, a definable degree of surface roughness helps bones and implants fuse better. Improved implant fit also makes the surgeon’s job easier. Implant manufacturers are able to optimize 3D CAD data-based models quickly and benefit from maximum flexibility. As a result, the use of AM optimizes patient treatment, shortens hospital stays and minimizes unpleasant side effects.

60 SECONDS - DR HANS J LANGER

60 Seconds DR HANS J LANGER

TCT: What is the most important current challenge for 3D printing and why? DR HJL: We can certainly only talk for EOS. Our biggest challenges today are a combination of a comparatively low knowledge of what the technology can deliver and inflated expectations on the other hand. Additive Manufacturing (AM) will always be compared with established conventional manufacturing technologies that have been in use for a long period of time and as such are perceived as a trusted source. A lot of people we talk to still have a comparatively low knowledge of what the EOS technology can deliver and where it can add value to their customer value chain. We have to build up trust first. In addition, an industrial 3D printing technology like EOS is offering it, is not a plug’n play technology. Instead, it needs substantial training to achieve high quality parts which can then prove that the AM technology is definitely a valid choice, certainly depending on application. TCT: What are you looking forward to seeing at this years’ TCT Show + Personalize? DR HJL: • More AM-based applications • More variety of AM products and solutions • More new businesses that are being established based on AM

September 2014

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

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60 SECONDS - WILFRIED VANCRAEN

60 Seconds WILFRIED VANCRAEN TCT: It’s the September in the year 2024: What’s on the front cover of TCT magazine? WV: In September of 2024, you are likely to see the picture of a 3D printer machine part in Africa on the cover of TCT. It is not unheard of for developing countries to skip an entire stage of technological development. The best example of this being the fact that most if not all African countries will never see land line phone networks set up, going straight to mobile networks instead. I believe that the same could happen with manufacturing in Africa, with many skipping over technologies for mass production and exploring instead the benefits of AM. This could have the same drastic effect on their economies and standards of living as the introduction of the mobile phones has already had, especially when AM is put to use in the design and manufacturing of medical devices. TCT: How has the increased coverage of 3D printing in the mainstream media affected your business / business model? WV: Although the increased coverage of 3D Printing has been very positive in terms of raising awareness about the technology, it has not had too much effect on how we create our business models. The business models we have been developing are a result of long term strategy to find applications that can most benefit from AM technology and to develop the software and systems needed to make those applications printable. We approach this scientifically and with a strong focus on quality. Where we do see the increased coverage coming into effect though is in the general knowledge of the public about AM and an increased willingness to explore what it has to offer. This in turn increases the size of the market for the applications we develop.

Q&A

TCT: How can 3D printing have positive impact sustainable living models? WV: Not only will 3D Printing have a positive impact on sustainable living models, but in fact, 3D Printing will not be successful if it fails to do so. I strongly believe that 3D Printing will only thrive if it is use to create applications that have a positive impact on our world – whether this is through waste reduction, lightweight designs, more organic and intelligent designs, personalized healthcare, or many of the other applications we at Materialise have long been committed to realizing. In fact, from the very first day of Materialise almost 25 years ago, our mission has been to innovate product development resulting in a better and healthier world for this very reason. TCT: What is the most important current challenge for 3D printing and why? WV: One of the most important current challenges for 3D Printing is the hype surrounding it. While the market for 3D Printing is huge and transformative, and deserves to be hyped, the hype creates the feeling that everything will happen quickly and easily. The fact is that progress in this industry requires a huge amount of effort as well as a serious and sustained investment. TCT: What are you looking forward to seeing at this years’ TCT Show + Personalize? WV: During this years’ TCT Show + Personalize, I am looking forward to seeing companies who have realistic ambitions and who are ready to change components in their products using new systems that have been developed for AM. September 2014

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TCT Sept 22-5_Layout 1 26/09/2014 12:57 Page 77

60 SECOND INTERVIEW JENNY LAWTON

Q&A

60 Seconds JENNY LAWTON

TCT: It’s the September in the year 2024: What’s on the front cover of TCT magazine? JL: MakerBot’s ruggedized 3D printer on Mars shuttle used to fix critical failures and saves all on board. TCT: How has the increased coverage of 3D printing in the mainstream media affected your business / business model? JL: We spend less time explaining what 3D printing is and more time talking about what it means to a specific person. How 3D printing can be your iterative design process as real-time prototyping and how we create accessibility through the MakerBot 3D Ecosystem. TCT: How can 3D printing have positive impact sustainable living models? JL: We us PLA - which is an organic material. 3D printing can be used to make a part to make a part ... The iteration can be virtuous and the end result a part of a full-cycle continuum.

TCT: What is the most important current challenge for 3D printing and why? JL: Educating people that no matter how simple we want it to be 3D printing is still a patient, complex and iterative process. TCT: What are you looking forward to seeing at this years’ TCT Show + Personalize? JL: I always love to see other technologies and work and the innovative solutions people use tools to solve problem. Innovation is inspiring.

September 2014

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Q&A

60 SECONDS - ANDY CHRISTENSEN

60 Seconds ANDY CHRISTENSEN TCT: It’s the September in the year 2024: What’s on the front cover of TCT magazine? AMC: TCT’s 2024 cover shows 3D printed composite implants of varying materials and living, 3D printed tissues. 3D printing-centric technologies have made a huge impact in medicine, in 2024 it’s a bit of a look back on key applications making a difference in millions of patient’s lives. TCT: How has the increased coverage of 3D printing in the mainstream media affected your business / business model? AMC: Interestingly we’ve seen large medical device OEM’s have a mandate from the top-down to find a way to incorporate 3D printing into their product offering. C-level executives are getting the message from mainstream media, consultants and colleagues and they are pushing that others in their organization find a place for it. This interest leads to investigation in earnest of how 3D printing fits and is leading to technology adoption. TCT: How can 3D printing have positive impact sustainable living models? AMC: There is a lot of inefficiency in the medical device industry which comes by way of excess inventory. For every single knee or hip surgery the hospital must stock (and the medical device OEM must place on loan) a very large array of instruments and implants. Imagine a day ahead where the supplies for a patient’s surgery are 3D printed the day before surgery either at the hospital. The kit of implants and instruments would be personalized to the patient, the surgeon, and the hospital’s needs.

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TCT: What is the most important current challenge for 3D printing and why? AMC: Materials are improving all the time, throughput of 3D printing processes are improving all the time; these aren’t the biggest challenges for 3D printing. I believe the biggest challenge comes from a lack of knowledge in the “design for additive manufacturing” area, taking advantage of the complexity offered by AM. Looking at an application area of total joint replacement for knees or hips these implants are typically over-engineered to limit failure. Many times the 15-20 year lifespan of a total joint replacement is cut short by the adjacent bone’s reaction to the mis-match of bone and metallic biomaterials, leading to implant loosening and failure. Some of these issues could be solved by better engineering and a better way to manufacture these optimized implants using 3D printing. TCT: What are you looking forward to seeing at this years’ TCT Show + Personalize? FW: TCT has gained a reputation as a place to see a lot of what’s new and how people are using 3D printing-centric technology. I’m looking forward to meeting up with old friends and hearing from the group for where they think things are going next.

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September 2014

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September 2014

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GRIMM COLUMN

About the Author Todd Grimm is a stalwart of the additive manufacturing industry, having held positions across sales and marketing in some of the industries biggest names. Todd is currently the AM Industry Advisor with the AMUG. You can contact him on tgrimm@tagrimm.com

Get Excited about the Mundane

Concentrating on making a big breakthrough can take your eye away from an incremental improvement that elicits real benefit for your organisation, explains Todd Grimm.

undane, tedious, dull, ordinary, routine and commonplace… when it comes to 3D printing, we rarely hear tales of success where these adjectives are fitting. Exciting, amazing and inspiring stories have the impact that makes them news- and conversation-worthy. Printing cars, houses, aircraft engines, satellites and implants: those successes have the sizzle that draws attention. I find them fun to read, interesting to discuss and thought provoking, which can be a catalyst for big dreams and long-term goals. Yet, for most of us, these are somewhat exotic, exceptional and beyond our reach. Further distancing the applications from our reality, these stories often have recognizable, big-corporate names behind them. These big-budget, bigrisk, big-reward 3D printing inspirations may not be viable options for smaller organisations with immediate needs.

WORDS | Todd Grimm

You can find tremendous success with 3D printing when tackling the ordinary and routine. While your successes won’t be front-page news, you can create significant rewards with minimal risk if walk before you run.

But you don’t need to feel compelled to tackle such grand projects through 3D printing. Equating these to a four-minute mile, it is perfectly suitable and just as rewarding to run a 10-second 100 metre sprint. Do the latter 15 times, and you’ve cover the same distance. You can find tremendous success with 3D printing when tackling the ordinary and routine. While your successes won’t be front-page news, you can create significant rewards with minimal risk if walk before you run. Product development and manufacturing can be improved by doing the more of mundane work with 3D printing. You can find mundane applications throughout the product lifecycle, from early concept models through series production and into end-of-life. You can find them in design departments, testing labs and production floors. The mundane are out there in the form of models, mockups, prototypes, shop tools, fixtures and hidden bits within a series-production product. The mundane also takes the form of small adjustments to work flows, procedures and daily practices that are enabled by 3D printing. You will know mundane applications by their lack of visibility. Unless you call attention to them, they can be invisible to those in your organization. From that obscurity flows the low-risk

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component of the small-reward value proposition. Trying and failing has little impact because you can recover quickly and try something else. But when you try and succeed, the rewards will come, and they can accumulate to become quite substantial. In product development, a mundane application may be the completion of three design iterations in the same time span of one conventionally made prototype. Each iteration adjusts the product a wee bit, but when combined they improve the design, performance or manufacturability. You may also have a big reward from these small-risk attempts if you reveal a hidden flaw that would otherwise have led to delays and cost overruns.

In manufacturing, my favorite mundane application is jigs, fixtures and related manufacturing aids, such as organisers, gauges and templates, for the production floor. Ask anyone in manufacturing if they could use more of these tools and the answer will be an emphatic “Yes.” 3D printing makes it easy and nearly effortless to make a fixture – some call it the path of least resistance – that will enable you to deploy many more of them. Within a day, and with little investment, you can be testing a new fixture. If it doesn’t work, you lost a small investment and a few hours of time. But if it does work, the benefit can be quite large, considering the impact on throughput and quality over tens of thousands or hundreds of thousands of units. But even with a large impact, the fixture blends into the environment and becomes transparent to all that pass by it. Boring and mundane? Absolutely. Beneficial? Without a doubt. I am not saying to stop innovating and pushing the envelope. That’s important, too. I’m just recommending that you don’t let the big stories and grand visions distract you from having many small wins along the way. It’s a practical and pragmatic approach that lets you create your future one small step at a time rather than relying on one big leap. Dream of manufacturing revolutions and plan for disruptions. But don’t overlook the things that you can do tomorrow that inch the needle forward. These mundane applications are something to get excited about.

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Introducing Renishaw’s PlusPac™ upgrade

at: See us 14 TCT 20 F22 , stand Hall 3A

PlusPac - cleaner, faster, easier The AM250 laser melting system is ideal for many applications. Existing customers can now benefit from the PlusPac upgrade package to meet the ever increasing demand for faster process rates and cleaner process environments. Renishaw’s PlusPac includes: • New Optical Control Software (OCS) • Gas knife lens window protection system • High capacity filtration system These systems give the user tighter control over the build process and ultimately result in better parts faster, saving you time and money. PlusPac is available as an upgrade option on new AM250 machines or as an on-site retrofit upgrade to most existing AM250 machines.

Find out more at www.renishaw.com/additive

Renishaw plc Whitebridge Way, Whitebridge Park, Stone, Staffs ST15 8LQ United Kingdom T +44 (0)1785 285000 F +44 (0)1785 285001 E additive@renishaw.com