3-D printing on way to becoming affordable
More and more companies are selling 3-D printers within the price range of consumers. Most machines several years ago cost tens of thousands and were sold primarily to architects and engineers. Cheaper commercial self-assembly kits now go for about $1,100.
By Alexis Krell
ELLEN M. BANNER / THE SEATTLE TIMES
Professor Mark Ganter, right, co-director of the University of Washington's Solheim Rapid Prototyping/Rapid tooling Manufacturing Lab, gets the computer ready as grad student Charlie Wyman watches. The two are standing in front of the 3D powder printer in Ganter's lab, where they are going to print a mold.
ELLEN M. BANNER / THE SEATTLE TIMES
These three pieces were made using 3D printing by University of Washington grad student Grant Marchelli.
3D Printing at UW
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University of Washington professor Mark Ganter sees the future, and it's printing apple pies.
And maybe vital organs, furniture and buildings.
Ganter experiments with using alternative materials to print three-dimensional objects, part of growing efforts to make 3-D printing more diverse and accessible to consumers.
The machines print layers of material to produce the models. Some printers add layers of powder and liquid binder, while others melt layer upon layer of plastic.
At the UW's Solheim Rapid Prototyping/Rapid Manufacturing Lab, which Ganter codirects, he's constantly asking students: "What did you make?"
The results have included, among other things, pineapples made out of mango iced-tea mix and miniature plaster replicas of Easter Island's colossal Moai statues,
Ganter estimates his team of "printistas," the term he's coined for professional 3-D printers, has worked with almost 50 different materials. He jokes that he'll stop when he's tried 1,000, and has talked about experimenting with mashed potatoes.
Ganter's lab is not alone in the changing landscape of 3-D printing.
More and more companies are selling 3-D printers within the price range of consumers. Most machines several years ago cost tens of thousands and were sold primarily to architects and engineers. Cheaper commercial self-assembly kits now go for about $1,100.
"As the bottom end blows up, there are many more households than there are industries," Ganter said about companies beginning to cater to home users.
2Bot, a Redmond-based startup, is interested in the bottom end of the 3-D printing market, though others in the industry prefer to classify machines such as 2Bot's in the more general category of rapid prototyping devices.
The company advertises to classrooms as a machine that's cost effective for students to use.
Founder and CEO Paul Nye compares the current 3-D printing industry to the early PC market.
"Out of 50 or so players, all of the sudden a few popped up," Nye said. "I see us as being one of those companies to pop up."
Its ModelMaker uses subtractive technology, removing material to sculpt the models, unlike traditional 3-D printers, which combine layers of material to create the final product.
The device sculpts foam, among other materials, many of which make the cost of printed models less than those produced by other machines.
"We're kind of breaking the rules in this space, so it's hard to describe what we are," Nye said. "It's just a very different class of machine."
Back at the Solheim lab, Ganter describes the price comparison between the machines and materials for 3-D printing as that of razors and razor blades; the cost of printing materials sold by the manufacturers can quickly exceed the cost of the machines.
Commercial printing plastic can cost more than $100 per pound, and printing powder can cost about $30 per pound, not including the cost of the binder.
"We have the capability to push the boundaries of materials in 3-D printing, and we're going to keep doing that if we can," Ganter said. "I think we're just starting."
He predicts that the technology may become as prevalent as desktop inkjet printers, but it's not anyone who can pour powdered glass into one of these machines to make a model; Ganter's lab goes through multiple recipes for each material before being able to print a solid final product.
Because of the skill required to operate some of these machines, Ganter says he could also see a future for 3-D print shops.
Metrix Create:Space in Capitol Hill is heading in this direction; the business operates as a coffee shop for the design and tech communities. Customers include robotics hobbyists, professionals looking for affordable models, jewelry makers and engineers, to name a few.
The space provides a communal work area with tools and craft supplies, including 3-D printers.
The big attraction is Metrix's laser cutter, but owner Matt Westervelt said he's seen an uptake in the use of his 3-D printers over the past year. He began with machines that print plastic and added a powder printer to his collection in January.
"You bring us a file, we'll give you a thing," Westervelt said.
He said clients sometimes ask for help to operate the machines themselves, while others ask the business to do the printing.
"We've done stuff that people have sketched on napkins," he laughed.
Thursday nights, clients bring in their own, self-assembled 3-D printers to Metrix to fine-tune the machines and work on printing projects together. Robot parts, figures designed for video games and a topographical relief map of Washington state have all been printed at Metrix.
Ganter is a regular at the space.
Westervelt says 3-D printing is expanding beyond this niche community. His shop makes and sells the parts needed to build more 3-D printers for $50 per set — a cloning project of sorts. They produce the parts using other 3-D printers.
"It's coming," Westervelt said. "It's going to be a mainstream thing."
Saturday, January 7, 2012
Monday, August 9, 2010
pu casting
PU or polyurethane casting by China Prototyping Center
We offer low volume production by Polyurethane casting or vacuum casting (RTV)
PU resin casting is a prototyping technology used when you need a small series or short run of your 3d cad model made out of a PolyUrethane with properties close to real injected plastics such as ABS, POM ,PA or TPE's. Usually series of 5-100 pieces will be run.
The process:
The first step of PU Casting process involves encapsulating/enclosing a master model in a liquid Silicone rubber. Than a vacuum is applied to the mould. The mould is then cured in an oven at around 70°C
Once cured the mould can be split up in 2 or more parts, at which point the master model is removed leaving a mould cavity perfectly replicating the master model.
what is possible with vacuum casting?;
We can make double or triple shot products, we can cast rubber or TPE or TPR like materials. (with 20-80 shore A hardness)
We can vacuum cast optical clear plastics ( same like PMMA)
WHAT ARE THE ADVANTAGES OF PolyUrethane casting?
The main advantages of this process are lower tooling costs and a quicker turn-around than traditional mould making (e.g. moldings within days of receipt of masters) The products have an exceptional detail and accuracy.
Minimal shrinkage permits use of duplicates or sub-masters for multiple impressions, useful if originals are delicate. Flexible moulds and inserts allow significant undercuts, simplifying mould-making and containing costs.
We offer low volume production by Polyurethane casting or vacuum casting (RTV)
PU resin casting is a prototyping technology used when you need a small series or short run of your 3d cad model made out of a PolyUrethane with properties close to real injected plastics such as ABS, POM ,PA or TPE's. Usually series of 5-100 pieces will be run.
The process:
The first step of PU Casting process involves encapsulating/enclosing a master model in a liquid Silicone rubber. Than a vacuum is applied to the mould. The mould is then cured in an oven at around 70°C
Once cured the mould can be split up in 2 or more parts, at which point the master model is removed leaving a mould cavity perfectly replicating the master model.
what is possible with vacuum casting?;
We can make double or triple shot products, we can cast rubber or TPE or TPR like materials. (with 20-80 shore A hardness)
We can vacuum cast optical clear plastics ( same like PMMA)
WHAT ARE THE ADVANTAGES OF PolyUrethane casting?
The main advantages of this process are lower tooling costs and a quicker turn-around than traditional mould making (e.g. moldings within days of receipt of masters) The products have an exceptional detail and accuracy.
Minimal shrinkage permits use of duplicates or sub-masters for multiple impressions, useful if originals are delicate. Flexible moulds and inserts allow significant undercuts, simplifying mould-making and containing costs.
Sunday, May 9, 2010
rapid prototyping process
Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. To learn more about rapid prototyping, herunder I elaborate a 5 steps process to create a rapid prototyping model
1. A 3D Computer aided model (CAD) of the initial idea or concept sketch design will be created.
2. This 3D CAD model will be converted in a STL or IGES format.
3. The STL model will be sliced into thin cross-sectional layers.
4. The model will be constructed one later atop another.
5. The model will be finished and cleaned: your rapid prototype is ready!
CAD Model Creation: First, the object to be built is modeled using a Computer-Aided Design (CAD) software package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately than wire-frame modelers such as AutoCAD, and will therefore yield better results. The designer can use a pre-existing CAD file or may wish to create one expressly for prototyping purposes. This process is identical for all of the RP build techniques.
Conversion to STL Format: The various CAD packages use a number of different algorithms to represent solid objects. To establish consistency, the STL (stereolithography, the first RP technique) format has been adopted as the standard of the rapid prototyping industry. The second step, therefore, is to convert the CAD file into STL format. This format represents a three-dimensional surface as an assembly of planar triangles, "like the facets of a cut jewel." 6 The file contains the coordinates of the vertices and the direction of the outward normal of each triangle. Because STL files use planar elements, they cannot represent curved surfaces exactly. Increasing the number of triangles improves the approximation, but at the cost of bigger file size. Large, complicated files require more time to pre-process and build, so the designer must balance accuracy with manageablility to produce a useful STL file. Since the .stl format is universal, this process is identical for all of the RP build techniques.
Slice the STL File: In the third step, a pre-processing program prepares the STL file to be built. Several programs are available, and most allow the user to adjust the size, location and orientation of the model. Build orientation is important for several reasons. First, properties of rapid prototypes vary from one coordinate direction to another. For example, prototypes are usually weaker and less accurate in the z (vertical) direction than in the x-y plane. In addition, part orientation partially determines the amount of time required to build the model. Placing the shortest dimension in the z direction reduces the number of layers, thereby shortening build time. The pre-processing software slices the STL model into a number of layers from 0.01 mm to 0.7 mm thick, depending on the build technique. The program may also generate an auxiliary structure to support the model during the build. Supports are useful for delicate features such as overhangs, internal cavities, and thin-walled sections. Each PR machine manufacturer supplies their own proprietary pre-processing software.
Layer by Layer Construction: The fourth step is the actual construction of the part. Using one of several techniques (described in the next section) RP machines build one layer at a time from polymers, paper, or powdered metal. Most machines are fairly autonomous, needing little human intervention.
Clean and Finish: The final step is post-processing. This involves removing the prototype from the machine and detaching any supports. Some photosensitive materials need to be fully cured before use. Prototypes may also require minor cleaning and surface treatment. Sanding, sealing, and/or painting the model will improve its appearance and durability.
Roger van der Linden owns a website called "ProtoTypingChina.Com" which is a great place for rapid prototyping service. If you are looking for Perfect prototyping then this is the place for you. For more information of prototyping please Visit our prototype company.
1. A 3D Computer aided model (CAD) of the initial idea or concept sketch design will be created.
2. This 3D CAD model will be converted in a STL or IGES format.
3. The STL model will be sliced into thin cross-sectional layers.
4. The model will be constructed one later atop another.
5. The model will be finished and cleaned: your rapid prototype is ready!
CAD Model Creation: First, the object to be built is modeled using a Computer-Aided Design (CAD) software package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately than wire-frame modelers such as AutoCAD, and will therefore yield better results. The designer can use a pre-existing CAD file or may wish to create one expressly for prototyping purposes. This process is identical for all of the RP build techniques.
Conversion to STL Format: The various CAD packages use a number of different algorithms to represent solid objects. To establish consistency, the STL (stereolithography, the first RP technique) format has been adopted as the standard of the rapid prototyping industry. The second step, therefore, is to convert the CAD file into STL format. This format represents a three-dimensional surface as an assembly of planar triangles, "like the facets of a cut jewel." 6 The file contains the coordinates of the vertices and the direction of the outward normal of each triangle. Because STL files use planar elements, they cannot represent curved surfaces exactly. Increasing the number of triangles improves the approximation, but at the cost of bigger file size. Large, complicated files require more time to pre-process and build, so the designer must balance accuracy with manageablility to produce a useful STL file. Since the .stl format is universal, this process is identical for all of the RP build techniques.
Slice the STL File: In the third step, a pre-processing program prepares the STL file to be built. Several programs are available, and most allow the user to adjust the size, location and orientation of the model. Build orientation is important for several reasons. First, properties of rapid prototypes vary from one coordinate direction to another. For example, prototypes are usually weaker and less accurate in the z (vertical) direction than in the x-y plane. In addition, part orientation partially determines the amount of time required to build the model. Placing the shortest dimension in the z direction reduces the number of layers, thereby shortening build time. The pre-processing software slices the STL model into a number of layers from 0.01 mm to 0.7 mm thick, depending on the build technique. The program may also generate an auxiliary structure to support the model during the build. Supports are useful for delicate features such as overhangs, internal cavities, and thin-walled sections. Each PR machine manufacturer supplies their own proprietary pre-processing software.
Layer by Layer Construction: The fourth step is the actual construction of the part. Using one of several techniques (described in the next section) RP machines build one layer at a time from polymers, paper, or powdered metal. Most machines are fairly autonomous, needing little human intervention.
Clean and Finish: The final step is post-processing. This involves removing the prototype from the machine and detaching any supports. Some photosensitive materials need to be fully cured before use. Prototypes may also require minor cleaning and surface treatment. Sanding, sealing, and/or painting the model will improve its appearance and durability.
Roger van der Linden owns a website called "ProtoTypingChina.Com" which is a great place for rapid prototyping service. If you are looking for Perfect prototyping then this is the place for you. For more information of prototyping please Visit our prototype company.
rapid prototyping in china
Since a couple of years China is an ideal country to make your prototypes.
Once you need CNC machined prototypes China can be very competitive. Prices are much lower for CNC milled real working models that come directly from your Cad system.
First of all, the basic price of basic sheet material, like ABS sheets or blocks, is lower than in the Western world. POM , PC are also common materials and even PA + 30% glass filled blocks can be milled.
Second the cost per hour to machine the 3d model is less than in Europe or US. Often local or Taiwanese CNC centers are used that are very suitable for the job, also overhead factors like electricity is a fraction of that in the Western world.
And last but not least to finishing the prototype model, often done by a Chinese low cost worker, can be done quickly and at low cost. We don’t have to explain the difference in labor costs of Chinese workers!?
In our company, China prototype Center, we strive to make the same or better quality than in the West, with a lot of cost savings for you!
If you have any rapid prototype request please let me know
contact: info@prototypingchina.com
Once you need CNC machined prototypes China can be very competitive. Prices are much lower for CNC milled real working models that come directly from your Cad system.
First of all, the basic price of basic sheet material, like ABS sheets or blocks, is lower than in the Western world. POM , PC are also common materials and even PA + 30% glass filled blocks can be milled.
Second the cost per hour to machine the 3d model is less than in Europe or US. Often local or Taiwanese CNC centers are used that are very suitable for the job, also overhead factors like electricity is a fraction of that in the Western world.
And last but not least to finishing the prototype model, often done by a Chinese low cost worker, can be done quickly and at low cost. We don’t have to explain the difference in labor costs of Chinese workers!?
In our company, China prototype Center, we strive to make the same or better quality than in the West, with a lot of cost savings for you!
If you have any rapid prototype request please let me know
contact: info@prototypingchina.com
Sunday, April 12, 2009
rapid prototyping technologies
what is a prototype:
A prototype is the first or original example of something that has been or will be copied or developed; it is a model or preliminary version.
In the design process making prototypes is a very important step to get feedback from the designs: The virtual design is made in "real life" . It can be a very rough model or an exact example that later will be copied.
prototype technologies;
we have several rapid prototyping technologies:
Some authors or rapid prototype specialist donnot count the abrasive technologies as rapid prototyping technologies, however we mention these as aa technology often used to make quick models:
the abrasive group exist of technologies in where from a block or sheet material will be removed: an example is CNC machining or milling; In our company our main technology to make rapid prototypes is cnc milling
a classification that we can find in the rapid prototyping literature is based on the initial form of the used material:
a. liquid based or
b. solid based
liquid base rapid prototyping technlogies are for example stereo lithography SLA
A prototype is the first or original example of something that has been or will be copied or developed; it is a model or preliminary version.
In the design process making prototypes is a very important step to get feedback from the designs: The virtual design is made in "real life" . It can be a very rough model or an exact example that later will be copied.
prototype technologies;
we have several rapid prototyping technologies:
Some authors or rapid prototype specialist donnot count the abrasive technologies as rapid prototyping technologies, however we mention these as aa technology often used to make quick models:
the abrasive group exist of technologies in where from a block or sheet material will be removed: an example is CNC machining or milling; In our company our main technology to make rapid prototypes is cnc milling
a classification that we can find in the rapid prototyping literature is based on the initial form of the used material:
a. liquid based or
b. solid based
liquid base rapid prototyping technlogies are for example stereo lithography SLA
Monday, March 30, 2009
As owner of a rapid prototyping company, i will put here some usefull information of lessons we have learned in executing rapid prototyping projects for our customers.
first I start with the rapid processes we can offer:
- abresive technologies; like cnc milling, turning, lathe.
- molding or tooling technologies
- printing or sintering technologies
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