cs 294-12 -- october 2002 rapid prototyping and its role in design realization carlo h. séquin eecs...

CHSCHSUCBUCB CS 294-12 -- October 2002CS 294-12 -- October 2002

Rapid Prototyping and its Role in

Design Realization

Carlo H. Séquin

EECS Computer Science Division

University of California, Berkeley

CHSCHSUCBUCB Focus of TalkFocus of Talk

How can we use the visualization power offered by computer graphics and by computer-controlled rapid prototyping in design and in design realization?

CHSCHSUCBUCB DESIGNDESIGN

The following questions should be raisedand be answerable:

What is the purpose of the artifact ?

What are the designer’s goals for it ?

How will the artifact be evaluated ?

What are the associated costs ?

How can we maximize the benefit/cost ratio ?

CHSCHSUCBUCB Example TaskExample Task

“Design an Instrument as an Interfaceto an Existing Data Base.

Purpose: Enhance access to data base.

Goals: Provide: novel insights, deeper understanding, better user interface.

Evaluation: Let several users use the device and observe what emerges.

Costs: Fabrication, as well as operation.

Optimization: Heavily dependent on approach taken.

CHSCHSUCBUCB Design is an Iterative ProcessDesign is an Iterative Process

Formal Specifications

Detailed Description

Clear Concept

1st `hack'

Demo Prototype

Usable Evaluation Series

Marketable Systems Product

Vague ideaRevision of

artifact

Experiments,

get feedback

CHSCHSUCBUCB A Specific ChallengeA Specific Challenge

Create as soon as possible a 3D "free-form" part

(not a box-like thing that can be built from flat plates)

for evaluation in its application context.

This includes:

visualization

tactile feedback

function verification

simulation of final use.

CHSCHSUCBUCB Conceptual PrototypingConceptual Prototyping

The Traditional Options:

Model from clay

Carve from wood

Bend wire meshing

Carve from styrofoam – perhaps with surface reinforcement

Mill from a block of plastic or aluminum (3- or 4-axes machines)

CHSCHSUCBUCB ““Hyperbolic Hexagon II” (wood)Hyperbolic Hexagon II” (wood)

Brent Collins

CHSCHSUCBUCB Brent Collins’ Prototyping ProcessBrent Collins’ Prototyping Process

Armature for the "Hyperbolic Heptagon"

Mockup for the "Saddle Trefoil"

Time-consuming ! (1-3 weeks)

CHSCHSUCBUCB New Ways of Rapid PrototypingNew Ways of Rapid Prototyping

Based on Layered Manufacturing:

Build the part in a layered fashion-- typically from bottom up.

Conceptually, like stacking many tailored pieces of cardboard on top of one another.

Part geometry needs to be sliced, and the geometry of each slice determined.

Computer controlled, fully automated.

CHSCHSUCBUCB Slices through “Minimal Trefoil”Slices through “Minimal Trefoil”

50% 10%23%30%

45% 5%20%27%

35% 2%15%25%

CHSCHSUCBUCB ““Heptoroid” Heptoroid” ( from Sculpture Generator I )( from Sculpture Generator I )

Cross-eye stereo pair

CHSCHSUCBUCB Profiled Slice through the SculptureProfiled Slice through the Sculpture

One thick slicethru “Heptoroid”from which Brent can cut boards and assemble a rough shape.

Traces represent: top and bottom,as well as cuts at 1/4, 1/2, 3/4of one board.

CHSCHSUCBUCB Emergence of the “Heptoroid” (1)Emergence of the “Heptoroid” (1)

Assembly of the precut boards

CHSCHSUCBUCB Emergence of the “Heptoroid” (2)Emergence of the “Heptoroid” (2)

Forming a continuous smooth edge

CHSCHSUCBUCB Emergence of the “Heptoroid” (3)Emergence of the “Heptoroid” (3)

Thinning the structure and smoothing the surface

CHSCHSUCBUCB ““Heptoroid”Heptoroid”

Collaboration byBrent Collins &Carlo Séquin(1997)

CHSCHSUCBUCB Some Commercial ProcessesSome Commercial Processes

Additive Methods with Sacrificial Supports:

Fused Deposition Modeling (Stratasys)

Solidscape (Sanders Prototype, Inc.)

Solid Printing / Imaging (3D Systems)

Stereolithography

Powder-Bed Based Approaches:

3D Printing (Z-Corporation)

Selective Laser Sintering

CHSCHSUCBUCB SFF: Fused Deposition ModelingSFF: Fused Deposition Modeling

Principle:

Beads of semi-liquid ABS* plastic get deposited by a head moving in x-y-plane.

Supports are built from a separate nozzle.

Schematic view ==>

Key player: Stratasys: http://www.stratasys.com/

* acrylonitrile-butadine-styrene

CHSCHSUCBUCB Fused Deposition ModelingFused Deposition Modeling

CHSCHSUCBUCB Looking into the FDM MachineLooking into the FDM Machine

CHSCHSUCBUCB Zooming into the FDM MachineZooming into the FDM Machine

CHSCHSUCBUCB Single-thread Figure-8 Klein BottleSingle-thread Figure-8 Klein Bottle

As it comes out of the FDM machine

CHSCHSUCBUCB Layered Fabrication of Klein BottleLayered Fabrication of Klein Bottle

Support material

CHSCHSUCBUCB Klein Bottle Skeleton (FDM)Klein Bottle Skeleton (FDM)

CHSCHSUCBUCB Fused Deposition ModelingFused Deposition Modeling

An Informal Evaluation Easy to use

Rugged and robust

Could have this in your office

Good transparent software (Quickslice)with multiple entry points: STL, SSL, SML

Inexpensive to operate

Slow

Think about support removal !

CHSCHSUCBUCB What Can Go Wrong ?What Can Go Wrong ?

Black blobs

Toppled supports

CHSCHSUCBUCB Solid Object PrintingSolid Object Printing

ModelMaker II (Solidscape)

CHSCHSUCBUCB SFF: Solid Object PrintingSFF: Solid Object Printing

ModelMaker II (Solidscape)

Alternate Deposition / Planarization Steps Build envelope: 12 x 6 x 8.5 in.

Build layer: 0.0005 in. to 0.0030 in.

Achievable accuracy: +/- 0.001 in. per inch

Surface finish: 32-63 micro-inches (RMS)

Minimum feature size: 0.010 in.

Key Player:Solidscape*: http://www.solid-scape.com/

* formerly: Sanders

CHSCHSUCBUCB SFF: Solid Object PrintingSFF: Solid Object Printing

Projection of 4D 120-cell, made in “jewelers wax.”

(2” diam.)

CHSCHSUCBUCB SFF: Solid Scape (Sanders)SFF: Solid Scape (Sanders)

An Informal Evaluation

The most precise SFF machine around

Very slow

Sensitive to ambient temperature

Must be kept running most of the time

Poor software

Little access to operational parameters

Based on comments by B. G.: http://www.bathsheba.com/

CHSCHSUCBUCB SFF: Solid ImagingSFF: Solid Imaging

Droplets of a thermoplastic material are sprayed from a moving print head onto a platform surface.

Need to build a support structures where there are overhangs / bridges.

These supports (of the same material) are given porous, fractal nature.

They need to be removed (manually).

Key player: 3D Systems: http://www.3dsystems.com/index_nav.asp

CHSCHSUCBUCB SFF: Solid ImagingSFF: Solid Imaging

Supports made from same material, but with a fractal structure

CHSCHSUCBUCB SFF: Solid ImagingSFF: Solid Imaging

Thermojet Printer (3D Systems)

Technology: Multi-Jet Modeling (MJM)

Resolution (x,y,z): 300 x 400 x 600 DPI

Maximum Model Size: 10 x 7.5 x 8 in (13 lb)

Material: neutral, gray, black thermoplastic: ThermoJet 88: smooth surfaces for casting

ThermoJet 2000: more durable for handling

CHSCHSUCBUCB SFF: Solid ImagingSFF: Solid Imaging

That’s how partsemerge from theThermojet printer

After partial removalof the supportingscaffolding

CHSCHSUCBUCB 9-Story Intertwined Double Toroid9-Story Intertwined Double Toroid

Bronzeinvestment casting from wax original made on 3D Systems’“Thermojet”

CHSCHSUCBUCB SFF: Solid ImagingSFF: Solid Imaging

An Informal Evaluation Fast

Inexpensive

Reliable, robust

Good for investment casting

Support removal takes some care(refrigerate model beforehand)

Thermojet 88 parts are fragile

CHSCHSUCBUCB Powder-based ApproachesPowder-based Approaches

Key Properties:

Needs no supports that must be removed!

Uniform bed of powder acts as support.

This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.

CHSCHSUCBUCB SFF: 3D Printing -- PrincipleSFF: 3D Printing -- Principle

Selectively deposit binder droplets onto a bed of powder to form locally solid parts.

Powder Spreading Printing

Build

Feeder

Powder

Head

CHSCHSUCBUCB 3D Printing: Some Key Players3D Printing: Some Key Players

Z Corporation: http://www.zcorp.com/Plaster and starch powders for visualization models.

Soligen: http://www.zcorp.com/Metal and ceramic powdersfor operational prototypes.

Therics Inc.: http://www.therics.com/Biopharmaceutical products,tissue engineering.

CHSCHSUCBUCB 3D Printing:3D Printing: Z CorporationZ Corporation

The Z402 3D Printer Speed: 1-2 vertical inches per hour

Build Volume: 8" x 10" x 8"

Thickness: 3 to 10 mils, selectable

CHSCHSUCBUCB 3D Printing:3D Printing: Z CorporationZ Corporation

CHSCHSUCBUCB 3D Printing:3D Printing: Z CorporationZ Corporation

Digging out

CHSCHSUCBUCB Optional Curing: 30 min. @ 200ºF Optional Curing: 30 min. @ 200ºF

Keep some powder in place

<-- Tray for transport

CHSCHSUCBUCB 3D Printing:3D Printing: Z CorporationZ Corporation

Cleaning up in the de-powdering station

CHSCHSUCBUCB 3D Printing:3D Printing: Z CorporationZ Corporation

The finished part

Zcorp,

6” diam.,

6hrs.

CHSCHSUCBUCB 120 Cell -- Close-up120 Cell -- Close-up

CHSCHSUCBUCB 3D 3D ColorColor Printing: Z Corporation Printing: Z Corporation

The Z402C 3D Color Printer

Differences compared to mono-color printer: Color print head with: Cyan, Yellow, Magenta,

Black, and Neutral.

Smaller build area.

Specs: Speed: 0.33 - 0.66 vertical inches per hour

Build Volume: 6" x 6" x 6"

Thickness: 3 to 10 mils, selectable

Color depth: 80 mils

CHSCHSUCBUCB 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

CHSCHSUCBUCB 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Use compressed air to blow out central hollow space.

CHSCHSUCBUCB 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors.

CHSCHSUCBUCB What Can Go Wrong ?What Can Go Wrong ?

Blocked glue lines

Crumbling parts

CHSCHSUCBUCB Broken PartsBroken Parts

CHSCHSUCBUCB 3D Printing: Z Corporation3D Printing: Z Corporation

An Informal Evaluation

Fast !

Running expenses: moderate,(but overpriced powder)

Color print head and tubes need some care in maintenance.

Somewhat messy cleanup !

Lot’s of dust everywhere ...

CHSCHSUCBUCB SFF: Stereolithography (SLA)SFF: Stereolithography (SLA)

UV laser beam solidifies the top layerof a photosensitive liquid.

Build Stage

UV Laser Beam

Photopolymer

CHSCHSUCBUCB SFF: Stereolithography (SLA)SFF: Stereolithography (SLA)

SLA Machine by 3D Systems

Maximum build envelope: 350 x 350 x 400 mm in XYZ

Vertical resolution: 0.00177 mm

Position repeatability: ±0.005 mm

Maximum part weight: 56.8 kg

CHSCHSUCBUCB StereolithographyStereolithography

An Informal Evaluation

Can do intricate shapes with small holes

High precision

Moderately Fast

Photopolymer is expensive ($700/gallon)

Laser is expensive ($10’000),lasts only about 2000 hrs.

CHSCHSUCBUCB Séquin’s “Minimal Saddle Trefoil”Séquin’s “Minimal Saddle Trefoil”

Stereo-lithography master

CHSCHSUCBUCB Séquin’s “Minimal Saddle Trefoil”Séquin’s “Minimal Saddle Trefoil”

bronze cast, gold plated

CHSCHSUCBUCB

Minimal Trefoils -- cast and Minimal Trefoils -- cast and finished by Steve Reinmuthfinished by Steve Reinmuth

CHSCHSUCBUCB What Can SFF Be Used For?What Can SFF Be Used For?

CHSCHSUCBUCB Use of 3D HardcopyUse of 3D Hardcopy

What is 3D Hardcopy good for? (cont.) Consumer Electronics Design Prototypes

==> touch and feel !

Mathematical & Topoplogical Models==> visualization and understanding

Artistics Parts & Abstract Sculptures==> all-round visual inspection, including light and shadows.

My goal is to inspire you to put these SFF technologies to new and intriguing uses.

CHSCHSUCBUCB Consumer Electronics PrototypesConsumer Electronics Prototypes

Role of 3D Hardcopy -- Part 1:Modeling and Prototyping

Packaging of various electronics components.

Custom designed housing for other utility products.

The physical frame for an “instrument” …

CHSCHSUCBUCB Prototyping Consumer ProductsPrototyping Consumer Products

“Solarcator” and “Contact-Compact”

Two student-designed “products” in ME221

http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/

CHSCHSUCBUCB Model Model Prototype Prototype Mold Mold Part Part

Injection-Molded Housing for ST TouchChip

CHSCHSUCBUCB Geometrical / Topoplogical ModelsGeometrical / Topoplogical Models

Role of 3D Hardcopy -- Part 2: Visualization of objects, when 2D is not quite enough.

Self-intersecting surfaces.

Projections of 4-D polytopes.

CHSCHSUCBUCB Single-thread Figure-8 Klein BottleSingle-thread Figure-8 Klein Bottle

Modelingwith SLIDE

CHSCHSUCBUCB Triply-Twisted Figure-8 Klein BottleTriply-Twisted Figure-8 Klein Bottle

FDM, 9” diam. 6 days

CHSCHSUCBUCB Projections of Reg. 4D PolytopesProjections of Reg. 4D Polytopes

4D Cross-Polytope

CHSCHSUCBUCB Artistics Parts, Abstract SculpturesArtistics Parts, Abstract Sculptures

Role of 3D Hardcopy -- Part 3:Maquettes for Visualization

All-round inspection, including light and shadows.

Parts that could not be made in any other way …

Prototyping modular parts, before an injection mold is made.

CHSCHSUCBUCB Family of Scherk-Collins TrefoilsFamily of Scherk-Collins Trefoils

CHSCHSUCBUCB ““Viae Globi” SculpturesViae Globi” Sculptures

FDM maquettes of possible bronze sculptures

CHSCHSUCBUCB Brent Collins at Bridges 2000Brent Collins at Bridges 2000

CHSCHSUCBUCB Photos by Brent CollinsPhotos by Brent Collins

CHSCHSUCBUCB Collin’s Construction DescriptionCollin’s Construction Description

SWEEP CURVE (FOR DOUBLE CYLINDER)IS COMPOSED OF 4 IDENTICAL SEGMENTS,FOLLOWS THE SURFACE OF A SPHERE.

CHSCHSUCBUCB Reconstruction / Analysis (v1)Reconstruction / Analysis (v1)

AWKWARD ALIGNMENT

FROM THE FDM MACHINE

CHSCHSUCBUCB Further Explorations (v2: add twist)Further Explorations (v2: add twist)

CHSCHSUCBUCB A More Complex Design (v3)A More Complex Design (v3)

CHSCHSUCBUCB Verification with 3D Model (v4)Verification with 3D Model (v4)

GALAPAGOS-4

CHSCHSUCBUCB Fine-tuned Final(?) Version (v5)Fine-tuned Final(?) Version (v5)

CHSCHSUCBUCB Galapagos-6 in the MakingGalapagos-6 in the Making

CHSCHSUCBUCB Galapagos-6 (v6)Galapagos-6 (v6)

CHSCHSUCBUCB Sculpture Design: “Solar Arch”Sculpture Design: “Solar Arch”

branches = 4 storeys = 11 height = 1.55 flange = 1.00 thickness = 0.06 rim_bulge = 1.00 warp = 330.00 twist = 247.50 azimuth = 56.25 mesh_tiles = 0 textr_tiles = 1 detail = 8 bounding box: xmax= 6.01, ymax= 1.14, zmax= 5.55, xmin= -7.93, ymin= -1.14, zmin= -8.41

CHSCHSUCBUCB Competition in Breckenridge, COCompetition in Breckenridge, CO

CHSCHSUCBUCB FDM Maquette of Solar ArchFDM Maquette of Solar Arch

2nd place

CHSCHSUCBUCB We Can Try Again … in L.A.We Can Try Again … in L.A.

CHSCHSUCBUCB ““Whirled White Web”Whirled White Web”

Design for the 2003 International Snow Sculpture Championship Breckenridge, CO, Jan.28 – Feb.2

CHSCHSUCBUCB Which Process Should You Pick?Which Process Should You Pick?

Do you need a prototype (not just a model)?

SLS, FDM (for robustness, strength).

Do you need a mold for a small batch?

SLA (for smooth, hard surface).

Does part need multiple colors?

3D Color-Printing.

Does part have convoluted internal spaces?

3D-P, SLS, SLA (easy support removal).

CHSCHSUCBUCB The Most Challenging SFF PartThe Most Challenging SFF Part

3rd-order 3D Hilbert Curve: much weight

much length

no supports

only two tube-connectionsbetween the two halves.

CHSCHSUCBUCB Informal Process Ratings MatrixInformal Process Ratings Matrix

Hollow Sphere

Hollow Sphere with Drain/Vent

2 Nested, Perforated Spheres

3D Hilbert

Pipe

Preassembled Gear

Mechanism

LOM (F) F F D F

SLA (F) D C B D

FDM (F) F C C D

3D-P (F) A A C B

SLS (F) A A B B

CHSCHSUCBUCB How Can You Get Access to SFF ?How Can You Get Access to SFF ?

We have under our control:

A Fused Deposition Modeling Machine

A Z-Corp Color/Mono 3D Printer

You need to prepare:

A “watertight” boundary representation with less than 100’000 triangles

In .STL format.