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