Download slides at https://sphereinabox.wordpress.com/

TEST SLIDE

• Is this text readable in the back?

• Are the corner dots visible?

ITERATING FASTER WITH A 3D PRINTER

More of a 3d printing overview

SLIDES WILL BE ON MY BLOGhttps://sphereinabox.wordpress.com/

Q'S FOR AUDIENCE

Have you watched a 3d printer work?

Can you handle millimeters?

SB STARTUP WEEKEND TROPHIES 2014

I made these

VIRTUAL REALITY DISPLAY USING IPAD MINI

My first 3d printing based project

Completed before the delivery for the Oculus Rift

Another dumb project of mine

The ratchet locks the screen in place so the motor can be turned off.

Santa Barbara Hackerspace is a Non-Profit to help educate the community and help them build stuff. Members can use the space, wifi and tools including 2 FDM 3d printers, laser cutter, electronics bench and more.

We’re open to everyone on Saturday afternoons after 2PM so stop by and see what we’re working on or ask us questions.

ZAR PLOTTEREarly Prototype

Notice the motors hose clamped down to a board.

ZAR PLOTTER DRAWING BANNER

RANDY SZARZYNSKI

“SUBTRACTIVE MANUFACTURING”Make a part by removing (subtracting) material

Nobody calls it that.

SUBTRACTIVEShopBot Desktop at Crash Space in Culver City

This part shows up later

ADDITIVE MANUFACTURINGBuild up part by adding material

Video is time lapse of Zortrax M200 print starting

CAN'T MILL THISHerringbone planetary gear skateboard wheels

http://www.thingiverse.com/thing:151216

Yes I know these are a dumb idea.

Download slides at https://sphereinabox.wordpress.com/

UV SENSITIVE RESIN PRINTING

• Selectively cure layers of resin, using laser or DLP projector

Little RPForm Labs… many more

ENTRY LEVEL RESIN PRINTER KITS $800 INCLUDING THE

PROJECTORLittleRP

[pre-release machine shown][projector not shown]

Super high detailLimited build volumeExpensive material ($90/liter or more)

Download slides at https://sphereinabox.wordpress.com/

SLS (LASER SINTERING)• On each layer, spread a new layer of powder, and

selectively melt it with laser or heat.

• Various materials and costs:

• Nylon is cheaper, machine costs [lots]

• Metals like titanium are possible but machines would cost over $500,000

Video introduction to nylon SLS printer https://www.youtube.com/watch?v=wD9-QEo-qDk

The patent covering this is about to, or just expired so things are going to get fun here.

SLS INTRODUCTIONClip by Solid Concepts

Video clip from Solid Concepts (now Stratasys) https://www.youtube.com/watch?v=9E5MfBAV_tA

SLS RESULTSRaw (grainy) or Sanded

(Shapeways Strong and Flexible)

https://www.shapeways.com/materials/strong-and-flexible-plastic

Layers are .12mm

SLS patents have started expiring so others will start making these machines

Download slides at https://sphereinabox.wordpress.com/NO "STANDARD" METAL

PRINTING PROCESS• Do lost-wax casting from resin, plastic, or jet process

print

• Glue metal powder together, move into bed of sand, then use as mold

• Laser welding then post-machining

• Standard welding then post-machining

[Glued metal powder casting process video] https://www.youtube.com/watch?v=i6Px6RSL9Ac

Also additive laser weldinghttps://www.youtube.com/watch?v=yKnlmfuMSgo

FUSED DEPOSITION MODELING (FDM) / FUSED FILAMENT FABRICATION (FFF)Draw part by drawing lines of

plastic layer by layer

FDM is a Stratasys trademark

WHY ARE 3D PRINTERS A POPULAR THING NOW?

… answered in future slides

REPRAP PROJECTMake a machine that replicates itself when supplied raw

materials

OPEN SOURCE

Download slides at https://sphereinabox.wordpress.com/TYPICAL OPEN SOURCE

LICENSE

• You can use this and create derivatives as long as:

• You make the source files available for others to build on.

• And your derivative works are also available under the terms of this license

Paraphrased GPL

“Available” means “include them with your copy” or “have a process to get them for the cost of media and postage”

FEBRUARY 2008 DARWINFirst model to replicate it’s major parts

http://reprap.org/wiki/Darwin

University of Bath (England)

OCTOBER 2009 MENDEL

MAKERBOT CUPCAKE

April 2009

Photo by Bre Pettis (Founder of MakerBot)

Wow this thing is terrible.

Repeating wobble due to riding on Z threaded rods which aren’t straight.

Motors VERY loud because current/voltage is wrong.

Extruder calibration is nearly impossible because it’s driving a DC motor without an encoder. Later models had a stepper driven extruder.

You can yell over one. Here’s the SB hackerspace’s printing https://www.youtube.com/watch?v=bN6HSEdB3co

Photo by Bre Pettis CC-BY 2.0 https://www.flickr.com/photos/bre/3458247336/

MAKERBOT REPLICATORJanuary 2012

http://www.makerbot.com/blog/2012/01/09/introducing-the-makerbot-replicator

MAKERBOT REPLICATOR 2September 2012

End of open source updates from MakerBot, likely in response to clones.

https://en.wikipedia.org/wiki/File:MakerBot_Replicator_2.jpg

NOW

Hey look, a MakerBot clone.

Download slides at https://sphereinabox.wordpress.com/CONSUMER FDM/FFF

MATERIALS

• PLA

• ABS

• PET variants

• Nylon

Download slides at https://sphereinabox.wordpress.com/CONSUMER FANCY FDM/FFF

MATERIALS

• Co-Polyester-based plastics

• Flexible Urethane based plastic (Ninjaflex)

• PLA with metal powder (Bronze, Copper, Iron, Stainless)

http://www.ninjaflex3d.comhttp://www.proto-pasta.com

Download slides at https://sphereinabox.wordpress.com/

EXOTIC FDM/FFF MATERIALS

• These require higher temperature nozzle, and a controlled temperature chamber.

• Polycarbonate (Print 300°C in 100°C chamber)

• PEEK (About 350°C nozzle in 100°C chamber)

HEATED BEDLulzbot TAZ 5 printing HIPS on 110°C bed

WITHOUT SUPPORT MATERIAL

This is one of our most successful makerbot cupcake prints. Yes I know it looks terrible.

SUPPORT MATERIAL

(REMOVABLE)

Support removed in left photo, sitting behind part.

Lower right photo shows interior of object is hollow.

SUPPORT MATERIAL

(DISSOLVABLE)PLA dissolves PLA caustic soda

in ultrasonic water bath

HIPS: Dissolve HIPS with Limonene

PVA: Dissolve PVA in water

Pictured:HIPS (White) supportABS (Black) print material

Print is the comet the Rosetta space probe landed on.

Create a plaster mold around the original 3d printed part, with vent and pour inlet

Burn/melt out printed material

Pour in molten metal

When cool, brake plaster to get part. Then trim spout+vents and polish.

This perfectly replicated our print defects.

Download slides at https://sphereinabox.wordpress.com/TYPICAL PRINTING

WORKFLOW

• Design in a computer, export STL file

• Load STL file in "Slicer" to generate g-code. Choose options like layer height, fill density, and support material.

• Send g-code to printer to print file.

CAD or whatever

Export STL

Load into Slicer and nearly instantly get result

OPTIONSOnly really need two of these

Support material on/off is about the only setting I change

If I’m switching between printing strong parts and ones that look good, I may change shell thickness and layer height

Download slides at https://sphereinabox.wordpress.com/

DESIGN APPROACHES

• Solidworks, OnShape or other solid modeling packages

• Sculpting

• 3d Scanning

Download slides at https://sphereinabox.wordpress.com/

DESIGN CONSTRAINTS

• Solids

• Thin features

• Thin walls

• Overhangs

Shapeways description pages do a good job of describing each of these but I don’t want to read you the material pages for a full hour.

https://www.shapeways.com/materials/?li=nav

OVERHANGSNice beard

NON-MANIFOLDUsually the opposite of “Watertight”

http://www.thingiverse.com/thing:40262

I expect this was intended for video games where the inside of the car didn’t need to be solid.

CURA (SLICER) TRIES ITS BEST

CURA X-RAY PREVIEWHighlights problems in red

Download slides at https://sphereinabox.wordpress.com/TOLERANCES (CHEAP FDM/

FFF MACHINES)

• Small holes tend to be 0.4mm too small in diameter.

• Outer shapes tend to be 0.2mm too large

• Layer heights of 0.1-0.3mm are typical

Download slides at https://sphereinabox.wordpress.com/

FDM LIMITATIONS

• Temperature for printed part. PLA gets soft at 65°C (149°F)

• Strength and durability isn’t as good as molded or metal

• Parts weaker between layers then along their length

Download slides at https://sphereinabox.wordpress.com/

PRINTING SPEED

• Typical speed of moving print head is 30mm-80mm/sec (70-190 inches per minute)

• Typical layer height 0.1mm-0.3mm

• A part 4 inches long, 2 inches wide, and 1 inch tall may print in 2-6 hours.

PRINTING FASTERIncreasing federate has limits:

Melting plastic

Under extrusion

(from https://ultimaker.com/en/community/5586-can-your-um2-printer-achieve-10mm3-s-test-it-here )

MOVING FASTER IS HARDMechanics can only look nice moving so fast

INFILL DENSITYTo reduce print time and required materials, objects are

not printed solid.

I’m told stratasys doesn’t let you adjust this :-(

PRINTING FASTERThere are heaters/nozzles for extruding plastic at a higher

volume for thicker layers

e3d volcanohttp://e3d-online.com/Volcano/Volcano-Eruption-Pack-175

Don’t need to print EVERYTHING if you have other tools.

Laser cut reel holder

Mixed Laser/plastic VESA mount for tablet

"WIRE" PRINT

https://www.youtube.com/watch?v=Ea4V7kb2VsY

PRINTED PARTS ARE NOT FOR EVERYTHING

Don’t try this.

BRAKE CALIPERS PRESS HARDThe gray part was also 3d printed

Both lime and gray parts are 3d printed.

The car was not moved while these “brake pads” were installed.

ZORTRAX M200$1990 200x200x180mm build volume

Slow but good prints

https://zortrax.com/printers/zortrax-m200/

LULZBOT TAZ 5$2200 295x725x250mm build volumeFully open source machine, prints well

https://www.lulzbot.com/store/printers/lulzbot-taz-5

"REQUEST A QUOTE"Hobbyists need not apply

Screenshot is http://www.purpleplatypus.com/stratasys-3d-printers/

STRATASYS MOJO

MOJOApproximately $5000

Soluble support by default

$250/kilogram spools of plastic and support

127x127x127mm build volume

Spools are probably $200/44 cubic inches

The comparison $250/kilogram compares to reputable consumer suppliers selling ABS or PLA for $30/kilogram

UPRINT SE PLUS

$22,000 Machine

203x152x152mm build volume

Soluble Support by default

http://www.purpleplatypus.com/stratasys-3d-printers/uprintse/

price from http://www.hanselman.com/blog/3DPrinterShootout600PrintrbotVs20000UPrintSEPlus.aspx

SHAPEWAYSMost approachable 3d print service

AUTOMATED INSTANT QUOTE

Strong & Flexible Nylon round trip time is about 2 weeks

WEB BASED ERROR DISPLAY

There are some edges highlighted in yellow for being where the part is too thin

LOTS OF MATERIALS

Download slides at https://sphereinabox.wordpress.com/

PRINTING SERVICES

• Shapeways http://shapeways.com

• i.materialise https://i.materialise.com

• Stratasys Direct https://www.stratasysdirect.com/

• 3d Systems: http://www.3dsystems.com/quickparts

Download slides at https://sphereinabox.wordpress.com/MORE LOCAL, POTENTIALLY

FASTER TURN AROUND• I haven’t tried these but:

• Go Engineer has office in SB, offers FDM printing services http://www.goengineer.com/3d-printers-2/

• Stratasys Direct (formerly Solid Concepts) has office in Valencia https://www.stratasysdirect.com

• Steve Bond Design in Camarillo FDM http://stevebonddesign.com/3d-services.html

• Hollywood http://www.hollywood3dprinting.com/3d-printing-overview/ FDM, SLA resin or wax (detail)

• Gardena http://www.sbmolds.com/3d_printing.html Resin or FDM

“Request a quote” means “not in my hobbyist budget” so I haven't tried any of these

Download slides at https://sphereinabox.wordpress.com/

MORE• Los Angeles, http://3drp.com range of materials from resin to metal

• Los Angeles http://www.3d-cam.com/index.html resin-based materials that act like plastics

• Los Angeles http://www.3dwaxprinting.com for jewelry masters

• Los Angeles http://www.guruprinters.com/3D-Printing.html full color gypsum (not durable)

• Irvine http://www.purpleplatypus.com/3d-printing/ Resin (polyjet) or FDM

BONUS SLIDES

3D SCANNING

PARALLAX FROM LINE LASER ($3000 NEXTENGINE)

more links, photos, videos on http://www.eevblog.com/forum/reviews/3d-scanner-the-nextengine-2020i-my-latest-purchase/

PHOTOGRAMMETRY ($180 PHOTOSCAN, “FREE” 123D CATCH)

phtoscan: http://www.agisoft.com

123d catch: http://www.123dapp.com/catch

Image above from 123d catch video, doesn't show software in use but shows how to arrange photos: https://www.youtube.com/watch?v=7TfXXJxDsXw

STRUCTURE SENSOR ($380)Reconstruct the world using a Primesense “Depth

Camera”

http://structure.io

Picture is screenshot of scanning using Skanect from http://structure.io/getstarted/first-use

3D SCANNING

PREPGet rid of glossy parts of what you intend to scan

Unscented might be better.http://www.amazon.com/Gold-Bond-Spray-Powder-Fresh/dp/B00B4CYRHA/

REMOVE EXTRA SCANNED MATERIAL

source: http://www.nasa.gov/sites/default/files/files/3DScannerTutorial.pdf

FILL HOLES

WHY STEPPER MOTORS IN 2016?(MakerBot Mini)

… because they’re cheap

These are the one-of prices on http://robotdigg.com

GOING VERTICAL

3D PRINTED VUVUZELA

3d Printed Vuvuzela for if you missed during the 2010 South

Africa World Cup