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3D Printing & Rapid Prototyping

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Delvinia
Delvinia

3D Printing aka Rapid Prototyping is a game changing technology that is changing the way that designers produce prototypes and short-run manufacturing. This presentation is part of Delvinia's internal Lunch & Learn workshops and is intended for educational purposes only.

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This presentation is part of our ongoing series of Lunch & Learn educational sessions presented by members of the Delvinia team. 3D PrintingRapid PrototypingJanuary 27, 2010
Agenda> Imagine…> What is it? > How does it work?> Demo> (if we have time)The Future
ReplicationWe are aFirm.the replicatorIs not just science fiction anymore...
Imagine...printing anentire buildingWe are a
Imagine...printing thebody for yournext car
Imagine...printingyourlunch
Imagine...printing skin, blood vessels & human organs
Imagine...We are aif humanscan be manufactured(dramatic pause)Firm.
Why are talking about 3D printing?It’s a game changer…It’s a technology that will change the prototyping, manufacturing and distribution of physical objectsIt’s teleportation via the internet
Transformative Technologies
Transformative Digital Businesses
What is it?“Rapid Prototyping (aka. 3D Printing) is the automatic construction of physical objects using additive manufacturing technology.”
HistorySubtractive Manufacturing is the oldest way of making something. It’s laborious, requires specialized skills and each item is unique.
HistoryIt has been updated a bit by the Industrial Revolution and computers. But it’s still basically the same thing:Chopping bits off.
HistoryPrototyping (before the ‘Rapid’ part was invented) went something like this: Someone would imagine the design of a new product and draw blueprints of it’s dimensions and a list of materials required.Lego Minifig
HistoryThen a craftsperson would spend many hours carefully machining a prototype based on those blueprints.HugeAssLathe 3000
HistoryAfter some back-and-forth a final prototype would be signed off on and couldbe moved intoproduction.For plastic items this could involve building a negative mould, which would have heated plastic injected into it to form the final part.LegoInjectionMould
HistoryPowderedMaterialFrikin’LaserConvert toMachine CodeComputerDesignMelted Layersof MaterialBecomethe PartSelective Laser Sintering(SLS) Process OverviewThe technology for Additive Manufacturing, or Rapid Prototyping, became available in the late 1980s.
AdvantagesAdvantages of Rapid Prototyping for a CompanyIt’s faster to print out a prototype than for one to be hand crafted.You only use up as much raw material as is needed to create the part. Which is also good for the environment!You no longer require highly skilled machinists to make prototypes, instead you have printing machine operators.And…(Fleshy unitsare fired!)
AdvantagesThe equipment is relatively inexpensive to buy and run… for a company or government.Rapid Prototyping Worldwide
DisadvantagesSinteredSteelSinteredPlasticOriginalMakerbotThe surface quality and strength of a printed part may be poorer than machined or extruded parts.Once the moulds have been made it takes a lot less time to extrude or cast a part than it does to print one.
DisadvantagesThe Economy of Scale: For a single or a few parts it can make sense to use Rapid Prototyping to create them. For hundreds, thousands or millions of copies of a part, you need to get heavily industrial.Honda EV-N ConceptToyota iQ
DisadvantagesAlthough it may be sign that Rapid Prototyping is maturing that some manufacturer are including RP’d parts in their products… or in this case, it’s what they plan to do once they go into production.KOR EcoLogicUrbee
3D Printing @ HomeThe proliferation of home computers and the invention of the Arduino - a cheap microcontroller aimed at electronic hobbyists - has made it possible for home users to get their hands on relatively inexpensive 3D printing machines with controller boards based on the Arduino.
3D Printing @ HomeRight now home 3D Printing is at about the same stage of development as home computers were back in 1975.If you wanted one you pretty much had to order a kit from a hobby magazine, build it and program it yourself.Altair 8800 Computer
3D Printing @ HomeThe first really home-user friendly printer was the Darwin, created in 2008 by the RepRap* Project at the University of Bath in the U.K.*Replicating Rapid-prototyper. The goal of the project is to create a machine which is capable of printing out the majority of the parts required to make another one.
3D Printing @ HomeIt’s open-source design was quickly taken up, modified, and commercialized. Which is where my Makerbot “Cupcake” comes from.
3D Printing @ HomeRepRap Mendel(The next generationpost Darwin.)An exampleof a home made“RepStrap”machineFab@HomeThere are other home printers out there, but currently the ones sold by Makerbot are the most popular kits.
3D Printing @ HomeFor roughly $1000 the Cupcake kit comes as sheets of laser cut plywood, lots of hardware, motors, drive belts and circuit boards.(Some assembly required.)Note: The Cupcake is no longer available, and has been replaced by it’s successor, the Thing-O-Matic. ($1225)
3D Printing @ Home1lb. of Black ABS Plastic ($15)Plastruder Mk.5 ($185, included in kit)Makerbots print objects from a plastic filament, squirting it from the tip of a heated nozzle.
3D Printing @ HomeDremel Mountby clothbotFrostruder ($150)Unicorn Plotter ($85)There are other tool heads for printing with frosting, plaster, clay, etc. A plotter pen holder. And some user-designed ones, such as this bracket for mounting a Dremel cutting tool.
3D Printing @ HomeMakerBot also sells the parts for a 3D scanner, which allows you to create a 3D model that you can use to print copies.Requires that you also buy a Pico Projector and either a PS3 Eye Camera, iPod Touch, iPhone or other VGA video camera.Cyclops ($50)
3D Printing @ HomeDouble Coat Hookby hoekenPrinted by jagOpen-Source printers and 3D models are driving a large hobbyist market for buying & building. Including community websites where you can find 3D files for open-source objects which you can download and print, modify and re-share… and of course you can upload your own designs.
How to 3D PrintOnce you have a 3D printer you need objects to print. You can download them from a community website like Thingiverse or you can make your own using free software like Google Sketchup or (if you’re a masochist :) ) Blender.BlenderSketchup
How to 3D PrintOpen the file in ReplicatorG - free software for controlling 3D printers - and click the “Generate GCode” button.GCode is the step-by-step instructions that control the printer’sX, Y & Z motors, the extruder’s motor and the heating elements.ReplicatorG
How to 3D PrintOnce the GCode is generated you’re ready to print! Get the printer set up, click the Print button and be ready to click the Stop button… just in case.
Future of 3D Printing @ HomeNew & improved designs for printers that will be less expensive, easier to build & operate and that will have larger printing areas.Improved electronics which will be less expensive, more powerful and quieter.More printing head types for a wider variety of materials.The ability to print multiple material types in one item.
FutureApplications
foodMIT conceptual model
Raw food cartridges (think Tassimo)
A 3D model or recipe drives the printing head
The recipe takes into account heat sequences, wait times, etc.http://www.geek.com/articles/gadgets/yummy-mit-creates-a-3d-food-printer-concept-20100722/
foodCornell
Solid Freeform Fabrication (SFF) http://ccsl.mae.cornell.edu/node/194

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3D Printing & Rapid Prototyping

  • 1. This presentation is part of our ongoing series of Lunch & Learn educational sessions presented by members of the Delvinia team. 3D PrintingRapid PrototypingJanuary 27, 2010
  • 2. Agenda> Imagine…> What is it? > How does it work?> Demo> (if we have time)The Future
  • 3. ReplicationWe are aFirm.the replicatorIs not just science fiction anymore...
  • 7. Imagine...printing skin, blood vessels & human organs
  • 8. Imagine...We are aif humanscan be manufactured(dramatic pause)Firm.
  • 9. Why are talking about 3D printing?It’s a game changer…It’s a technology that will change the prototyping, manufacturing and distribution of physical objectsIt’s teleportation via the internet
  • 12. What is it?“Rapid Prototyping (aka. 3D Printing) is the automatic construction of physical objects using additive manufacturing technology.”
  • 13. HistorySubtractive Manufacturing is the oldest way of making something. It’s laborious, requires specialized skills and each item is unique.
  • 14. HistoryIt has been updated a bit by the Industrial Revolution and computers. But it’s still basically the same thing:Chopping bits off.
  • 15. HistoryPrototyping (before the ‘Rapid’ part was invented) went something like this: Someone would imagine the design of a new product and draw blueprints of it’s dimensions and a list of materials required.Lego Minifig
  • 16. HistoryThen a craftsperson would spend many hours carefully machining a prototype based on those blueprints.HugeAssLathe 3000
  • 17. HistoryAfter some back-and-forth a final prototype would be signed off on and couldbe moved intoproduction.For plastic items this could involve building a negative mould, which would have heated plastic injected into it to form the final part.LegoInjectionMould
  • 18. HistoryPowderedMaterialFrikin’LaserConvert toMachine CodeComputerDesignMelted Layersof MaterialBecomethe PartSelective Laser Sintering(SLS) Process OverviewThe technology for Additive Manufacturing, or Rapid Prototyping, became available in the late 1980s.
  • 19. AdvantagesAdvantages of Rapid Prototyping for a CompanyIt’s faster to print out a prototype than for one to be hand crafted.You only use up as much raw material as is needed to create the part. Which is also good for the environment!You no longer require highly skilled machinists to make prototypes, instead you have printing machine operators.And…(Fleshy unitsare fired!)
  • 20. AdvantagesThe equipment is relatively inexpensive to buy and run… for a company or government.Rapid Prototyping Worldwide
  • 21. DisadvantagesSinteredSteelSinteredPlasticOriginalMakerbotThe surface quality and strength of a printed part may be poorer than machined or extruded parts.Once the moulds have been made it takes a lot less time to extrude or cast a part than it does to print one.
  • 22. DisadvantagesThe Economy of Scale: For a single or a few parts it can make sense to use Rapid Prototyping to create them. For hundreds, thousands or millions of copies of a part, you need to get heavily industrial.Honda EV-N ConceptToyota iQ
  • 23. DisadvantagesAlthough it may be sign that Rapid Prototyping is maturing that some manufacturer are including RP’d parts in their products… or in this case, it’s what they plan to do once they go into production.KOR EcoLogicUrbee
  • 24. 3D Printing @ HomeThe proliferation of home computers and the invention of the Arduino - a cheap microcontroller aimed at electronic hobbyists - has made it possible for home users to get their hands on relatively inexpensive 3D printing machines with controller boards based on the Arduino.
  • 25. 3D Printing @ HomeRight now home 3D Printing is at about the same stage of development as home computers were back in 1975.If you wanted one you pretty much had to order a kit from a hobby magazine, build it and program it yourself.Altair 8800 Computer
  • 26. 3D Printing @ HomeThe first really home-user friendly printer was the Darwin, created in 2008 by the RepRap* Project at the University of Bath in the U.K.*Replicating Rapid-prototyper. The goal of the project is to create a machine which is capable of printing out the majority of the parts required to make another one.
  • 27. 3D Printing @ HomeIt’s open-source design was quickly taken up, modified, and commercialized. Which is where my Makerbot “Cupcake” comes from.
  • 28. 3D Printing @ HomeRepRap Mendel(The next generationpost Darwin.)An exampleof a home made“RepStrap”machineFab@HomeThere are other home printers out there, but currently the ones sold by Makerbot are the most popular kits.
  • 29. 3D Printing @ HomeFor roughly $1000 the Cupcake kit comes as sheets of laser cut plywood, lots of hardware, motors, drive belts and circuit boards.(Some assembly required.)Note: The Cupcake is no longer available, and has been replaced by it’s successor, the Thing-O-Matic. ($1225)
  • 30. 3D Printing @ Home1lb. of Black ABS Plastic ($15)Plastruder Mk.5 ($185, included in kit)Makerbots print objects from a plastic filament, squirting it from the tip of a heated nozzle.
  • 31. 3D Printing @ HomeDremel Mountby clothbotFrostruder ($150)Unicorn Plotter ($85)There are other tool heads for printing with frosting, plaster, clay, etc. A plotter pen holder. And some user-designed ones, such as this bracket for mounting a Dremel cutting tool.
  • 32. 3D Printing @ HomeMakerBot also sells the parts for a 3D scanner, which allows you to create a 3D model that you can use to print copies.Requires that you also buy a Pico Projector and either a PS3 Eye Camera, iPod Touch, iPhone or other VGA video camera.Cyclops ($50)
  • 33. 3D Printing @ HomeDouble Coat Hookby hoekenPrinted by jagOpen-Source printers and 3D models are driving a large hobbyist market for buying & building. Including community websites where you can find 3D files for open-source objects which you can download and print, modify and re-share… and of course you can upload your own designs.
  • 34. How to 3D PrintOnce you have a 3D printer you need objects to print. You can download them from a community website like Thingiverse or you can make your own using free software like Google Sketchup or (if you’re a masochist :) ) Blender.BlenderSketchup
  • 35. How to 3D PrintOpen the file in ReplicatorG - free software for controlling 3D printers - and click the “Generate GCode” button.GCode is the step-by-step instructions that control the printer’sX, Y & Z motors, the extruder’s motor and the heating elements.ReplicatorG
  • 36. How to 3D PrintOnce the GCode is generated you’re ready to print! Get the printer set up, click the Print button and be ready to click the Stop button… just in case.
  • 37. Future of 3D Printing @ HomeNew & improved designs for printers that will be less expensive, easier to build & operate and that will have larger printing areas.Improved electronics which will be less expensive, more powerful and quieter.More printing head types for a wider variety of materials.The ability to print multiple material types in one item.
  • 40. Raw food cartridges (think Tassimo)
  • 41. A 3D model or recipe drives the printing head
  • 42. The recipe takes into account heat sequences, wait times, etc.http://www.geek.com/articles/gadgets/yummy-mit-creates-a-3d-food-printer-concept-20100722/
  • 44. Solid Freeform Fabrication (SFF) http://ccsl.mae.cornell.edu/node/194
  • 45. health & medicalProsthetic CoversWax-ups for teeth mouldsCustomized Hearing AidsBespoke Innovations
  • 48. This presentation is part of our ongoing series of Lunch & Learn educational sessions presented by members of the Delvinia team. For more information on this presentation, our work or anything else, contact us at one of the links below.Tel: 416-364-1455www.delvinia.comfacebook.com/delviniainteractivetwitter.com/delvinialinkedin.com/company/delvinia-interactiveEmail: contact@delvinia.comthanks!