Professional Documents
Culture Documents
recommends Windows
7 Professional.
for any editorial, photographic or typographic errors. All images are for illustration purposes only. For full Lenovo product, service and warranty specications visit www.lenovo. com The
following are trademarks or registered trademarks of Lenovo: Lenovo, the Lenovo logo, For Those Who Do and ThinkStation. Intel, the Intel logo, Intel Core, Core Inside, Xeon and Xeon Inside
are registered trademarks of Intel Corporation in the U.S. and other countries. Other company, product, and service names may be trademarks or service marks of others. 2012 Lenovo.
WWW.LENOVO.COM/THINKSTATION
Meet the all-powerful Lenovo ThinkStation. Unlike other
workstations, these machines are built to handle everything
from design to simulation - meaning you can get your
concepts up and running on a single machine.
www.thinklogic.co.uk/workstations
0845 4751155
Lenovo ThinkStation E32
Intel Xeon processor E3-1200v3 Product Family
Genuine Windows 7 Professional 64-bit
Tower or Small Form Factor chassis
Up to 32GB RAM
Intel or NVIDIA Quadro Graphics
3 year On Site Warranty
Prices from 525 Excl VAT
Lenovo ThinkStation S30
Intel Xeon processor E5-2600v2 Family
Genuine Windows 7 Professional 64-bit
Tower or Small Form Factor chassis
Up to 256GB RAM
Up to dual NVIDIA Quadro Graphics
3 year On Site Warranty
Prices from 720 Excl VAT
020 3178 6467
www.bios-it.co.uk
driveworkslive.com
DriveWorks
Design Automation & Sales Congurator
Develop3D Advert 05-2013_Light.indd 1 18/04/2013 14:25:12
14 Ads.indd 1 04/03/2014 07:19
DEVELOP3D.COM MARCH 2014 15
COMMENT
Admittedly, most of these patents are led
by companies and organisations as opposed
to lone inventors. So, does this suggest that
the era of the great inventor is over - that
somewhat romantic notion of a genius
concocting and experimenting in a lab or
shed before unleashing their invention on
the world? Possibly, yes. Invention doesnt
happen in a vacuum and is more likely a
team eort.
Even in the past, although one person was
credited for an invention, they seldom worked
in isolation. Edison, as an example, had set
up an industrial research lab (he can even
be credited for inventing R&D labs because
apparently that was the rst one) called
Menlo Park in New Jersey where he and his
team worked on several inventions together.
This surely proves that invention is a
collaborative process involving many
dierent people. And although Elon Musk
and Jonathan Ive could be attributed the title
of modern day inventors, their inventions
are absolutely a team eort. There is no way
that, considering the complexity of products
today, they could invent in isolation.
But then its the question: are todays
inventions less signicant? Some economists
think they are and even argue that the rate
of progress seems slow compared to that
golden era of invention. But couldnt it be
the case that instead of ground-breaking
inventions, todays inventions instead oer
incremental change and enhancements to
existing products. So, evolution rather than
revolution.
As James Bessen, a researcher and lecturer
at the Boston University School of Law,
states in his paper Where have the Great
Inventors gone?: Modern inventions may
be more incremental as with, for example,
the many minor improvements made in
frequent software upgrades. Each of these
improvements is less signicant individually
but this does not necessarily mean modern
innovation is less signicant when taken as
a whole.
One invention, which has been
incrementally developed over the years to the
point that it is now being lauded as ushering
I
f you had to ask someone to
name ve of the worlds greatest
inventors, I bet that most would
rattle off the names of inventors
long gone like Thomas Edison,
James Watt, Alexander Graham
Bell, Benjamin Franklin, Karl
Benz This got me thinking - who
are todays great inventors? Or, because
we cant readily name any, are we less
inventive?
One possible reason why we know
the names of these inventors from past
centuries is because their inventions were
so signicant in how fundamentally they
changed peoples lives.
For instance, Scotsman James Watt
created the rst viable steam engine in the
second half of the 18th century. This piece
of machinery was central to the Industrial
Revolution as it spearheaded quicker means
of transportation in the form of steam
locomotives and steamships (an interesting
fact: Watt coined the term horsepower as a
way to help explain how much work his steam
engines could do for a potential buyer).
Similarly, the American Thomas Edison
invented the rst commercially practical
incandescent light bulb in 1880. Thereafter
he founded the Edison Electric Light
Company (now General Electric) to oversee
the layout of the rst electric distribution
grid in Manhattan, New York. Pretty
signicant compared to what was used to
light up homes and businesses before.
Edison led 1,093 patents in his life, quite
a number for one person. But if the ling of
patents is a measure of how quickly we are
inventing, statistics suggest that today we
are more inventive than ever.
The United Nations World Intellectual
Property Organisation (WIPO), reported that
intellectual property patent lings worldwide
grew at their fastest pace in almost two
decades in 2012, reaching an estimated
2.35 million applications led. Whilst the
European Patent O ce recently reported
a new all-time high of patents led with
265 000 received last year, a 2.8 per cent
increase over 2012.
Most of us can reel o past inventions.
Does that mean modern day ones
are less signicant? Tanya Weaver
ponders this, the myth of the lone
inventor and possibly the greatest
invention of our time 3D printing
Tanya Weaver is the special projects editor
at Develop3D. The Beehaus has weathered our
wet, stormy winter and Tanya is about to don
her beekeeing gear and say hi to the bees
tanya@x3dmedia.com
If we are
to believe
the hype
that if you
dream it,
you can
build it,
3D printing
in theory
can make
inventors
out of all
of us
1 The 3D printed
window breather
pipe for use on the
BAe 146 aircraft
p20_21_22_24_D3D_MARCH14_BAE.indd 22 4/3/14 20:54:31
Real parts. Really fast.
A product development team needs parts
to meet its rapidly approaching deadline.
. . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
How
Many Parts?
2510,000+
parts
125
parts
Receive a
ProtoQuote
interactive
quote.
Finalise
quote and
submit P.O.
Receive
order
conrmation
with gate
and ejector
layout.
Approve.
Mould
design
and
milling.
Part
production.
Parts
ready
for
shipping.
From 995
Parts
ready
for
shipping.
From 50
Machining
begins.
Finalise
options,
order.
Receive
FirstQuote
interactive
quote.
Its easy to work with Proto Labs. Just upload your
3D CAD model and choose the best process for your project:
CNC machining in 13 days or injection moulding in 115 days.
Real parts in real materials, in daysnot weeks. And thats the
real story. Call +44 (0) 1952 683047 or visit www.protolabs.co.uk
Check out our
video design tips!
Visit www.protolabs.co.uk/parts today to receive your FREE
copy of our comprehensive comparison of rapid prototyping
technologies. Enter source code EUD314
Upload
3D CAD le.
Rapid Prototyping Technologies
Proto Labs 2014 ISO 9001:2008 Certied
D3D 297 x 210_new_Layout 1 14/01/2014 14:28 Page 1
24 MARCH 2014 DEVELOP3D.COM
At the
moment our
imaginations
are 50
years
ahead of
where the
technology
is. Currently
you cant
print an
entire
aircraft
wing but it
will happen
s
i
n
s
t
r
u
m
e
n
t
s
a
r
e
m
u
s
i
c
i
c
o
n
s
.
I
t
s
S
t
r
a
t
o
c
a
s
t
e
r
,
T
e
l
e
c
a
s
t
e
r
a
n
d
J
a
g
u
a
r
m
o
d
e
l
s
h
a
v
e
e
m
p
o
w
e
r
e
d
m
o
r
e
r
o
c
k
l
e
g
e
n
d
s
t
h
a
n
c
h
a
m
p
a
g
n
e
a
n
d
c
o
c
a
i
n
e
c
o
m
b
i
n
e
d
,
a
n
d
c
o
n
t
i
n
u
e
t
o
d
o
s
o
w
e
l
l
i
n
t
o
t
h
e
m
o
d
e
r
n
a
g
e
.
J
i
m
i
H
e
n
d
r
i
x
,
B
o
b
D
y
l
a
n
,
R
i
t
c
h
i
e
B
l
a
c
k
m
o
r
e
,
K
u
r
t
C
o
b
a
i
n
,
G
e
o
r
g
e
H
a
r
r
i
s
o
n
,
K
e
i
t
h
R
i
c
h
a
r
d
s
,
B
r
u
c
e
S
p
r
i
n
g
s
t
e
e
n
a
n
d
E
r
i
c
C
l
a
p
t
o
n
h
a
v
e
a
l
l
p
i
c
k
e
d
u
p
o
n
e
o
f
i
t
s
m
o
d
e
l
s
w
h
e
t
h
e
r
i
n
t
h
e
s
t
u
d
i
o
F
e
w
p
r
o
d
u
c
t
s
h
a
v
e
i
n
u
e
n
c
e
d
s
o
m
a
n
y
p
e
o
p
l
e
i
n
t
h
e
w
a
y
t
h
e
e
l
e
c
t
r
i
c
g
u
i
t
a
r
h
a
s
d
o
n
e
,
a
n
d
i
n
t
h
e
6
0
y
e
a
r
s
i
t
h
a
s
b
e
e
n
p
r
o
d
u
c
i
n
g
i
t
s
S
t
r
a
t
o
c
a
s
t
e
r
m
o
d
e
l
F
e
n
d
e
r
h
a
s
e
x
p
a
n
d
e
d
s
u
b
s
t
a
n
t
i
a
l
l
y
.
W
i
t
h
e
x
p
a
n
s
i
o
n
c
o
m
e
s
d
e
s
i
g
n
c
h
a
l
l
e
n
g
e
s
;
t
o
m
e
e
t
t
h
i
s
F
e
n
d
e
r
h
a
s
e
x
p
a
n
d
e
d
i
t
s
R
e
s
e
a
r
c
h
a
n
d
D
e
v
e
l
o
p
m
e
n
t
(
R
&
D
)
f
a
c
i
l
i
t
i
e
s
t
o
s
u
p
p
o
r
t
i
t
s
h
e
r
i
t
a
g
e
g
u
i
t
a
r
f
a
m
i
l
i
e
s
a
s
w
e
l
l
a
s
n
e
w
p
r
o
d
u
c
t
l
i
n
e
s
.
W
h
a
t
s
r
e
a
l
l
y
e
v
o
l
v
e
d
o
v
e
r
t
h
e
y
e
a
r
s
i
s
t
h
e
u
s
e
o
f
3
D
p
r
i
n
t
i
n
g
p
l
u
s
o
u
r
d
e
s
i
g
n
p
r
o
c
e
s
s
,
s
a
y
s
F
e
n
d
e
r
s
s
e
n
i
o
r
m
o
d
e
l
m
a
k
e
r
S
h
a
w
n
G
r
e
e
n
e
f
r
o
m
h
i
s
w
o
r
k
s
h
o
p
i
n
t
h
e
c
o
m
p
a
n
y
s
A
r
i
z
o
n
a
h
e
a
d
q
u
a
r
t
e
r
s
.
T
h
e
c
l
a
s
s
i
c
S
t
r
a
t
h
a
s
e
m
p
o
w
e
r
e
d
m
o
r
e
r
o
c
k
l
e
g
e
n
d
s
t
h
a
n
c
h
a
m
p
a
g
n
e
a
n
d
c
o
c
a
i
n
e
c
o
m
b
i
n
e
d
PROFILE
28 MARCH 2014 DEVELOP3D.COM
A 19-year career at Fender has seen Greene
traverse all its R&D departments, from
graphic and industrial design to nding his
domain among the physical model making.
From this position he has seen the
advancements in all its processes.
Now, were able to really go from sketch all
the way up to rst production units in a very,
very short amount of time.
GROWING VOLUME
Fenders growth has seen it expand from
electric guitars and basses to amps, pedals
and, now, high-end studio audio equipment,
with the complexity of the product at the
heart of the R&D turnover rate.
Over the years weve done very minor
refreshes, says James Giord , Fenders VP
of design and R&D. On the ip-side we have
projects that were doing now that are brand
new from scratch.
These full-blown design processes involve
extensive brainstorming sessions, concepts,
user observations and interviews with
consumers, repeatedly going back through
the conceptualisation process to gain extra
renement.
These major projects will probably take
the better part of a year to a year and a
half to complete before theyre actually on
the market. So theyre a little more time
consuming than a normal refresh.
A refresh can be on a guitar family that
has remained untouched for over two
decades, adding extra pressure to the design
team to keep fans happy.
All of the products begin life as sketched
concepts, whether a slight adjustment of a
classic guitar or a wholly new product.
One of our designers
here is very adept with
Keyshot and SolidWorks,
so he actually likes to use
that, says Giord.
On the ip side I have
another designer that is
really good at sketching
using the Wacom Cintiq
screen, so theres a little combination of
medium before design reviews, before we do
full 3D CAD, and the point where Shawn is
putting together physical models for us.
WOOD WORKS
As tactile products, Fenders designs need to
be physically prototyped: a digital model is
not enough to get a feel for a product, and is
unable to relay what sound it can produce.
For this reason Fender has modelshops at
all its facilities, spread around the hot and
dry southeast states one at its corporate
oces, another, along with its custom guitar
shop, at its Corona, California site where all
the American products are manufactured.
Then theres another model shop at
Fenders large manufacturing plant in
Ensenada, Mexico.
Utilising a blend of traditional and digital
cutting, Greene and his team use the main
CNC machine at the Corona facility, sending
the 3D les to California before the physical
models are shipped overnight back to
Arizona.
Weve just got a CNC machine in our model
shop too. Its a pretty small CNC, hints
Greene, But to tell you the truth, a lot of the
woodworking we do: if its a cabinet we have
table saws and all the woodworking materials
we need; if its a guitar, a
lot of times well do them
by hand.
Still, to this day, here
in the model shop some
of our guitar techs and
luthiers will still do initial
carvings with larger tools,
and then hand-shape it.
Its still old-school, and we like it that way!
Around 10 years ago Fender rst adopted 3D
printing for small prototyping jobs using a
bureau service.
At the time Fender was primarily wood
products and ampliers, a lot of wood and
vinyl, and we did what we did very well with
all of that, but as we grew we started to use
more plastic parts for dierent products like
foot pedals and drum parts.
As we acquired other companies and grew,
the need for doing really intricate moulds
and parts grew as well.
The old design process back then relied
on waiting for a quote back from the output
house, getting funding signed o for it, then
waiting on the part to be shipped a week-
long process, maybe even more, says Greene.
After four and-a-half years of working in
this way Greene and his team fully realised
the benets of 3D printing and the potential
of speeding up the process by bringing it
in-house.
The team started o with an Objet Eden,
although the limitations of having only one
print material saw them update the machine
to an Objet Connex350.
Now were able to do over moulding and
use the ABS-like material, justies Greene.
Fender relies on this single machine, but
The R&D woodwork
for Fenders guitars
is done using a blend
of traditional and
digital cutting
PROFILE
Now were able to
really go from sketch
all the way up to rst
production units in
a very, very short
amount of time
Sometimes, what we tend to nd is that LEGO resources can light a passion in a student
that you would never normally see before because its a hands-on way of learning
Gareth Boldsworth, LEGO Education Europe
2 Triple-stand
passenger boarding
bridge (PBB) at Dubai
Airport during a
docking between a
PBB and an A380-800
aircraft
3 Lift-and-drive
system
3
2
p33_34_D3D_MARCH14_Ansys.indd 38 4/3/14 20:58:05
DEVELOP3D.COM MARCH 2014 3D1
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
3D PRINTING
FOR THE
PROFESSIONAL
The fuTure of 3D
PrinTing:
Where are We
heading?
BuiLDing A 3D
PrinT BuSineSS:
TiPS FrOM
The PrOS
BeST PrAcTiceS &
workfLowS:
hOW TO geT The BeST
FrOM YOUr 3d daTa
3D PrinTing
MAchineS:
BreaKdOWn OF
eaCh BUiLd TYPe
incLuDing:
I
M
A
G
E
C
O
U
R
T
E
S
Y
O
F
N
I
K
E
I
N
C
.
SPONSORED BY:
3D PRINTING FOR PROFESSIONALS.indd 1 4/3/14 15:53:12
3D2 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
What drew me in was this fun,
new way to pull and twist models
into complex shapes.
David Perry
Founder & Engineer
OpenFab PDX, LLC
this document. 2014 Autodesk, Inc. All rights reserved.
3D PRINTING FOR PROFESSIONALS.indd 2 4/3/14 17:02:54
DEVELOP3D.COM MARCH 2014 3D3
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
What drew me in was this fun,
new way to pull and twist models
into complex shapes.
David Perry
Founder & Engineer
OpenFab PDX, LLC
this document. 2014 Autodesk, Inc. All rights reserved.
Producedby
DEVELOP3DMagazine
Technologyfor the
product lifecycle
DEVELOP3D, Rooms 108-109
4thFloor, 65 LondonWall
London, EC2M5TUK
+44(0)203355 7310
production@x3dmedia.com
FREESUBSCRIPTIONS
inprint andPDF@
www.develop3d.com
AlsoavailableontheiPhone,
iPadandKindle
2014X3DMediaLtd
All rights reserved.
Reproductioninwholeor part
without prior permissionfrom
thepublisher is prohibited. All
trademarks acknowledged
Al Dean
Editor-in-Chief
DEVELOP3D Magazine
@alistardean
I
f theres a word thats overused these days, its revolutionary.
It ts in neatly alongside innovation, paradigm shift and
all the other biz-speak were so accustomed to. As said in one
of my favourite books, some of us hanker after a time when
revolutionary means the angry poor invading the presidential
palace, not a really small phone thats also a camera.
But if you believe the media, the magazines and the tech websites that
seem to spring up every 34 seconds on a 24 hour cycle, 3D printing is
causing a revolution. Its the next industrial revolution no less.
In the workplace, in the hackerspace, in the home and now even, in the
kitchen. Imagine that, alongside the overly complex espresso machine,
well soon all be rotting our teeth that much more quickly as Martha
Stewart sells us 3D printed sweeties... or something.
The truth is that while the industry turns itself inside out to grab the
headlines, to get Jeremy Paxman staring blankly at an Objet machine on
Newsnight or Jay Leno laser scanning a car, some of us have work to do.
And there are plenty of things afoot to assist with the process of bringing
new products to market.
So, here in this 40 page report, our aim is to bring the professional
designer and engineer up to speed. To break a few of those old
misconceptions (SLAs arent all that brittle anymore and FDM parts
arent that rough), to get you familiar with the glut of technology thats
available; whether to use in house or to outsource to a service provider.
Well also explore how new design and 3D print led businesses are
being established, how rulebooks are being torn up, and perhaps, how
new ones are being written on the back of a cigarette packet as we speak.
Flip the tarot cards. Lets go!
DONT BELIEVE THE HYPE - OR SHOULD YOU?
As 3D printing goes mainstream, many in the professional
environment are wondering where things are heading. We explore
what this heightened awareness can mean for the professional.
Also see our handy jargon buster
04
FILAMENT-BASED MACHINES 08
UV RESINS & STEREOLITHOGRAPHY 10
LASER SINTERING FOR PLASTICS 12
3D PRINTING WITH METALS 14
ALTERNATIVES & SPECIAL PURPOSE 16
MATERIALS - ADAPTING PROCESS & DESIGN
To get the most out of new materials they need to be combined
with new ways of thinking in terms of design and engineering
26
GETTING THE BASICS RIGHT & SOFTWARE
The old adage of rubbish in/rubbish out is never more true than
when 3D printing. We explore what tools are available in 3D design
tools and standalone apps and offer advice on best practice
18
NEW RULE BOOK: DESIGN FOR 3D PRINT
Freedom from design rules is the refrain from many quarters.
Whats the reality and what are the best practices you need to
keep in mind if youre looking at design for 3D printing?
22
DOES COLOUR MATTER?
2014 looks to be the year of colour 3D printing. While its nothing
new, more vendors are bringing colour machines to market in a
drive to differentiate their offerings. We explore the potential
28
WORKING WITH BUREAUX
3D printing in house isnt for everyone. Theres a wealth of
service providers out there with the capacity and know-how to
help. How do you work with them to the best effect?
30
THE FUTURE IS INDUSTRIAL
If 3D printing is to be used in production, it will be essential to
automate, manage and plan the process.
34
BUILDING A 3D BUSINESS
3D printing lets you get up and running quickly with production
but its not without its problems and challenges. We talk to four
organisations on how to build a new business around 3D printing
32
FUTURES: 3D PRINTING FOR THE PRO
In a 3D printing market thats now exploded outside of its
industrial roots, we talk to three industry folks about what the
future holds for the professional
36
WHERE DO WE GO NEXT?
The 3D print industry is on an acceleration vector. Al Dean looks
at whats coming next, potential stumbling blocks and ultimately,
where were all heading
39
VIVE LA REVOLUTION?
3D PRINTING IN THE DESIGN OFFICE?
Thinking of bringing 3D printing into the offce environment?
Here are our top three tips
24
3D PRINTING FOR PROFESSIONALS.indd 3 4/3/14 17:03:19
3D4 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
Its all over the TV, the internet and newspapers, but what does the media love-in
with 3D printing mean for the professional? Al Dean explores the hype
DONT BELIEVE THE HYPE
OR SHOULD YOU?
Over the years the 3D printing industry has been rife with
legal action over patents. Patents have been fought over,
argued about and various parties taken to court at the
drop of a hat. It has also been said, particularly in the last
fve years, that the patent enforcement by the established
players in the industry has, in fact, held back developments
and more widespread adoption.
But change is happening. Adrian Bowyers RepRap project
at the University of Bath helped bring this to a head,
kickstarting a staid and tightly controlled industry into its
next evolution.
Bowyers RepRap saw the open source model applied to
3D printing, just at the point where the core patents for FDM
printing processes expired. Its open development processes
allows anyone to take the tools from that project and apply
them to their own work.
RepRap has been the driving force for almost every 3D
printer thats been launched in the last fve years. MakerBot,
Ultimaker - none of these would have existed without
Bowyer and his teams work.
Strangely, the progress of MakerBot, from its roots at
the Brooklyn NYC Resistor hackerspace, to darlings of the
next industrial revolution to its acquisition by Stratasys
last year, is a perfect case in point. MakerBot has done a
fne job of avoiding legal entanglements with Stratasys
(who own the majority of patents on the FDM process), but
this was holding it back somewhat. Many features such as a
temperature controlled build chamber and software controls
over how layers are constructed were off limits.
Now that MakerBot is part of Stratasys, well likely
see these features and many others in future MakerBot
products. But at the same time, its parent company is now
going after some of its competition in the maker/entry level
space, namely Afnia, itself a reseller of TierTimes Up! 3D
printers from China.
Were starting to see the same happen in both
Stereolithography (US patent # 4575330A) and the sintering
market (US Patent # US 4863538 A), already with new
machines on the market: see the FormLabs and BluePrinter
machines respectively.
Its fascinating to watch small, nimble companies, quite
often crowd funded through KickStarter, take a new
approach to these processes and fnd new ways to cut costs,
reduce complexity, the overall price and generally out gun
the established players in the market.
Its also interesting to watch new sub-markets open up
to support these new machines. With the wealth of FDM
machines now available, theres more material options
than you can shake a stick at. You can buy flament thats
all manner of colours, different materials (Nylon, ABS, PLA,
even a wood flament) that would never have seen the light
of day before. Despite these big advances, there are still
many 3D printing patents in effect. Whether you see them as
a right to protect your IP or a way for large corporations to
control their technology, they are certainly going to play a
major role in how the 3D printing industry evolves.
M
y rst ever 3D printing
conversation with a
layperson was with cab
driver at the tail end of
the nineties. Id been
to visit 3D Systems and
he asked what they do. I explained about how
SLA machines worked: lasers, resins, parts
appearing out of resins, as if my magic. I
used the example of him wanting a custom
steering wheel. Im not entirely sure he
believed me.
Fast forward fteen years and I nd
Im having the same conversations. The
dierence is cab drivers today have now
heard about this stu. 3D printing is
everywhere: on the TV, radio, in newspapers
and magazines.
In London recently I had much the same
chat with a driver. Hed read about 3D
printing in the newspaper that very day. Of
course, he heard about the 3D printed gun,
but wanted to know more if he could
do it himself. Hed need to learn some 3D
modelling, I explained (no, not like in Tron),
buy a machine or send the part o to be
made. So, I tell the machine what I want and
it pops out, yeah?
Im sure youve had that same conversation
yourself, made the same exhalation of breath
and thought Here we go again.
Welcome to the world of 3D printing and
the associated hype.
MYTHS VS REALITIES
In the last few years 3D printing has
broken out of the design and engineering
community and, grabbed the public, the
investment community and (seemingly) the
world, by the proverbial short and curlies.
Stock prices have rocketed up for the
established players and new entrants like. The
number of column inches and TV minutes in
all manner of media has risen sharply. And a
lot of the reporting has been inaccurate or the
truth stretched more than a little.
If you were to believe everything you read,
aerospace companies will be 3D printing
planes in the next 10 years, houses will be
extruded from concrete and well all be doing
our DIY with a 3D printed hammer. I wish I
was making these things up.
But with hype comes a burden on those
that best stand to take advantage of these
technologies, to sift through the nonsense,
the ill-thought out and misconstrued, and
nd areas of interest.
So lets start by breaking down one of the
most common myths about the technology
- that of exactly how quickly these machines
work. This is the cause of much confusion.
TIME TO PART
Many people assume that because a 2D
printer is fast, a 3D printer must be too.
Wrong. Blame the marketing bods, blame
the term Rapid Prototyping, these machines
certainly arent quick, never mind rapid. A
typical build can take anywhere from an hour
to a day or more.
When youre looking at these processes and
machines, perhaps with an eye to bringing
The 3D prinTing pATenTs piCKLe : prOTeCTiOn vs. prOgress
(Right) Figures from Chuck hulls 1984 patent (# Us
4575330 A) for stereolithography that started it all
3D PRINTING FOR PROFESSIONALS.indd 4 4/3/14 17:03:48
DEVELOP3D.COM MARCH 2014 3D5
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
things in house, you do need to know how
quickly you can turn around components.
In the prototyping phase, being able to
quickly crank out a part, try it, see if it works
has huge benets, which are negated if it
takes a day to churn it out.
In the production cycle, when youre
looking to produce nal use components (be
those actual products or those that support
other manufacturing process - such as jigs,
xtures, mould inserts, whatever) - time is
always a commodity closely guarded.
Most manufacturers will quote you a build
speed in terms of millimeters per hour, but
its an almost meaningless metric.
Build speeds dier massively depending on
the type of geometry, how you want the part
built, the settings you use, the number of
parts, the technology and the materials.
Metals are another kettle of sh entirely.
Most vendors will quote in cubic mm/
inches per hour. The Renishaw AM 250, for
example, quotes a range of between 5 and 20
cubic centimetres per hour. This is because
of the physical properties of the dramatically
dierent metals, their inherent heating and
cooling parameters and how dense the part is
youre building.
But before you get to building the part,
youve got to prepare the data. Again, this is
an area thats often glossed over.
MODEL PREPARATION IS EASY
Model preparation directly aects time to
part - and its not a simple case of loading an
STL le and hitting print. Its not just a case
of ensuring that your model is suitable for
printing, but also ensuring that the layout of
the build platform or chamber is as optimal
as possible - bearing in mind the required
orientation of the parts to account for both
structural requirements and surface nish.
In terms of model preparation, many
3D printers will build most components,
assuming that you adhere to the design
guidelines for those specic machines and
materials.
Weve categorised some of these on page
18, but machines vary as do materials
in use. Every vendor will have a set of
guidelines available as part of the machine
and materials documentation and its worth
studying these, whether youre outsourcing
parts or building them in house.
Some processes have specic requirements
to handle their own particular foibles.
For example, if youre building parts with
internal and trapped cavities (or building
parts hollow to save material), you need to
allow the powder or resin to escape where
appropriate - the route for removal of this
excess material ideally needs to be modelled
in (rather than drilled them after the fact).
If you have specic functionality built in
the parts, then this also needs to accounted
for. Most 3D print processes and their
associated materials are anisotropic,
meaning that the materials perform better
The hYPe VS. The realiTY
#1: its going to get cheaper #2: Freedom of design #3: its quick
THE HYPE: This is perhaps the biggest driving force
behind todays growing awareness of 3D printing
technologies. Machines are cheaper so more people
can aord them.
THE REALITY: In many respects, this one is absolutely
true. Whereas an FDM machine used to cost you 20 grand
or upwards, you can now order one, online, for 500 quid.
The RepRap project rewrote the rules (and the pricebook)
and its now happening with stereolithography and soon
sintering technologies. But material costs? Not so much.
THE HYPE: This is one thats been oating around for
decades the idea that by using 3D printing youre
somehow magically set free from the constraints of
Design for Manufacture and Assembly.
THE REALITY: By using 3D printing to build end use
parts, its true that you are free from traditional DFM
constraints. Draft angles, mould locked features and
inaccessibility for cutters dont gure. Whats not widely
discussed is how theres a new set of rules, for each
build method and for each material.
THE HYPE: Blame whoever coined the turn rapid
prototyping. A common misconception, particularly
those outside the professional industry, is that these
things work as quickly as a standard inkjet.
THE REALITY: Building a part on a 3D printer is
anything but quick. The benchmark is still 1 per hour
of vertical build. And probably always will be. Theres
only so much time that you can squeeze out of curing
UV resin, laying down lament or sintering powders. Its
physics and chemistry, folks.
#4: Theyre offce friendly #5: its easy #6: aBS is aBS is aBS
THE HYPE: Whether its 3D printing in the home or in a
busy oce environment, you pull out the box, you plug in
the machine and away you go.
THE REALITY: Um. No. At the entry level, lament-
based machines can be used in the oce, but they stink
and the health eects of inhaling molten PLA or ABS
is unexplored. The other systems, those with soluble
supports need a wash station, sintering needs heavy duty
extraction. And hitting powdered titanium with a laser is
pretty much an explosion waiting to happen.
THE HYPE: Install your machine, output your data,
hit print. Its that easy. Just like your desktop
document printer
THE REALITY: There are very few machines where
this is a reality. At the entry level, platform leveling
and constant maintenance is common. As things move
higher up the ladder of complexity and sophistication,
processes become more complex. The just hit print
machine just simply doesnt exist. Things are improving,
but its a long way o just yet, folks.
THE HYPE: 3D print vendors like to make much noise
about the materials that their machines use. ABS, PLA,
Nylon, Titanium, Aluminium.
THE REALITY: Part quality and structural strength is a
combination of the raw material, the production method
and post treatment. Yes, a 3D printed part might be
technically ABS, but its not been melted, injected into
steel mould at high pressure and cooled. 3D printed
parts are inherently weaker than their traditional
counterparts, often dramatically so.
Gartners annual technology hype cycle. This differs from previous iterations as it splits out consumer printing
(top of the curve) and enterprise 3D printing (further along to the right) (Image courtesy of Gartner Research 2014)
3D PRINTING FOR PROFESSIONALS.indd 5 4/3/14 17:03:59
3D6 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
in one direction than another.
Good, common examples are snap ts
and living hinges. You need to look at the
orientation of the layers and ensure that these
match the requirements of the feature. If it
needs to ex, then you need the layers to run
in that ex direction. Otherwise theyll snap.
All of these things add to the time required
to get parts o your machine and back to
work.
POST PROCESSING
Build speed is one thing but you also need
to consider post processing. This can
add signicant time between the
moment you hit print and when
you have a nished part in your
hands.
Filament machines either require
manual break out of supports or
the supports need to be dissolved
(that can take a good couple of
hours, even with a wash station
tumbling them).
Machines that use UV resins
often need to be photocured post build to
harden them o. This applies to SLA, Objet,
Envisiontec or FormLabs machines.
Sintering machines need to cool down the
powder cake that contains all of the parts.
This is in the order of hours. Then the parts
need to be removed from the powder, cleaned
and the unused powder recycled.
The real question is often how integrated
these processes are and whether you need
additional equipment. Theres much talk
about printing with metals, but its not often
discussed exactly what is needed to do it,
whether its an angle grinder to remove parts
from the build plate or a furnace to harden
parts for some systems.
HYPE IS GOOD
3D printing may be in need of a serious
reality check to bring down expectations,
but hype can also be a very good thing - with
professionals in design, engineering and
manufacturing set to gain the most.
With greater exposure and awareness, 3D
print manufacturers, old and new, get more
investment, a bigger customer base and
more potential to do interesting things we
can take advantage of in the design oce or
on the shopoor.
Will we care that there are legions of
hobbyists spending their disposable income
on a 3D printer that, chances are, will sit
unused in a box in the loft, in 12 months
time? Probably not, though it will make
eBays 3D printer listing interesting reading.
Will we read poorly researched articles in
the mainstream media, answer questions
from friends and family that give us
nightmares of 3D guns exploding in
someones face, over claimed benets and
future revolutions? Almost certainly.
Will the hypes lifecycle also mean that
the diverse nature of 3D print technologies
available expands in ways that it could never
have done before things stepped outside of
the industrial world and into the limelight?
Absolutely.
Were all looking forward to lower-cost,
more reliable, more capable machines in our
design oces that dont require specialist
technicians to run. We can wait for the ability
to realise parts in metal, directly, without the
need for wasting material and scrap
with CNC, casting or forging.
There is also huge potential
to reevaluate how things are
done, to break down traditional
manufacturing processes and
explore new avenues. New avenues
for lighter weight components,
leading to products that achieve
the same or better results more
eciently.
And its the professional designer or
engineer that stands the best chance of
doing it. We have the knowledge of form,
of function, of performance and to use
that knowledge, combined with new
technologies, to reinvent what we do,
integrate it with traditional manufacturing
and try new things.
Many talk of the next and third industrial
revolution. And you know who made the
most of the rst two? Yup. Us. The designers,
the engineers and the manufacturers.
BRE: No, its not a mispelled French cheese, Bre Pettis is
the CEO of MakerBot and now worth a small fortune since
his company was acquired by Stratasys. He also has good
hair and owns a DeLorean.
BUILD VOLUME: This one is pretty simple. Its the typical
maximum size of the part (or group of parts) that you can
build in one go.
FILAMENT: Plastic, extruded into a long thin wire like form.
Used in FDM machines, it comes in a variety of materials,
diameters (1.75mm and 3mm are common) and hues.
Street price is around the 30 quid for a kilogram.
Quality varies across suppliers and youll soon fnd which
you prefer for your machine.
G-CODE: FDM machines use G-Code to defne how the
machine moves. RepRap based machines expose this.
Others dont. Oh and you cant run it on a CNC machine.
INFILL: Parts dont have to be built using a solid
block of material. Instead you can build with different
infll methods resulting in lower material use and
improvements to build speed. However, structural
strength will weaken as the in fll becomes more sparse.
POLYAMIDE: This is a good one. Some vendors like to
give their materials fancy names. Polyamide is pretty
much nylon in powdered form. And it costs 80 Euros/Kg.
PLA: Polylactic acid. While ABS had been the most
common FDM material, PLA caught on as it runs at lower
temperatures and doesnt suffer from part warping quite
so much.
Its eco-credentials are also often quoted because it can
be composted. It can, if you have industrial composting
facilities nearby (chances are, you dont). Otherwise, its
landfll like the rest of it with a half life of decades, if not
centuries.
RECOATER BLADE: Powder-based machines use a blade
to spread the fresh layer of powder across the previously
built layer. This is the recoater blade. Technicalities differ,
but they all have one. And it can snap thin walled parts
pretty easily (See our design tips on page 22 for more info).
STACKABLE BUILD: Most 3D printers only allow you to
have one layer of parts on a build platform. Powder-
based systems differ in that you can build one part on top
of another, as the powder supports the parts.
SUPPORTS: If your part has overhangs, undercuts and
complex forms, supports are a necessary evil. Built either
in the part material or a special support material, theyll
give support where needed to allow the geometry to be
constructed.
More advanced systems offer water soluble supports,
otherwise its a case of going at it with a pair of long
nosed pliers Im afraid.
STL: Named after Stereolithography, the STL format is
the de facto standard for sending data to a 3D printer.
Its tessellated in nature and pretty much ubiquitous in
support from 3D design systems.
SLICING: 3D printers work by building a parts geometry
layer by layer. To do that, it takes the STL fle and creates a
slice for each layer, indicating where to deposit material.
TIP SIZE: Pro-level FDM machines offer different tip sizes
to lay down different sizes of flament beads on each
layer. The bigger the tip size, the bigger the bead and
quicker the build. But resolution can also drop.
THE NEXT INDUSTRIAL REVOLUTION: This one is
popular with pundits that 3D printing is bringing about
the third industrial revolution. Is it? Probably not.
UV OVEN: Commonly used to harden off parts out of
stereolithography or other UV curable resin based
systems. Some have them built-in, others need a
secondary unit. Search on eBay for UV Curing Oven.
Theyre commonly used in surgery for sterilisation of
implements.
WASHSTATION: A lot of machines come with water
soluble supports these days. That means you need to
wash them out. Stratasys has a handy product but third
party units are also available.
3D PRINTING
jARGON BUSTER
As with any technology feld, 3D printing is not adverse to its own jargon and
technospeak. For the uninitiated, this can cause confusion and, probably, mild irritation.
So, heres our irreverent guide to the most commonly used and abused terms
Competition is growing
3 ) that would be
diffcult to achieve using powder-bed techniques.
Once the near net shape component is ready, the 5-axis cutting
capability of the machine takes over and can use the companys
experience in machining to fnish and post machine those rougher
forms (fgure
4 ).
The company believes this can give up to 20x speed improvements
on existing technologies and can save 95% of material waste compared
to machining from billet. Engineering metals supported include steel,
nickel and cobalt alloys, brass and titanium.
dmgmori.com
Mlab Cusing r sLM 280HL renishaw AM250 Eos M sINT 400 DMG LAsErTEC 65 AM
The Mlab Cusing R is at the entry-level of Concept
Lasers metals machines range. It has a small build
platform that allows you to process a range of
materials at very high resolution. This makes it ideal
for small components in the medical or jewellery
industry (especially when combined with its support
for precious metals such as gold and silver).
It has multiple sized build chambers available, runs o
single phase power, has no extraction requirements
and will t through a standard door
The SLM (Selective Laser Melting) 280HL oers a
good sized build chamber with options to upgrade the
optics. Installing two lasers means that the system
can build ne details on the exterior of parts with one,
then ll in the internal parts of a layer with the other.
Build capability can get down to 0.2 mm in terms of
wall thickness and feature detail and can process
a wide range of materials, from steels through to
the more dicult metals such as aluminium and
titanium. There are also options available to automate
materials handling.
Renishaw is well known name in the world of
manufacturing. Its AM125 and AM250 machines
are recent entrants into the metals printing world
and oer two usable build envelopes in single,
integrated units. This means that no additional
stations are required for material recycling (unused
powder is automatically reintroduced into the
system while its running).
The option to extend the build envelope from 300mm
to 360mm also gives additional options for those with
larger component requirements.
EOSs M Sint machines have been on the market for
a decade or more now and the M SINT 400 is the
current state of the art, large frame machine.
With its 400 x 400 x 400 mm build chamber, it
combines larger capacity with a higher-speed 1 kW
laser for building metal components from an ever
expanding set of materials. Together with EOS
mastery of the complete process, from materials
handling, recycling and post processing, this is the
true state of the art.
DMG Mori Seiki will soon be launching this beast of
a machine, which combines metal deposition with a
3- and 5-axis CNC machining capability.
The machine uses what is essentially a CNC driven
weld bead to make the initial form. The part is then
allowed to cool and the system then machines the
exact form to the required tolerances. For those
working at the outer reaches of aerospace and
autosport, this could be very interesting indeed
(see box out top right for more info)
Price 180,000 350K to 400K depending on nal specication On Application On Application On Application
Build Envelope 50 x 50 x 80 mm 90 x 90 x 80 mm 280mm x 280mm x 350mm 250 x 250 x 300 mm (Z axis extendable to 360 mm) 400 x 400 x 400 mm 650/650/560 mm (CNC) | 500 x 350 mm (3D print)
Warranty 1 year (on-site with extension options) 2 years (with extension options) 1 year 1 year 1 year
Machine Dimensions 705 x 1,848 x 1,220 mm 1,800 x 1,900 x 1,000 mm 1,700 x 800 x 2,025 mm 4,181 mm x 1,613 mm x 2,355 mm 2,200 x 1,600 x 2260 mm
Layer Thickness 0.015 - 0.025 mm 0.2 mm 0.02 - 0.1mm 0.016 mm Not applicable
Material options
Golds (various colours), silver, bronze, stainless steel,
titanium and cobalt chrome
Titanium and aluminium alloys and also high
temperature materials including nickel and steel alloys
Stainless steel 316L and 17-4PH, H13 tool steel,
aluminium Al-Si-12, titanium CP, Ti-6Al-4V and Ti-6Al-
7Nb, cobalt-chrome (ASTM75), inconel 718 and 625
Aluminum, colbalt chrome, stainless steel,
titanium and nickel alloy
Stainless steels, tooling steels, non-ferrous alloys,
super alloys, precious metals, alumina
Website concept-laser.de | estechnology.co.uk slm-solutions.com | laserlines.co.uk renishaw.com eos.info dmgmori.com
R
enishaw has collaborated with
a British bicycle design and
manufacturing company to
create the worlds rst 3D printed metal
bike frame. Empire Cycles designed
the mountain bike to take advantage
of Renishaws additive manufacturing
technology, allowing them to create a
titanium frame that would be both strong
and light using topological optimisation.
The new frame is some 33% lighter than
the original.
The projects aim was to produce a
fully functioning bicycle, so the seat post
bracket was tested using the mountain bike
standard EN 14766; it withstood 50,000
cycles of 1 200 N. Testing continued to
six times the standard without failure.
Additional benets included the ability to
integrate internal strengthening features
that couldnt be manufactured using
traditional approaches and the ability to
optimise design right up to production
renishaw.com/empire
EMPIrE CYCLEs BUILDs FIrsT 3D
PrINTED FrAME WITH rENIsHAW
CoMBINING 3D PrINTED
METAL WITH 5-AxIs CNC
Jeremy Pullin is Rapid Manufacturing Manager at Renishaw (renishaw.
com) and runs one of the UKs most advanced prototyping centres to
support the companys own design, engineering and manufacturing
facilities. Here, he gives us 3 tips for printing in metals.
#1 You cant stack parts: 3D printing in metal powder isnt like
printing in plastic powders. Unlike plastic SLS, you cant stack the
build, as metal powder systems need supports so once the 2D
dimensions of your table is full of parts you can ft any more on.
#2 Never underestimate the importance of supports. The need
for supports has several far reaching implications. Metal supports
need to be mechanically removed which means you have to be able
to access them with your removal tools or leave them in place. If your
supports are stronger than your part features then your part may
well be damaged when you are doing support removal.
#3 Dont shortcut on health and safety: We all do the odd thing,
like stroking a dog that we dont know, when the paranoid health
and safety police arent looking, but with metal systems you need
to do it all by the book because these dogs can bite. Wear all of the
correct gear and control access to the area when youre working
with powders. Make sure that the environment is correctly set up for
ventilation and electrical requirements. Most importantly of all make
sure that the people using the correct kit are properly trained.
1 2
3 4
3D PRINTING FOR PROFESSIONALS.indd 15 4/3/14 17:05:42
3D16 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
Not every 3D printer can be compartmentalised as neatly as others. Here, we
explore some of the alternatives, either for pure originality or their speciality
ALTERNATIVES & SPECIALS
Mcor Technology Iris 3D Systems ProJet 1200 CeraFab 7500 VoxelJet VX500 ExOne S-PRINT
Mcors Iris machine uses the companys paper-based
3D printing to produce tough prototypes in full colour
(theyre layered paper).
The machine is a two stage process. Each sheet
(it uses A4 or Letter sized oce paper) is printed
with the colour requirements, then loaded into the
machine. This takes each layer, positions it with
remarkably accuracy and the prole is cut, along with
scoring to assist with break out of the model. Each
layer is then bonded to the previous.
SLA is perfectly suited to the building of small
scale, high resolution waxes for investment casting.
Whether in medical or jewellery or any other eld,
the combination of specialised materials and high
detail, means that its found a signicant home
in many organisations. The release of the Form1
from Formlabs meant that 3D Systems had serious
competition at the entry level. The ProJet 1200 is its
answer and combining a small form factor machine
with a low cost, its a good one.
Based on long-term research at the TU Wien (Vienna
University of Technology), Lithoz developed the
patented Lithography based Ceramic Manufacturing
(LCM)-process. This uses LED technology to build
directly in a number of ceramic materials.
The high resolution combined with unique materials
(including a bone like material called LithaBone)
means that the CeraFab is pretty unique on the
market, though competition is growing
VoxelJets range of machine have a unique trick up
their sleeves their powder-based processes can
work with both plastic and sand for both prototypes
and forms for casting/foundry work.
The VX500 sits in the middle of the product range
and oers the best price/performance/build size
for those looking to build substantial parts. Having
both capabilities is perfect for those with foundry
capability in house and the need for prototyping
components
The S-Print processes industry-standard casting
sand to create complex mould cores and patterns
for the foundry industry. Featuring a massive build
chamber and a level of automation that is both
rare and perfectly suited to the high demands of
industry practices, it is nding homes in foundries
that are pushing the boundaries of whats possible.
Production rates are high and the ancillary
equipment allows foundries to integrate it into their
more traditional processes and workows.
Primary Purpose Colour prints + Paper models Stereolithography for casting waxes Ceramics Plastic parts + Sand cores for foundry industry Sand cores/moulds for foundry industry
Price 30,600 $4,900 220,000 278,000 On Application
Build Envelope 275 x 265 x 240 mm 43 x 27 x 180mm 76 mm x 43 mm x 150 mm 500 x 400 x 300 mm 800 x 500 x 400 mm
Warranty 1 year 1 year Not available 1 year (on site with extension options) 5 year limited
Machine Dimensions 950 x 700 x 800 mm 228 x 228 x 358 mm 1,200 x 600 x 1,800 mm 1,800 x 1,800 x 1,700 mm 3,270 x 2,540 x 2,860 mm
Layer Thickness 0.075 mm 0.03 mm 0.025 - 0.1 mm 0.08 / 0.15 mm 0.254 / 0.33 mm
Material options
A4 + letter paper and proprietary CMYK ink +
PVA adhesive
VisiJet FTX Green material Aluminiumoxide + zirconiumoxide + LithaBone
ABS, Nylon, PC, PC/ABS, PPSF, Ultem 9085 (high temp
and FST rated)
Furan, Phenol and Silicate materials available
Website mcortechnologies.com 3dsystems.com lithoz.com voxeljet.com exone.com
THE BASICS : In terms of technology there
are many 3D printers that dont fall into a
specic category.
Some are developed for special purposes
to support specic materials or industry
practices. Others oer an entirely dierent
approach to producing parts or prototypes.
Here we take a look at what other machines
are out there and what they can do. We run
the whole gamut from paper-based full
colour models to machines specically
designed for wax models. There are also
machines that build exotic ceramics to
patterns and cores for sand casting purposes.
THE OPTIONS : 3D printing, as an industry,
has always been adept at taking mainstream,
mass appeal (relatively speaking)
technologies and adapting them to suit the
needs of specic industries or processes.
While weve covered only ve machines
to show the spread of options out there,
its worth spending time to nd out whats
available for your particular industry.
Chances are theres something thats a close
match and could provide an interesting edge
for new products or workows. Its also often
worth considering products perceived as
special purpose outside of their core focus.
THE FUTURE : Specialisation is not a new
thing in 3D print but it may well represent
an interesting take on its future. As the
technology becomes more mainstream,
investment grows and more organisations
will look to take lessons learned and apply
them to solve specic problems, bottlenecks
or provide new solutions. Just as the hearing
aid and dental industries took to both metal
sintering and stereolithography and special
purpose machines came to market as a
result, so will others in the near future. As
it stands, special purpose wont be massive
volumes of sales but, in niches, will thrive.
Broad range of alternatives
Ability to piggie back on other industries
Growing range of specialisation
Special purpose materials development
Lower costs of entry
Greater industry process support
Novel approaches to part building
Large build volume machines
Growing acceptance of entry level
DEVELOP3D.COM MARCH 2014 3D17
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
ALTERNATIVES & SPECIALS
3 Pro TIPs: sAND CorEs
WITH AN EXoNE s-PrINT
The schmolz + Bickenbach Guss Gruppe has been using voxeljets
3D print technology for the production of lost wax models from
small complex components to larger automotive castings for
wheels and gearboxes.
Thomas Peipp, Investment Casting Manager at Schmolz+Bickenbach
Guss GmbH in Ennepetal says: The problem is the cumbersome
production of the necessary wax models. This requires expensive
injection molding tools and wax presses. Tool costs can become
prohibitively expensive when used for small series production, as they
result in very high unit prices.
Using voxeljets Augsburg-based provider can produce plastic
models quickly, precisely and cost-effective. These PMMA models can
completely replace traditional wax models. And the most important
part: The production of the plastic models using 3D printing is very
simple. No tools are required, as the digital printing process is based
on the CAD data for the part. The 3D printer builds the model layer by
layer using the digital data.
The downstream process for digitally printed parts is the same as for
those parts produced conventionally by injecting wax into a metal tool.
Whether prototype, individual part or small series3D printing
technology makes it possible to produce highly complex design and
investment casting models quickly, easily and cost-effectively. Thats an
enormous advantage for investment casting specialists, and especially
our customers, concludes Thomas Peipp
voxeljet.com
Mcor Technology Iris 3D systems ProJet 1200 CeraFab 7500 VoxelJet VX500 Exone s-PrINT
Mcors Iris machine uses the companys paper-based
3D printing to produce tough prototypes in full colour
(theyre layered paper).
The machine is a two stage process. Each sheet
(it uses A4 or Letter sized oce paper) is printed
with the colour requirements, then loaded into the
machine. This takes each layer, positions it with
remarkably accuracy and the prole is cut, along with
scoring to assist with break out of the model. Each
layer is then bonded to the previous.
SLA is perfectly suited to the building of small
scale, high resolution waxes for investment casting.
Whether in medical or jewellery or any other eld,
the combination of specialised materials and high
detail, means that its found a signicant home
in many organisations. The release of the Form1
from Formlabs meant that 3D Systems had serious
competition at the entry level. The ProJet 1200 is its
answer and combining a small form factor machine
with a low cost, its a good one.
Based on long-term research at the TU Wien (Vienna
University of Technology), Lithoz developed the
patented Lithography based Ceramic Manufacturing
(LCM)-process. This uses LED technology to build
directly in a number of ceramic materials.
The high resolution combined with unique materials
(including a bone like material called LithaBone)
means that the CeraFab is pretty unique on the
market, though competition is growing
VoxelJets range of machine have a unique trick up
their sleeves their powder-based processes can
work with both plastic and sand for both prototypes
and forms for casting/foundry work.
The VX500 sits in the middle of the product range
and oers the best price/performance/build size
for those looking to build substantial parts. Having
both capabilities is perfect for those with foundry
capability in house and the need for prototyping
components
The S-Print processes industry-standard casting
sand to create complex mould cores and patterns
for the foundry industry. Featuring a massive build
chamber and a level of automation that is both
rare and perfectly suited to the high demands of
industry practices, it is nding homes in foundries
that are pushing the boundaries of whats possible.
Production rates are high and the ancillary
equipment allows foundries to integrate it into their
more traditional processes and workows.
Primary Purpose Colour prints + Paper models Stereolithography for casting waxes Ceramics Plastic parts + Sand cores for foundry industry Sand cores/moulds for foundry industry
Price 30,600 $4,900 220,000 278,000 On Application
Build Envelope 275 x 265 x 240 mm 43 x 27 x 180mm 76 mm x 43 mm x 150 mm 500 x 400 x 300 mm 800 x 500 x 400 mm
Warranty 1 year 1 year Not available 1 year (on site with extension options) 5 year limited
Machine Dimensions 950 x 700 x 800 mm 228 x 228 x 358 mm 1,200 x 600 x 1,800 mm 1,800 x 1,800 x 1,700 mm 3,270 x 2,540 x 2,860 mm
Layer Thickness 0.075 mm 0.03 mm 0.025 - 0.1 mm 0.08 / 0.15 mm 0.254 / 0.33 mm
Material options
ABS + PLA (Proprietary cartridge) + 3 colour build
options available
VisiJet FTX Green material Aluminiumoxide + zirconiumoxide + LithaBone
ABS, Nylon, PC, PC/ABS, PPSF, Ultem 9085 (high temp
and FST rated)
Furan, Phenol and Silicate materials available
Website mcortechnologies.com 3dsystems.com lithoz.com voxeljet.com exone.com
E
lster Aeroteh is Romanias main
producer of equipment for gas
measurement and regulation.
When it set out to produce a new, simpler
pressure regulator model especially for the
Romanian industry, it was important that it
be developed and manufactured locally.
The company initially attempted to build
CNC prototypes, but found it hard to obtain
the level of detail required to get a true
picture of the products performance. Thats
when they went to LogiCAD Solutions, a
Romanian CAD/CAM service provider.
LogiCAD was able to accurately cast
aluminium alloy prototypes for this
particular piece by making wax patterns on
a 3D Systems ProJet 3510 CPX 3D running
the RealWax material for high resolution
investment casting. In 12 days four wax
test pieces were printed, casted using
aluminium and machined.
3Dsystems.com
WAX CAsTING For
GAs rEGULATors
CAsTING THE CoMPLEX
WITH VoXELJET PATTErNs
Advanced automotive casting expert, Grainger and Worrall !
(gwcast.com) recently acquired one of ExOnes S-Print machines.
Here, Antony Middleton, manager for the facility, gives us a run down
of what theyve learned.
#1 Foundries not included: Having a sand printer on site has
been a fantastic beneft to our productivity and reaction time to
customers. However, this system is an INDIRECT digital manufacture
method. Once we have produced the sand moulds, they still have to
be poured with metal (aluminium, iron, steel etc.) to achieve your
fnal metal part.
#2 Big parts, big space. The S-Print has an 800 x 500 x 400 mm
build area and can print this in a little over 10 hours (depending on
layer thickness). This equates to over 500kg of sand being produced
a day. Typically, we can produce 2 tonnes of moulds and cores per
week. That requires a lot of space for raw materials, cleaning, part
storage. We also split our setup into 2 areas (one for printing and one
for post processing and storage).
#3 Big parts, bigger savings: Unlike most RP technologies, the raw
materials are relatively cheap. Looking at a standard powder based
printer, the powder costs around 700 per 15kg. The S-Print sand
(powder) costs 300 per tonne and any unbound sand can be reused.
Aside from our sand moulds, we are starting to work with companies
looking at other uses such as large composite moulds (GRP and
carbon fbre), art sculptures and building applications. 3D printed
house bricks, closer than you think!
3D PRINTING FOR PROFESSIONALS.indd 17 4/3/14 17:05:59
3D18 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
GETTING THE BASICS RIGHT
3D printers can only replicate the data you give them. Al Dean looks at
the tools available, some emerging trends and the best practice to get it right
T
he process of sending data to a
3D printer is often fraught with
problems. The most common
mistakes are often the most
basic after all, these are the
most easily overlooked.
Our goal here is to look at some of the best
practices for making sure the prints you get
out of the machine or back from a bureau
in a styrofoam and bubble wrap packed box
are just as your design skills and 3D design
system intended.
FORMAT? STL... OF COURSE
While theres much talk about direct
integration between CAD systems and 3D
printers (well discuss that shortly), unless
youre running one of a very small number of
machines, the chances are your process will
be like this: get your CAD data then Save As
or Export as an STL le. Job done, right? Not
so fast, buster.
STL is a format rst developed by 3D
Systems back in the 1980s as a means of
taking analytic surfaces and solids from
3D CAD tools and getting them into the
stereolithography machines of the day. That
format, due to its simple nature and relative
ease of adding support into the software,
gained traction and it has been the de facto
standard ever since.
Essentially, STL is a tessellated le format
and is about as basic as it gets. Itll take your
nice clean CAD geometry and convert it
into a mesh comprising of hundreds, if not
thousands, of triangles.
Whats interesting is how varied the
support for such a basic le format can be
in dierent CAD systems. And, in order to
get the best results, it is essential that, when
exporting this data, you understand the best
approach, the best settings for each. After all,
if youre going to spend eight hours building
a part overnight, you dont want to come
into work the following morning and nd a
blocky, facetted representation of the design
work youve just spent four days working on.
TESSELLATION SETTINGS
The rst part of the process is to get to grips
with tessellation and the controls. While we
dont have space to detail every CAD systems
particular settings and options, we should
be able to give you enough information to
interpret into your workhorse tool.
Resolution: Most design systems work with
presets for exporting STL les, which give
you specic values for a couple of settings.
Whether its referred to as chord height,
triangle edge length or something else, you
need to master these to control the triangle
size. As you can see in gures A to C above,
taking a simple sphere and creating an STL
le with dierent settings, gives you very
dierent results.
If we then do the same with a more
complex example of a part, in gures D to
F youll see the impact of using too low a
resolution. In gure E, the portions of the
model that are based on cylindrical forms
are facetted, the grips are the same around
the lower feature set. The end result of this
will be a model that, while the same basic
shape of your starting point, will need hand
nishing if its to be of real use.
As shown in gure F, using a higher
resolution tessellation setting will give you a
much cleaner result. The part will come out
of the printer without much need for sanding
or post processing. Itll also give you a much
better t with the components that surround
it (particularly where holes and parts that t
into them are concerned).
It is worth noting that most CAD systems
give you access to the advanced settings
for tessellation. Take time to explore these,
particularly if youre working with highly
complex parts: those with small features in
larger overall geometry sets. It may be that
you need to wind down the settings and up
the resolution to get the best results across a
complex part.
ASSEMBLIES
Another option available in most systems
thats worth exploring is the ability to work
with assembly models. Its uncommon to
be working with a single part, on its own,
and every CAD system lets you work with
multiple parts in a single le. The STL
export options in most systems allow you to
output STL data from assemblies in one of
two modes.
B Low-res tessellation
C High-res tessellation
A Inside 3-matic,
import (or create)
the solid geometry
for the product
youre working on,
with separate bodies
representing the
space envelope for
the lattice structure
to be built within
B 3-matic then
creates a graph.
This is a wireframe
representation of
each element, to
which a thickness is
applied. The system
has a large number of
presets, but the user
has complete control
C Once complete,
tested (using FEA)
and fnalised, the
part can be output
directly to Magics
software or to sTL
for building. The fnal
end result built in
titanium can be see
to the right
FDM BAsED
MACHInEs
sInTERInG
WITH PLAsTICs
3D PRInTInG
WITH METALs
3D PRINTING FOR PROFESSIONALS.indd 23 4/3/14 17:13:13
3D24 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
BRINGING 3D PRINTING TO
THE DESIGN OFFICE
If you are thinking of bringing 3D printing into your design oce here are
three things to consider that might not be immediately obvious
Y
ouve looked at the options, youve
looked at your budgets, youve
worked out that having 3D printing
in house would be benecial to your
business and youve chosen your process. So
what are your next steps? Here are three of
our top tips you should think about before
signing o that purchase order.
#1 THE USE CASE
This might sound obvious, but its one that
needs to be properly thought through. Are
you looking to cut-back on outsourcing
and do the same work in house? Or are you
looking to have more immediate feedback
in your design process? Theres a subtle
dierence between the two.
Having a 3D printer in your oce,
available when you need it, is incredibly
powerful. As you have the equipment to
hand, you can experiment more and test out
ideas without having to wait for delivery,
handle budgets and approvals.
If youre purely looking to replace
outsourced work, some thought needs to
be given to the volume of work and how
much of an existing team members time
that is going to take up. All of this needs to
factored into your budget.
#2 THE SPACE AND ENVIRONMENT
Some printers are labelled oce friendly
but even these have peculiarities that
need to be taken into account. Some FDM
machines require manual break out of
supports but if the supports are soluble, you
will need facilities to remove them.
Automated solutions are available, but
while these might appear oce friendly,
there can be noise and smell implications.
As you get into more complex processes,
the complexity of the post processing
requirements typically increase as well. You
need to look at the whole process, rather
than just the build portion.
Most materials typically have special storage
requirements and these need to be adhered
to, otherwise you end up wasting cash on
unusable or sub-part materials and youll end
up with crappy builds out of your machine.
#3 TOTAL BUDGET
Its easy to get carried away with the
excitement of bringing 3D printing in
house. Even with entry-level machines,
the total costs are masked quite well
particularly when it comes to consumables.
And lets be clear, were not just talking
about raw materials (whether thats resin,
lament or powder).
Most machines have components that
need to be swapped out or maintained
regularly to keep your machine in good
working order. Whether its consumables
for build plates, cleaning agents, extrusion
tips for lament machines, solvents for
cleaning resin parts or a new set of pliers
every now and then.
You need to look at the total cost of these
parts, bearing in mind that, in most cases, the
more you use the machine (which is clearly a
good thing for productivity), the more youll
need to replace parts and maintain it.
You then have additional costs in terms of
leaving these machines running over night,
when everyone has cleared out and you need
a set of parts for the next day.
With electricity prices constantly on the
rise, energy consumption can become
an issue, particularly as you move up the
complexity ladder.
SEE 3D PRINTING IN ACTION
15 APRIL 2014
CONFERENCE & EXHIBITION
WARWICK ARTS CENTRE, UK
REGISTER NOW FREE
DEVELOP3DLIVE.COM
BRONZE SPONSORS SILVER SPONSORS GOLD SPONSORS PRINCIPAL SPONSORS
at
All prices are excluding VAT. Our economy service offers an 8-10 day
turnaround with a minimum order of 15 and our express service offers
a 2-3 day turnaround with a minimum order of 30.
3D PRINTING FOR PROFESSIONALS.indd 24 4/3/14 17:13:23
DEVELOP3D.COM MARCH 2014 3D25
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
SEE 3D PRINTING IN ACTION
15 APRIL 2014
CONFERENCE & EXHIBITION
WARWICK ARTS CENTRE, UK
REGISTER NOW FREE
DEVELOP3DLIVE.COM
at
All prices are excluding VAT. Our economy service offers an 8-10 day
turnaround with a minimum order of 15 and our express service offers
a 2-3 day turnaround with a minimum order of 30.
3D PRINTING FOR PROFESSIONALS.indd 25 4/3/14 17:13:31
3D26 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
MATERIALS: ADAPTING
PROCESSES & DESIGN
To get the most out of new materials they need to be combined with new
ways of thinking in terms of design and engineering, writes Al Dean
M
aterials are arguably
the biggest area of
research for 3D printing
at present. While the
core build processes
have been established
for some time (UV curable resins, laments
and sintering of both metals and
plastics), its the materials science
thats going to bring us new advances
in both the short and long term.
At the moment theres a huge
range of materials available for
all manner of 3D print methods
and these are worth exploring and
getting up to speed with.
FILAMENT MATERIALS
With its exponential growth in the
last few years the lament market is seeing
some serious activity and much of this has
come from the less established players.
Stratasys has always had a strong range
of materials for its printers, but these have
often been restricted to higher-end models.
If you want to build in more exotic
materials (whether thats PC-BS, Nylon or its
heat resistant materials), then youd need to
look at the more costly machines. Otherwise
its ABS.
Now the rise of lower-cost lament-based
machines is giving greater freedom to run
the materials you want, on the machine you
want. For those capable of working without
non-proprietary materials, theres now
nylon, transparent materials, wood lled
laments all manner of things.
Check out companies such as TaulMan3D
(taulman3d.com) who are doing very
interesting things to not only test the
potential but also to ne tune settings which
gain the best results.
RESINS AND POWDERS
UV resin and sintering powder processes
have always been more open. Part of this is
enabled by the nature of the beast. If youre
loading a machine with powder or resin,
its much harder to control whose materials
youre using than if youre loading a material
cartridge.
Sintering masters EOS and
3D Systems both have a good
range of materials available, from
standard nylons through to more
exotic materials lled with glass,
aluminium and carbon. There are
also special purpose materials -
whether its exible components or
elastomer replication.
There are other providers as well.
Italian rm Windform (windform.eu)
oers a range of materials focussing on glass
and carbon lled powders.
On the UV curable resins front, Objet /
Stratasys has been doing interesting things
with its Connex3 machine and users are
reporting that the new ABS mimic material
performs very nicely as a competitor to FDM
(in terms of toughness of parts) but has the
EXPLORING NEW SINTERING MATERIALS AT PARKER RAPID
A good place to start when researching 3D print
materials is to fnd an organisation thats been pushing
the boundaries of what can be achieved in a production
environment.
We caught up with 18 year veteran of 3D printing, Paul
Gray, Manager of Advanced Manufacturing Technologies at
Parker Rapid (Parker Fluidic Solutions Division) to fnd out
what gets him excited and to gain some insight into how
best to use some more advanced materials.
Parker runs several 3D print processes and has done so for
13 years, but its mainstay is a brace of 3D Systems sintering
machines running a variety of materials.
Our philosophy has always been to embrace these new
materials, as a result we have a wealth of experience in
this area, says Gray. We have always strived for quality
over quantity and all of our materials are used in Rapid
Manufacturing within Parker.
Two of the most interesting materials hes fnding success
with are DuraForm Flex for fexible components and a Nylon
derivative called Duraform EX both from 3D Systems.
Standard materials such as standard Nylon 12-based
material and its variants are well established in the
additive manufacturing world and have been for 15 years
or so, says Gray. New materials have come along during
that time which have proved very useful to designers. The
issue with these materials is that they have proved more
diffcult to process with consistent results.
DuraForm Flex: This is a rubber mimic that can be run
on a 3D Systems Sinterstation. It produces strong rubber
like parts that can be used in real applications as well as
for prototypes. Processing is diffcult but Parker Rapid
has developed methodologies that enable the company to
satisfy its demanding customer base.
When designing for this material its limitations must be
considered, says Gray. For instance, I would not use it in a
situation where surface porosity is critical, although it can
be made airtight, its surface will attract and retain particles.
Over the years we have been able to get good results,
even down to 1mm thick sections, which can be useful in
certain design applications.
DuraForm EX: This is a Nylon 11 derivative and has many
useful properties over and above standard PA. It is great
for semi ridged parts or live hinges. Available in black
and white this is a particularly tough and durable Nylon 11
derivative that is good in thin sections. When designing live
hinges, consideration needs to be given to the alignment
of the hinge and the strata of the build. Other design
constrictions also exist but in general it is a reliable material
when processed correctly.
Parker Rapid provides services to many of its
sister divisions, but the companys services are also
available to anyone thats in need of them.
+44 (0) 1908 561515 | paul.gray@parker.com
DuraForm Flex,
a rubber mimic
material
3D PRINTING FOR PROFESSIONALS.indd 26 4/3/14 17:13:40
DEVELOP3D.COM MARCH 2014 3D27
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
benet of high resolution builds.
Finally there has always been a healthy
range of third party SLA materials available
from a number of sources.
MATERIALS + DESIGN
Materials advances and machine
improvements is one thing, but only through
new thinking in design and engineering can
these materials be put to good use.
Its truly a case of chicken and egg. If
a new material isnt tried out, its never
heard of and its application never explored.
Conversely, if a new application isnt tried
and tested, the material requirement isnt
necessarily identied.
Development from designers and
engineers is a given, but academics are
also at the heart of this research. After all,
when you have a technology with such a
groundswell of awareness and interest,
its much easier to apply for and receive
funding than if youre experimenting with
CNC technologies or other production
methods. And the vendors like it because
new machines and materials are usually
sold near list price once the research grant
is given.
Hobbyists are also playing an increasingly
important role thanks to the lowering cost of
3D print technologies
Whether its a father developing an
assistive device to help his son overcome
dexterity problems with an articial hand,
or a team developing an open source violin,
built using 3D printers, boundaries continue
to be pushed from all areas.
OPEN VS CLOSED
3D printer manufacturers typically fall into
one of two camps: those that close out their
machines and restrict the use of materials
and those that dont.
By taking the closed route manufacturers
can laser-target materials to their own 3D
print technology, helping ensure customers
get the most appropriate material for the
production method. And this is important
if you want repeatable prints and consistent
part quality.
But does that mean they should stie
experimentation and give users the freedom
to see what else their machines can do?
Just as you wouldnt expect an injection
mould machine tool vendor to lock you down
in terms of what plastic granules you feed
into the hopper, I believe the same should
also be true in the 3D print world.
Materials are going to be the future of
3D printing, for both prototyping and
manufacture of end use components and
only through an open approach to materials
will we truly be able to push the boundaries
of whats possible.
SuStainability & 3D PRintinG: MytHS anD REalitiES
in recent years there has been a lot of talk about
sustainability in 3D printing. This has ranged from claims
about the recyclability of PLA used in entry-level machines
to how by manufacturing components locally reduces the
need for transportation.
With the current emphasis in design and engineering to
create products with a lower environmental impact, close
attention should be paid to 3D printing.
The problem is that many of the claims are either
inaccurately reported, over exaggerated or simply just not
true. So lets look at some of the most common myths and
realities surrounding sustainability and 3D printing.
Polylactic acid or Pla is compostable: PLA, as a material,
is compostable. That doesnt mean that itll break down if
you throw it in your compost bin at the end of the garden.
To break down in a couple of months, PLA needs
industrial composting facilities, which are few and far
between in most countries. You also have the issue of
getting your 3D prints and waste to those facilities. It
can take years to break down in household composting
facilities.
The upsides are two fold. Firstly, when PLA does
breakdown, itll break down safely into water and carbon-
dioxide. The second is that the production process to
produce PLA is less energy intensive than many other
common 3D print materials.
3D printing uses less energy: 3D printers are, for the most
part, energy intensive beasts. Whether its heating a build
chamber and a hot extruder to 270 degrees for 15 hours or
running a laser and optics system to melt titanium 0.2mm
layer by layer energy is consumed and rather heavily.
Its also often a much slower process compared to more
traditional manufacturing processes. More active time
typically means more energy use.
build local: Yes. Building products closer to their point of
use is good practice. The reality is that the transportation
of the product is, typically speaking, a small fraction of its
total energy consumption and environmental impact over
its lifetime.
life time energy use: This one is massive and a reason
for much of the research being conducted in both the
automotive and aerospace felds. While the 3D print
processes used in these more demanding industries are no
doubt higher than traditional machining from billet or near-
net shape cast forms, they do have a huge beneft in terms
of geometry freedom.
What this means is that geometry of components can be
tailored to specifc applications and performance criteria.
If a structure can be manufactured that uses less material,
theres an obvious beneft.
Where it really hits the sweet spot is over the lifetime
of the component. With the desire to reduce the fuel
consumption in the aerospace industry, lighter structures
means less fuel. Ultimately, less fuel use over an aircrafts
20 year + lifecycle, means less impact. And with in use
impacts being the big hitter, everyone wins.
Mass customisation means better products means less
inventory: This is a slightly nebulous one. The concept is
that if you can tailor a product to a customers needs, then
youre ending mass production. The problem is that most
customers dont care about the products they use. And if
they do, theyll typically prefer a product designed by a
professional. In the medical feld, this could be a winner,
however, as patient specifc implants, orthoses and other
devices, are proven to improve recovery and success rates.
Further reading
This is an area thats going to see much more research
over the coming years (After all, sustainability + 3D
printing = academic grants).
In the meantime, Id strongly suggest a read of the
report by Jeremy Faludi on the subject of 3D printings
eco-credentials on the Autodesk Sustainability Workshop
blog (sustainabilityworkshop.autodesk.com).
The team at 3D print analyst, Econolyst, have also
recently introduced an online software tool called
WillIt3DPrint (willit3dprint.com).
the Rowenta division of appliance maker SEB is
proud of the Made in Germany branding its ironing
products carry. However manufacturing in a high-labour
cost location such as Europe means making full use of
automated production technologies as well as novel
designs to reduce costs and to deliver products that
consumers want to buy.
The average buyer makes an initial choice based on
appearance. If they like something, they pick it up so for
us the handle is a key element of the iron, says Rowenta
project engineer Klaus Maier. If it feels substantial in
your hand, thats the mark of a good iron.
Rowenta carries out its moulding in-house and uses
conformal cooling, where cooling channels follow the
form of the mould to give more even cooling properties
than drilled channels. This is used in the most critical
parts of the tools including sections with complex ribs or
where space is restricted.
The company uses 3D printed conformal cooling tool
inserts (produced using the LaserCusing technology) and
integrates these into conventionally built and tempered
moulds. The technique allows cooling channels to be
placed close to the mould surface and to follow the
surface contour conformal.
Typically, cooling channels of around 5mm diameter are
used and are placed between 2-3mm of the surface.
The key beneft is the lack of distortion. It accounts for
the positive assembly characteristics, that is, the excellent
dimensional accuracy of all the different mandrels and
metal tubes that have to ft perfectly, says Maier. He also
explains that start-up is much faster, with the required
dimensional accuracy achieved very quickly.
rowenta.com
COnFORMal COOlinG
at ROWEnta
Prosthetic hand, built
using ExOnes metal
printing process
3D PRINTING FOR PROFESSIONALS.indd 27 4/3/14 17:13:51
3D28 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
DOES COLOUR MATTER?
Al Dean takes a look at the growing trend for colour-capable 3D printers,
delving into colour accuracy and the potential for the design oce
C
olour has always been the
missing link in the 3D printing
industry. From the earliest days
to the present day, weve pretty
much been stuck with colour
options that are directly linked
to the build material.
With an FDM machine, the lament
dictates the colour, regardless of whether
youre building with one, two or three heads.
With a powder-based process, colour comes
from the powdered nylon, unless you get
involved in dying components.
As a result, many of us have become used
to the practice of priming, prepping and
painting a 3D print if we want to accurately
represent colour in a prototype.
For many years the only exception was
Z Corp. Its machines were the only real
option if you wanted to print in more than
a couple of colours and show items such as
labels directly without any post processing
Now assimilated into the 3D Systems empire,
Z Corps ZPrinter is gone, but the ProJet 460,
660 and 860 reign on
REBIRTH OF INTEREST
In the last year everything has changed and
theres now an emerging set of machines that
support colour printing in various guises and
build methods.
Mcors paper-based Iris machines take a
dierent approach to most. Theyre essentially
an oset printer (the paper is printed
separately from the trimming process), applied
to 3D. Once the stack of colour layers are ready,
theyre fed into the machine and each is cut,
glued and assembled to the one below it. The
parts are solid and tough (theyre essentially
laminated wood) and the colour representation
is excellent just as you would expect from an
inkjet printer.
Stratasyss Objet 500 Connex3 takes the
companys polymer jetting technology that
allows it to vary hardness of materials and adds
the ability to print with coloured materials.
Objets method allows the printed material
to be controlled at the near-particle level, so
colours can be mixed and dierent shades
acquired. The machines are not cheap though
and weigh in at over a couple of hundred
grand. Meanwhile, 3D Systems is expanding
its colour 3D print range with the CubeJet.
Details are still sparse but the machine looks
very interesting and is claimed to oer full
colour printing for around $5,000.
A DIFFERENT WORKFLOW
With colour comes a new challenge of model
preparation. While many designers and
engineers will know how to create STL les
from their workhorse 3D design system,
few are familiar with exporting data that
contains colour and texture information as
well as geometry.
Most colour systems rely on le formats
that are capable of holding colour and texture
information, whether its OBJ, a variant of
STL or, God forbid, the VRML (.WRL) format.
Then theres a fair bit of manual tinkering
in the set-up software. Mcors ColorIT
system lets you take standard STL data and
apply textures and labels where you need
them. Adobes recent updates to Photoshop
introduce a range of tools for not only
painting, texturing and editing 3D models,
but also communicating directly with a
growing range of 3D printers.
BUT WHAT USE, COLOUR?
From a technical standpoint, full colour 3D
printing is certainly interesting, but how
useful is it really in the design oce?
From talking with our community the
general consensus is that faster, cheaper
machines are more desirable than full colour
prototypes. However, the biggest interest in
full colour capable machines comes at the
conceptual design stage. Here, a colour print
is ideal when a quick model is required, and
time and cost constraints dont allow for full
model making, post processing, primer and
a paint job.
It can allow non-technical folks to get
the whole picture of a design, rather than
evaluating it in, as one reader describe it,
grubby white sintered nylon.
So why arent we all printing in colour?
One reason is cost, but theres also the issue
of colour accuracy. Apart from the Mcor Iris,
most systems struggle with this. Printing in
colour, with a range of materials, is always
going to be a big challenge.
But as processes improve and costs drop
colour-capable 3D printers are sure to gain
traction. Anyone else remember a time when
we printed colour documents on dot matrix
printers through a multi coloured ribbon?
Resolution
x, y & z axis: 12, 12, 100
(0.0004in, 0.0004in, 0.004in)
Colour
1 million+ colours (CYMK
4 cartridges including black)
x, y & z axis: 5760 x 1440 x 508dpi
Build Size
A4 Paper: 256 x 169 x 150mm
Letter Paper: 9.39 x 6.89 x 5.9in
Build Material
A4 Standard Ofce Paper 80gsm
(160gsm ply colour only)
US Letter Standard Paper 20lb
(43lb ply colour only)
Layer Thickness
0.1 mm (0.004 in) and 0.19mm
(0.007in ply colour only)
Recyclable Parts/Materials
www.mcortechnologies.com
Orange is just one of
the million colours you
can bring to life.
lowst cost
eco-friendly
tru colour
ourabl parts
MCOR TECHNOLOGIES IRIS
The Mcor Iris is a curious beast. It essentially takes the
offset printing process and applies it to 3D printing with
some rather fabulous technology.
The colour is printed at full depth (1 million+ colours)
onto each sheet of A4 paper. Sheets are then cut,
trimmed and glued to a very high degree of accuracy.
You end up with a precut block of paper, from which the
model is broken out.
Mcor operates on a
rental basis, so once
youve paid up, youre
looking at the cost of the
CMYK inks and reams of
office paper.
It doesnt get much
more cost effective for
producing robust parts.
mcortechnologies.com
3D SYSTEMS PROJET & CUBEJET
When Z Corp was acquired by 3D Systems, the companys
colour-capable ZPrinters were absorbed into 3D Systems
ProJet family. The products have been evolving ever since.
3D Systems ProJet 460plus, 660Pro, 860Pro and the
mammoth new ProJet 4500 use a combination of powder
and a coloured binding agent to make colour models.
They give good results for aesthetic evaluation, but
suffer from brittleness.
3D Systems is now
introducing the CubeJet.
Details are scarce but it
looks like concepts from
the powder-based ProJet
machines are being
applied to a smaller form
factor machine perfect for
the desktop.
3Dsystems.com
STRATASYS OBJET 500 CONNEX 3
Stratasys/Objet has been doing interesting things with
its PolyJet materials, resulting in mixed hardness 3D
printed parts, such as over-moulded components. The
company has now added colour into the mix meaning the
new Connex3 machine offers an extremely versatile set of
materials in a single build.
If theres a downside, it relates to how the machine mixes
colours. Although quoted as being full colour, it only gives
access to specifc palettes
of colours and you can
only use those colours on
in a single build. If the two
you want are on separate
palettes, youre out of
luck and will need to fnd
the closest match to your
intent.
stratasys.com
Whos GoT CoLoUR?
3D PRINTING FOR PROFESSIONALS.indd 28 4/3/14 17:13:59
DEVELOP3D.COM MARCH 2014 3D29
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
Resolution
x, y & z axis: 12, 12, 100
(0.0004in, 0.0004in, 0.004in)
Colour
1 million+ colours (CYMK
4 cartridges including black)
x, y & z axis: 5760 x 1440 x 508dpi
Build Size
A4 Paper: 256 x 169 x 150mm
Letter Paper: 9.39 x 6.89 x 5.9in
Build Material
A4 Standard Ofce Paper 80gsm
(160gsm ply colour only)
US Letter Standard Paper 20lb
(43lb ply colour only)
Layer Thickness
0.1 mm (0.004 in) and 0.19mm
(0.007in ply colour only)
Recyclable Parts/Materials
www.mcortechnologies.com
Orange is just one of
the million colours you
can bring to life.
lowst cost
eco-friendly
tru colour
ourabl parts
3D PRINTING FOR PROFESSIONALS.indd 29 4/3/14 17:14:07
3D30 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
WORKING WITH
SERVICE PROVIDERS
Stephen Holmes and Al Dean consider best practice for outsourcing
and give three tips on how to work best with a 3D print bureau
B
ringing the benets of
3D printing in-house is
increasingly attractive
and aordable, yet many
organisations will still benet
from outsourcing much of
their 3D print work to service providers.
GO PRO OR GO HOME
The huge increase in awareness of 3D
printing has led to a slew of new service
providers, but you need to ensure your
chosen partner is geared up for working with
professionals.
Look for case studies and previous projects
and dont be afraid to contact other customers
to ask what they thought of the parts and
service they received.
To borrow a quote from legendary bomb
disposer and oil well re ghter, Red Adair, If
you think its expensive to hire a professional
to do the job, wait until you hire an amateur.
Weve seen service providers start
up in their bedroom because theyve
scrabbled together enough cash to
buy a MakerBot.
You need to question if these
people are accustomed to working
under NDA and have security in
place to protect your data. Do they
understand the tolerances you need
and how to build your parts so you
get the functionality you need?
A WORKING RELATIONSHIP
Working with an established reputable rm
certainly minimises your risks but there are
still many things to consider before you send
o your model to be printed.
A good service provider will be able to advise
you on all aspects of the 3D printing process
from model preparation and materials to
limitations and shortcuts.
To get some expect advice we spoke to the
teams at three of the UKs leading service
providers 3T RPD, IPF and Laserlines
to nd out what some of the most common
mistakes and errors customers make and how
to avoid them. Below is a summary.
#1 - UNITS, UNITS, UNITS
Units. Theyre a pain in the arse, to be frank.
STL is the main method for communicating
your geometry but it doesnt allow you to
store the units that were used to generate
the mesh data (the AMF format does). This
means you need to ensure you know what
unit base is used to export the data, and then
communicate that to your service provider.
If youre using an automated delivery
provider, such as Shapeways, you can add that
information in. If dealing with real people,
then you need to let them know.
Problems arise when this is not clear inside
your 3D design system; some are explicit, but
with others you need to have a dig around to
nd out if its imperial or metric. Some even
output in centimetres (God knows why).
Which leads nicely on to
#2 - DOUBLE CHECK YOUR DATA
Would you send a manufacturer a drawing
without any dimensions on it and without
anyone checking it? No, you wouldnt.
The same applies to sending 3D data. While
3D CAD systems typically include a preview
of your resultant mesh during the export
process, this shouldnt be relied upon.
Theres also the question of water-tightness:
crappy models create crappy prints.
Prime culprits are hobbyist 3D modelling
systems where parts are knocked together
using multiple bodies (according to those
in the know Google SketchUp is absolutely
evil in this regard as are surface-based
models constructed with poor modelling
practices).
Other common problems from professional-
level solid modelling tools include the export
of multiple parts or bodies, some of which
were hidden during the export process.
There can also be issues with how systems
preview the resultant mesh. Due to their
graphical wizardry they can often mask the
fact that your resolution settings are too low.
To share a bitter personal experience, a nice,
cylindrical face on a casting pattern can turn
out to be a 9-sided polygon thats going to
need drilling out.
The good news is there are a tools out
there to check and x les and some of
them are free. Download some and try them
out. Theyll nd errors and x any issues in
either how youve exported the part or how
the system has generated the data in the
rst place.
#3 - KNOW THE PROCESS & MATERIALS
Ten years ago, 3D print methods could be
categorised in one of two ways: strong and a
bit rough or high delity and brittle. Today,
with so many options available, everything
has changed.
A good service provider will be able to
advise you on which build process and
material will give you the best result for
what you want to achieve.
Its crucial that we try to educate
all our clients in which materials
and technologies best suit each
of their projects, even if it does
occasionally mean they place
orders elsewhere, explains Gary
Miller, head of 3D printing and
rapid prototyping at IPF Rapid
Prototyping.
If we help clients better
understand what IPF can provide it
saves everyone time, it also means the client
becomes part of the process and nds further
uses for the technology.
Dont dismiss a particular build process or
material because you had a bad experience
in the past. With 3D print technology things
can change very quickly so its important to
keep up to date. Materials in particular, are
developing at a frantic pace.
Keeping abreast of all the materials,
machines and performance of outputs can
be a tough task, so by using a bureau you
already have a professional that can handle
all this for you.
Add to this having someone to check,
adjust and generally take the pain out of the
process and it makes the cost of third-party
production far more palatable for those
holding the purse strings.
1
5
,
9
9
5
e
x
V
A
T
www.blueprinter.dk info@blueprinter.dk
BluePrinter A4 Ad.indd 1 28/02/2014 13:10:09 3D PRINTING FOR PROFESSIONALS.indd 30 4/3/14 17:14:15
DEVELOP3D.COM MARCH 2014 3D31
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
the worlds rst desktop
plastic sintering machine
Ofce compatible system Integrated 3D printer +
depowdering unit Materials starter kit
1
5
,
9
9
5
e
x
V
A
T
www.blueprinter.dk info@blueprinter.dk
BluePrinter A4 Ad.indd 1 28/02/2014 13:10:09 3D PRINTING FOR PROFESSIONALS.indd 31 4/3/14 17:14:23
3D32 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
BUILDING A BUSINESS
WITH 3D PRINTING
M
akieLab was established
in 2011 with the goal of
bringing the rst 3D printed,
toy-safe doll to market.
The small team has mastered
mass-customisation and gamication,
oering customers the ability to
customise their own doll, experiment
with how it looks and, combined with
a number of accessory options, give
them the exact product they want.
No tooling, no lengthy supply chain battles direct out of the
machine. Never before has a company managed to combine the world
of digital play, 3D printing and product customisation to this level.
With the likes of David Cameron, Prince William, Rob Brydon
and Jessie J bringing their own brands of organic exposure (and
their own custom dolls) to a larger market, recent retail adventures
with Selfridges agship London store, the company is just in the
latter stages of launching its second iOS app.
MakieLab uses laser sintered nylon to build its products which
are a mix of standard parts across the whole range, along with the
customised parts that each user designs. It has also mastered the
art of dying sintered nylon to provide more options to customers.
Products are then packaged and dispatched from its headquarters
in Shoreditch, London.
makielab.com
ALICE TAYLOR
CEO, MAKIELAB
KOTA NEzu DESIGNER & CREATIVE
COMMuNICATOR, zNuG DESIGN
WHAT WOULD YOU DO DIFFERENTLY?
We launched with a 10 high doll, the same size as Barbie. That set
the benchmark for the production costs and has meant that while
were in alpha, prot margins are slim. A smaller doll would have
been lower cost.
WHAT DID YOU NOT FORESEE?
We knew sintering was going out of patent, so machine prices would
come down. We also thought powdered nylon costs would come down,
but, in fact, they went up. We also didnt expect how long it would take
us to get into retail, but I suspect thats down to our experience in
software development, rather than the traditional toy market.
WHAT DO YOU WANT FROM THE FUTURE?
Cheaper machines for sintering. Id also like the App Stores to have
a better discovery system. We have online and mobile. Its hard to
compete. Theres 2,500 apps being uploaded to the Apple App Store
every day. How do you compete in that and get noticed?
TIPS FOR THOSE INTERESTED?
Its messy. Theres lots of tinkering. Readers
of the report and your magazine wont
mind, but Joe Bloggs might have second
thoughts. Also, do your spreadsheets rst.
Its expensive, and somewhat unpredictable!
Lastly, get stuck in. Its a ton of fun.
T
okyo-based znug design, is
a creative communication
agency that providers industrial
and product design services to both
individuals and large companies.
The company is headed up by chief
design and creative communicator, Kota
Nezu, who recently launched zecOO,
a radical new electric motorcycle,
collaborating with a team of specialists
in the elds of engineering and electric
transportation.
zecOO is a mix of futurist styling, raw performance and
sustainable transportation with a serious edge. With each
vehicle adapted to individual customer requirements, wishes and
desires, zecOO has been making use of 3D printing to validate the
custom designs.
znug has also been conducting research to laser scan customers
and to present them with a scale 3D printed replica and/or toy
before production begins.
znug.com | zecoomotor.com
WHAT ARE THE CHALLENGES IN ELECTRIC VEHICLE DESIGN?
In terms of design challenges, being able to have rapidly charging
batteries will give designers and engineers more freedom in design.
Also, having electric charging points in cities will enable these
vehicles to become more popular and see greater adoption.
WHAT DO YOU WANT FROM THE FUTURE?
Im interested in the 3D printing of metal but this is underway
already. Alongside this, Im interested in systems that enable the
manufacture of products using multiple materials in dierent
combinations
TIPS FOR THOSE INTERESTED?
Do not try to force the use of 3D printing in your projects and
products. Ask yourself whether you need to use the 3D printer, then
consider what you want to do actually do. There may be another way.
P
h
o
t
o
C
r
e
d
i
t
:
K
a
z
u
n
o
b
u
Y
a
m
a
d
a
3D PRINTING FOR PROFESSIONALS.indd 32 4/3/14 17:14:45
DEVELOP3D.COM MARCH 2014 3D33
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
We asked four 3D printing pioneers from a range of industry sectors how they use
3D printing to benet their business, how they did it and what theyve learned
DAVID PERRY FounDER AnD
EngInEER, oPEnFAB PDX
mIchIEl coRnElIssEn
InDustRIAl DEsIgnER
F
ormed in early 2013,
OpenFab PDX is exploring
useful applications of low-
cost digital design and fabrication
tools with a focus on 3D printing.
Founder, David Perry, became
infatuated with hobbyist 3D
printing at the 2012 Open Source
Hardware Summit in New York
City. Enthusiastic about the
capabilities of inexpensive 3D
printers, but a little disappointed by the common applications, David
bought a machine and got to work.
OpenFab instigates open source projects and produces products
straight o the printer such as the Fused Filament Fiddle, or
F-F-Fiddle, an open source 3D printed electric violin that can be
printed without support material using hobbyist equipment. David is
experimenting with a variety of services and inexpensive CAD tools,
scanners, and fabrication tools allow him to oer mechanical design
services that are aordable for individuals.
He is also pursuing youth and community engagement at libraries,
schools, and 3D printing themed birthday parties..
openfabpdx.com
B
y his own admission, Michiel
has been a designer for a
while.Lets just say I remember
drawing boards, he says. Most of the
rst part of his career was about design
and creative direction of consumer
products and professional systems for a
large electronics company.
A couple of years ago, Michiel
couldnt control the itch to strike out
on his own anymore, so he quit his job
and started his own studio. Right around that time, he bumped into
3D printing as a means to manufacture products (as opposed to
prototypes, for which hed been using it already). It took him about
ve seconds to catch the bug. Michiel says hes been very lucky to
have created the right product at the right time, like the Happy Bird
jewellery or his Apple accessories, so hes been able to reach quite a
few people, retailers and media with those.
michielcornelissen.com
WHAT WOULD YOU DO DIFFERENTLY?
Ive been a little bit in denial about my attraction to 3D printing, so
Ive probably only spent about 30% of time on it, up until recently. I
sometimes think I should have dropped everything 4 or
5 years ago and spent 100% of my time on 3D
printing; although I realise its still not an easy
area for a designer to make a living, so another
part of me is pretty happy about the industrial
design work Ive been able to do for clients.
WHAT DID YOU NOT FORESEE?
How my view on aesthetics would evolve by seeing whats possible
in 3D printing, and the subsequent need for dierent design tools
such as Rhinos Grasshopper (which is now a passion in its own
right). How cool it is to have your own printer, given the technical
limitations of FDM printers compared to industrial printers. Its
just very liberating to be able to manufacture your own stu.
WHAT DO YOU WANT FROM THE FUTURE?
I want the 3D print providers to realise their sales potential with
regular folks. Theyre good at providing services for hobbyists and
professionals, but suck at creating a satisfying shopping experience
for normal customers.
TIPS FOR THOSE INTERESTED?
I see a big gap between what many people create with 3D printing,
and what most people need. So if youre coming in from the
technical 3D printing side of things: study design, marketing, study
people in general to learn how to make creations that are more
than a novelty, but truly relevant. Designers with a background in
traditional manufacturing should realise that translating their ideas
into 3D printing is a totally dierent game, in terms of geometric
possibilities, limitations, economics, and distribution.
WHAT WOULD YOU DO DIFFERENTLY?
When you look closely at the F-F-Fiddle, the dierent elements
of the instrument are very contrasting, and it lacks an underlying
intention that ties the form together. I would like to have taken
more time at the front end to establish that intention and reect it
with the design. Were working on that now.
WHAT DID YOU NOT FORESEE?
I found the F-F-Fiddle project incredibly compelling, but I never
expected others to feel the same way. The reaction from the design
and 3D printing community has been extremely validating and
exciting! I hope to use the project and the experience to show
others that they can make things that are impactful.
WHAT DO YOU WANT FROM THE FUTURE?
Theres a huge wealth of innovation that remains largely
untapped. We are all users of something: instruments, toys,
books, transportation and its our user knowledge that lets
us create relevant and innovative solutions. Im very excited to
further democratise innovation by way of new business models
and tools (like 3D printing).
TIPS FOR THOSE INTERESTED?
Just get started! Find something that you think is really exciting
and do it. Whether that means printing things from thingiverse,
exploring new materials, or designing something new try not
to worry about whether or not its any good or if anyone else will
like it. Do things that you feel driven to do, then do them over and
over again until theyre awesome.
3D PRINTING FOR PROFESSIONALS.indd 33 4/3/14 17:14:55
3D34 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
THE FUTURE IS INDUSTRIAL
If 3D printing is to be used in production, it will be essential to automate,
manage and plan the process. Al Dean explores what the future holds
T
heres much talk of how
3D printing or additive
manufacturing is going to
revolutionise manufacturing.
The concept of manufacturing
components directly, using mass
customisation as a driver, is entirely valid
and companies have been doing exactly this
for many years under the radar.
What is rarely discussed are the heavy
requirements for both process planning and
the sheer scale of the facilities.
Take the sintering of plastics, for example.
This is perhaps the most widely-used process
for end use parts and there are requirements
to make those machines work and deliver
consistently. Theres also a lot of ancillary
equipment required to support it powder
load, part breakout, clean up and nishing,
powder recycling and reuse.
If you want to talk metals, then you can
add in heavyweight equipment to withstand
explosions (or at least, stop them). After all,
powdered titanium, other than being used to
print kick ass metal parts, is also a core part
of most reworks. Compared to traditional
manufacturing techniques, this area is more
underdeveloped than many might think.
One company that has been working on
solving this for sometime is Electro Optical
Systems (EOS). Due to the popularity of
its sintering machines in an industrial
setting (both within service providers and
engineering companies), its Integrated
Process Chain Management is perhaps the
most well developed of all vendors.
Materialise also got into the automation
and process control game very early on. And,
as youd expect from Europes largest service
provider, it has nailed the process required to
ramp up 3D printed part production.
Harnessing the software development
experience it has from its Magics and 3-matic
products, Materialise has built Streamics, one
of the rst software platforms to assist those
looking to truly automate 3D printing in a
production like environment. It provides an
integrated business process, from quotation to
production management, rather than a series
of explicit and disconnected steps, and covers
le acquisition and repair (with integration
with Magics), customer and job management,
reporting, machine control, planning as well as
quality control and traceability.
CONCLUSION
For an industry thats 30 years old, 3D
printing is not keeping up in terms of
industrialisation. Where other methods of
production are receiving greater levels of
automation and being infused with more
and more intelligence, 3D print, for all its
promises to revolutionise the manufacturing
world, is falling behind.
That said, there are hints that a more
industrialised future is coming. Expect to see
more automated processes, more automated
equipment (EOS and ExOne are perhaps
the leading exponents in this at present).
Only then will we really see the factory of the
future that the hype is promising.
EOS Integrated Process
Chain Management
covers the end to end
workfow, from powder
to parts to recycling
LOOK FOR THE ENABLING SERVICES & FuTuRE BuSINESS SuPPORT
Alongside the frenetic pace of
developments on the machines
and market side of 3D printing,
theres also an interesting
trend in new organisations
bringing products, services and
technologies that enable further
experimentation.
There is a stream of online sales
channels opening up and exploiting
the growing interest in mass
customisation and 3D printing.
Founded in the Netherlands
after being spun out of a
Philips incubator, Shapeways
(shapeways.com) is building a
community and economy that
centres on two things: providing
3D build services (and a huge
range of materials) and enabling
its community to sell items
directly to customers.
Michiel Cornelissen and Joshua
Harker are two prime examples.
Both have made their names
and a healthy revenue stream
by developing products that are
handled purely by Shapeways. We
talk to them later on in this report.
Digital Forming is also doing
interesting things in the same
space (digitalforming.com).
Designers create a base product,
then customers can interact with,
manipulate and order their own
custom variants.
Another interesting movement is
the provision of components that
support the development of 3D
printed products.
A perfect example is Eyewearkit
(eyewearkit.com), recently
launched in the Netherlands.
This frm provides pre-cut lenses
that can be built into 3D printed
custom built spectacle frames. The
companys web-site also includes
geometry templates for the various
items, design tips and such.
While good examples are
currently few and far between,
we predict this area of industry
will explode in the coming years.
As people experiment more with
production of plastic components
(in particular), its natural that
they will want to replicate
traditionally manufactured items
and the additional components
and specialist functionality
required. Then, when ready,
places to sell them.
Custom
frames from
Eyewearkit
Streamics, your AM automation & control system
For more information:
software.materialise.com/streamics-robot-develop3d
Or contact us:
UK: software@materialise.co.uk
US: software@materialise.com
Global: software@materialise.be
Efcient, Consistent and Easy
Automated part operations: conversion,
xing, minimal Z-orientation, property
extraction and preview generation
Integration through API with website,
Streamics Control System or
3
rd
party system
Instant Quoting
Powered by Streamics
TM
Robot
SAM advertentie A4 [print-ready].indd 1 28/02/14 09:40
3D PRINTING FOR PROFESSIONALS.indd 34 4/3/14 17:15:03
DEVELOP3D.COM MARCH 2014 3D35
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
Streamics, your AM automation & control system
For more information:
software.materialise.com/streamics-robot-develop3d
Or contact us:
UK: software@materialise.co.uk
US: software@materialise.com
Global: software@materialise.be
Efcient, Consistent and Easy
Automated part operations: conversion,
xing, minimal Z-orientation, property
extraction and preview generation
Integration through API with website,
Streamics Control System or
3
rd
party system
Instant Quoting
Powered by Streamics
TM
Robot
SAM advertentie A4 [print-ready].indd 1 28/02/14 09:40
3D PRINTING FOR PROFESSIONALS.indd 35 4/3/14 17:15:11
3D36 MARCH 2014 DEVELOP3D.COM
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
WHAT DOES THE FUTURE
HOLD FOR THE PRO?
E
ngineers and
manufacturers have
always had familiarity
with 3D printing in the forms
of Rapid Prototyping and
Additive Manufacturing (AM).
Some manufacturers and early
adopters have been using 3D
printing technology to their
advantage since its inception.
Many invested later down the
line. Others tested it in the early
days and decided to wait until
the technology matured. While
the AM market was growing
healthily, until the mid-2000s it
still remained a niche within the
industrial engineering world.
In 2009, the term 3D printing
started to become more widely
recognised as media attention
focused on the potential the
technology oered and 3D
printers for consumers became
available. This ignited a renewed
wave of interest in industrial 3D
printing. Inspired by the idea
that AM might have progressed,
many manufacturers started to
actively research the technology,
and started to invest in it more
heavily.
Industrial 3D printing is
not the Rapid Prototyping
that you used to know. With
seven core technologies at
3D Systems, almost any
manufacturing requirement can
be met, with accuracy of build,
resolution, full colour, robust
and lightweight materials and
condensed processes that drive
manufacturers towards new
levels of productivity.
With 3D printing, you can
quickly create end-use parts
without having to invest in the
time and expense of tooling,
or use signicant short cuts to
creating tooling, should you
need it.
3D printing not only provides
alternatives to traditional
manufacturing methods, but
brings with it a developing
paradigm shift in the way parts
are designed and the materials
are used.
For example, multiple parts
can be more easily combined
into a single part, enabled by the
printing of complex geometries
not possible with traditional
manufacturing. In addition,
using new, lightweight polymers
in place of sheet or cast metal
parts decreases weight, without
reducing mechanical properties.
3D printing also allows for
parts that were previously
considered impossible, or at
least restrictively expensive,
to become real, incorporating
complex assemblies and cavities
in a single build.
As this paradigm shift occurs,
manufacturers are investing
heavily in on-site research,
teaching engineers new
approaches to design for 3D
printing and comprehensive
testing of new materials.
Those manufacturers who
successfully exploit new ways
to build products, in lighter
materials, with more ecient
(but previously impossible)
designs, will be the ones who will
deliver the most exciting, cost-
eective and innovative products.
A
wareness of 3D printing
by the masses is a
double edged sword.
The most obvious advantage for
professional service providers
is that if more people are aware
of 3D printing, then more will
want more things 3D printed.
Some of these things will, of
course, be things that they would
previously have made by other
means such as CNC machining.
But also, in some cases, it relates
to things that they would not
have had made at all.
The proliferation of
personalised items also creates
its own demand by creating
a mindset that says I want
personalised things because I
can have personalised things.
So, generally speaking, demand
is created through awareness
and (sometimes) by people and
organisations genuinely taking
advantage of 3D printings
capabilities. So far then, all
seems lovely but then we have
to take a look at the downside.
The technology itself is full
of opportunities and increased
capabilities but unfortunately,
these can never match the
inated expectations created by
poorly informed commentators,
journalists and questionable
marketing practices. This causes
problems for professionals when
customers expect them to deliver
on these incorrect claims and
false promises. It only takes a few
marketing executives (or CEOs)
to use phrases like colouring
book simplicity and complexity
for free or the only limit is your
imagination to bring the entire
industry into disrepute. Such
claims are all too frequently
written about and preached.
As people see through these
for being the nonsense that they
are (and those who dont already
will do so at some point) the
professional service providers
have to bear the weight of the
industrys damaged reputation.
Regardless of whether using 3D
printers for in-house use or as a
sub-contractor, you want to meet
your customers expectations.
The last thing you want to do
is to keep telling your customer
things like I know that you have
been told that this can be done
but it cant so we wont be able
to do it. From a professional
manufacturing point of view
the miseducation of the masses
can mean that 3D printing is
used where it really shouldnt
be as people choose turn to
what they are told is a panacea
of manufacturing capabilities
rather than selecting a far more
suitable form of manufacturing.
3D printing does indeed bring
new and amazing capabilities to
the manufacturing table. These
capabilities are being expanded
on all the time. If irresponsible
marketing and poorly researched
articles can educate the masses
about the true nature of 3D
printing (warts and all) then
the positives outlined in my
rst paragraph can be realised
without the negatives outlined
in the second paragraph and this
will be good for professionals
and customers alike.
Kevin McAleA chief iMpAct
Officer, 3D SySteMS
JereMy pUllin MAnAger, rApiD
MAnUfActUring, reniShAW
3D PRINTING FOR PROFESSIONALS.indd 36 4/3/14 17:15:19
DEVELOP3D.COM MARCH 2014 3D37
3D PRINTING FOR THE PROFESSIONAL
SPONSORED BY:
3D PRINTING FOR THE PROFESSIONAL
In terms of public awareness 3D printing is at a point of inection,
but how is this shift changing things for the professional? We asked an industry
executive, a hardcore professional and an analyst for their opinions.
I
f you read the same
thing over and over again
in dierent respected
publications, even the most
illogical claims start to appear
factual. If we believe everything
we read, we are entering the era
of a new industrial revolution,
where, before long, disease and
disgurement will be eradicated
by 3D printed organs and limbs.
Aircraft will be ultra-ecient;
burning almost no fuel due
to lightweight topologically
optimised fuselages and highly
optimised jet engines. Whats
more, transport and logistics
infrastructure will become
obsolete along with the classical
supply chain, as consumer goods,
clothes and even food are printed
in our homes and communities.
Worryingly, these are all claims
reported in the popular media,
and to a greater or lesser degree
form the basis of the information
now being used by senior
managers and C-suite executives
to gauge the future importance
and impact of 3D printing on
organisations around the globe.
So are we really on the cusp of
something revolutionary, or is
it now time for designers and
engineers to become the gate
keepers of business reality and
to apply a sanity check to the
aspirations of top oor executives.
There is no doubt that there is a
buzz around low cost consumer
3D printers and online printing
services but these will, for the
foreseeable future, be limited to
low cost and low status product
manufacture. Against this back
drop of bobble-heads, mini-mes
and avatar characters there is
without doubt a growing use of
additive technology in mainstream
manufacture. But, the pace of
industry adoption and the pace of
technology development remain
relatively slow and conservative
compared to the whirlwind of the
consumer 3D printing domain.
The industrial Additive
Manufacturing (AM) market is
growing at a steady and healthy
30% each year, compared to a
consumer 3D printing sector
experiencing growth nearer to
150% (hence, the media frenzy).
Some might see this disparity in
growth as a failure on the part
of industrial AM machine and
materials vendors to simulate
adoption, or the lack of credible
design & simulation software
needed to enable the front end of
the AM process chain. However,
given the critical applications in
which AM makes the most sense
(aerospace, medical implants,
pharmaceuticals and defence), a
conservative approach should be
welcomed not disparaged.
So can we expect the future to be
as slow as the past?
Undoubtedly not, as estimates
put the current public & private
sector investment in AM related
R&D at some $350-million per
annum globally, a gure that
has tripled in the last 5-years.
This investment is enabling
concerted research eorts to
improve productivity, increasing
material choice and ensuring
better part quality and repeatability
all critical factors that will
undoubtedly accelerate technology
adoption in the future. But this will
be a gradual acceleration, based
on technology evolution, rather
than an industrial revolution
based solely on the world waking
up to 3D printing, after all the
technologies are largely the same
as they were 20-years ago!
In this new world order the role
of designers and engineers will
be paramount, as they will be
the champions of realism, with
the skills and knowledge to truly
understand the impact that AM
will have to a business along with
the technological limitations to
adoption. To make AM work,
engineers must understand the
production economics of making
parts layer by layer, the benets of
using powders and liquids rather
than solids and the variances
encountered using lasers and
optics rather than spindles and
cutting tools. In short there is a
lot to learn, but learn we will.
In any business hierarchy
looking towards 3D Printing
and AM it is therefore critical to
put the views of engineers and
design professionals above those
of futurists, technology scouts,
marketers or the media.
Remember, if something seems
implausible, it probably is just
ask an engineer.
So what should be the simple
take-away for the guys in the
C-suites up there on the top oor?
In the world of AM, the smart
money is on the tortoise, not the
hare. Think long term business
sustainability not short term
marketing gain. And dont
worry about missing the boat
another bigger, faster, shinier
one will be along shortly, with
better navigation aids, better life
vests and less chance of hitting
an iceberg.
PHIL REEVES ManagIng
dIREctoR, EconoLYSt
QUADRO
K6000
Misco
www.misco.co.uk
Tel: 0800 038 8880
Jigsaw
www.jigsaw24.com
Tel: 03332 400 888
The NVIDIA
Quadro
K6000 is the most powerful pro graphics board on the planet, combining
12 GB of GPU memory, 2880 NVIDIA CUDA parallel processing cores, accelerated double-precision
computation, plus the ability to drive up to four ultra-high resolution displays or projectors to empower
artists, designers, and engineers to realize their biggest visions.
These advanced display capabilities for large-scale visualization and support for high-performance
video I/O make theNVIDIA
Quadro
Oering impressive
portability in a
stylish package, the
Dell Precision M3800
is in a class of its own
W
eve seen 14-inch
mobile workstations
come and go over
the years, but none
can touch the HP ZBook 14 when it
comes to mobility.
Pitched as the worlds frst
workstation Ultrabook, HPs little
beauty is a mere 21mm thick,
weighing a touch over 1.6kg. Even
with the 65W power adapter the
whole package comes in at 2kg. This
is a mobile workstation like no other.
Of course, the tradeoff for mobility
is performance. The AMD FirePro
M4100 GPU is very much entry 3D
and while most mobile workstations
have headroom for a 37W CPU, the
ZBook sets its limits at 17W.
The clock speed of 2.1GHz - 3.3GHz
on our test machines Intel Core
i7-4600U CPU may be impressive for
such a low powered chip, but with
only 2 CPU cores, there will likely be
bottlenecks in everyday use.
Windows, drivers and software
all fght for CPU cores, and multi-
threaded 3D software will suffer.
But to pull up this machine on
performance would be missing the
point. Cranking down key components
(and ommitting a DVD drive) are the
very reasons the ZBook 14 is so light.
And it is an exceptional piece of
design. The island style keyboard is
a pleasure to use, the Touchpad silky
smooth and the mouse buttons have
a good amount of give. Theres even
a Pointstick should you prefer.
Because of the 14-inch form factor
theres no dedicated numeric keypad,
but pressing fn and num lk together
turns the centre of the keyboard into
a pseudo numeric keypad.
Even with its slender body, HP has
still managed to include a standard
RJ45 port. This ingenious design has
a spring-loaded hinge that expands
the port to its full width when you
plug in an Ethernet cable. VGA
and DisplayPort v1.2 ports allow
connection to external displays.
Unlike most mobile workstations,
all four ports are USB 3.0. One is
always on for charging, denoted by
a miniscule lightning symbol, which is
very hard to see. Its a real shame this
port isnt colour-coded. HP isnt the
only manufacturer to miss this trick.
WiFi on our test machine supports
802.11a/b/g/n (2x2), but you can
upgrade to 802.11ac (2x2) to boost
transfer rates. Mobile broadband
modules are optional.
The display in our test machine is
impressive a 14-inch full HD IPS
panel, which delivers crisp lines
and vivid colours. There are other
options available from a 1,600 x
900 touchscreen down to a more
standard 1,366 x 768 display.
Despite its tiny chassis, the ZBook 14
still offers exceptional serviceability.
Slide a catch on the underside and
the HP Easy Access Door simply clips
off. Now you have direct access to
battery, memory, hard drive and mini-
cards making it exceptionally easy
to upgrade or replace components.
Theres hardly a screw in sight.
For power the three cell 50WHr
battery can be supplemented with
a secondary 6-cell (60 Whr) slice
battery, which connects via a port
on the underside of the machine.
Enterprise-users are catered for
through a dedicated docking port (on
the side rather than underneath), a
smart card reader and a fngerprint
reader to the right of the touchpad.
To add another layer of security
the 2.5-inch 256GB SSD in our test
machine features Self Encrypting
Drive (SED) technology. There are
plenty of other storage options and
if you want to double up on drives
theres an optional 120GB M.2 SSD.
The ZBook 14 is a great little
machine, well built with exceptional
serviceability. Its ideal for truly
mobile CAD but limited to small
assembly modelling. Considering the
core spec its a little expensive, but
its hard to put a price on mobility.
HP Zbook 14
Dell Precision M3800
U
LT
R
A
M
O
B
IL
E
1
4
-IN
C
H
MOBILE WORKSTATION BUYERS GUIDE
U
LT
R
A
M
O
B
IL
E
1
5
-IN
C
H
Mobile workstations.indd 46 4/3/14 19:31:39
047 D3D Ads.indd 1 04/03/2014 09:33
48 MARCH 2014 DEVELOP3D.COM
T
his latest update to
Lenovos ThinkPad family
is a specialist piece of kit.
With an exceptional 15.5-
inch 2,880 x 1,620 display and an
X-Rite Pantone colour calibrator
built in, its ideal for colour-
critical workfows. Simply choose
a profle, close the lid and it does
the rest, making a few re-assuring
beeps along the way.
The IPS panel is stunning: colours
are vivid and jagged edges on
wireframe CAD models almost
invisible. Unfortunately, the cost of
having so many pixels on screen is a
drop in performance. We experienced
a 35% and 15% respective slow
down in SolidWorks and Creo when
going from 2,880 x 1,620 to standard
HD. This will vary according to
applications and models and it may
have no impact on some workfows.
However, if it is an issue, you can
always downgrade to an HD display.
Storage is fast, provided by a single
256GB Samsung SSD. Theres also
room for a second 2.5-inch drive but,
surprisingly, no mSATA.
The machine is optimised for
mobile workers. It has fast Intel
Dual Band AC 7260 WiFi and mobile
broadband built in so you can
send/receive data wherever you
can get a 3G/4G signal. Lenovo also
places a big emphasis on battery
life, automatically clocking down
the Intel Core i7-4800MQ CPU by
75% when not plugged in, though
this can be changed in the BIOS to
give priority to performance.
Overall, we had mixed feelings
about the W540. We loved the
display and colour calibrator,
but the touchpad can be
hugely frustrating, so use
an external mouse
whenever possible.
Lenovo ThinkPad W540
T
his mainstream 15.6-inch
delivers far more grunt
than its lightweight
sibling, the ZBook 14. It
can handle a high-end CPU (up
to the Intel Core i7-4900MQ), a
mid-range GPU (up to the Nvidia
Quadro K2100M) an ideal
combination for mid-range CAD.
Internal access is a breeze thanks
to the superb HP Easy Access Door.
Simply fip a switch and the back
panel pops off. No tools required.
Everything is beautifully laid out
inside. RAM slots are marked clearly
meaning upgrades can be done in
seconds. The 2.5-inch hard drive,
secured by a couple of screws, is
eased out with a green lever. No other
mobile workstation gets close to the
ZBook 15 in terms of its serviceability.
Its also a joy to use. The island
keyboard and trackpad are superb.
Wireless and sound can be switched
on/off instantly using two buttons
located above the numeric keypad.
Our test machines HP DreamColor
panel is also superb, by far the
best HD display on test this month.
Colours are vivid and dont drop off
at wider viewing angles, but you
pay a premium for this high-quality
IPS panel. There are some lower-
cost options, all of them HD.
Kitted out with an Core i7-4700MQ
CPU and Nvidia Quadro K2100M GPU
our test machine delivered solid if
not spectacular performance. Its
8GB of RAM is a touch light for most
workfows, but with capacity for
32GB this can be easily remedied.
Storage takes the middle ground
between SSD and HDD, courtesy of
a 2.5-inch 750GB hard drive and a
32GB mSATA SSD, which acts as a
cache drive. There are plenty of other
options including a 128GB mSATA.
Theres also scope for expansion
by swapping out the DVD/RW for
a drive upgrade bay to house a
second 2.5-inch drive.
There are 4 x USB ports, three
of them USB 3.0, but the machine
also comes with Thunderbolt for
exceptional transfer rates.
Overall, the ZBook 15 is an
impressive machine, well built with
exceptional serviceability. But quality
like this doesnt come cheap. Our test
machine will set you back the best
part of 2,000 and while this includes
the superb DreamColor display some
will fnd it hard to justify for a mid-
range mobile workstation for CAD.
D
ell has an impressive
pedigree when it comes
to mobile workstations
and its latest 15-inch
offering picks up where the
Precision M4700 left off.
The aluminium and magnesium
alloy chassis feels solid and built to
last; the keyboard, numeric keypad
and trackpad are all excellent and
theres a reassuring click when
closing the lid on the HD display. The
days of Dell using a cheap consumer
chassis for its mobile workstations
are long gone.
Despite this feeling of quality, our
test machine is not expensive. But
even with its budget 1,152 price
tag you get a top notch Intel Core
i7-4800MQ CPU, ideal for 3D CAD.
The AMD FirePro M5100 is an
excellent choice for Creo and
SolidWorks, standing shoulder to
shoulder with the Nvidia Quadro
K2100M and delivering solid scores
in our benchmarks.
You do get more bang for your
buck by going down the AMD route.
An equivalent spec M4800 with an
Nvidia GPU will set you back 1,189
and this will only secure you the
slightly less powerful Quadro 1100M.
The rest of our test machines
components are much more entry-
level. 8GB (2 x 4GB) RAM and a
500GB hybrid drive hardly inspire,
but with room for 32GB RAM
(4 x 8GB) and three drives there
are plenty of options.
Maxing out the storage means
swapping out the slot load DVD
drive for a second 2.5 drive (HDD,
SSD, or hybrid). The third drive is an
mSATA SSD, available in capacities
up to 512GB. This is signifcantly
larger than those offered by HP and
Lenovo in equivalent machines.
Providing you have the right
combination of drives, you can
boost drive performance or security
by confguring with RAID 0 or 1 (two
drives) or RAID 5 (three drives).
To keep costs down, theres no
optional fngerprint reader in our
test machine, so security is left to
the Smart Card Reader.
Overall, Dell has delivered
another solid mobile workstation
and one that is priced extremely
competitively. For mainstream 3D
CAD our test M4800 may be a little
unbalanced, but add an SSD into
the mix and top up the RAM and
you wont be disappointed.
HP Zbook 15 Dell Precision M4800
MOBILE WORKSTATION BUYERS GUIDE
M
ID
R
A
N
G
E
1
5
-IN
C
H
M
ID
R
A
N
G
E
1
5
-IN
C
H
M
ID
R
A
N
G
E
1
5
-IN
C
H
M
ID
R
A
N
G
E
1
5
-IN
C
H
H
IG
H
-E
N
D
1
7
-IN
C
H
Mobile workstations.indd 48 4/3/14 19:32:01
Interpro Ad.indd 1 04/03/2014 12:28
9th-10th April, Stratford, London, UK
Te technology making our future.
www.shapetofabrication.com
Zaha Hadid Architects, KPF
Heatherwick Studio, AKT II
Barber Osgerby, Populous
and many more...
www.shapetofabrication.com
STF 5 Conference: Te Game Changers
Tickets available from our webstore or call: 0208 498 9900
140303_STF_PR full page-arch_002.indd 1 03/03/2014 14:14
DEVELOP3D.COM MARCH 2014 51
T
o get the kind of 3D
performance on offer in
this 15-inch from German
frm Schenker youd
normally have to invest in a hefty
17-inch machine. 15-inch models
from the major manufacturers
max out at the Quadro K2100M,
but Schenkers W503 takes the GPU
up a notch to a Quadro K3100M.
In SolidWorks and Creo this extra
GPU horsepower is refected in some
elevated benchmark scores. In the
real world it means youll be able to
push up the quality settings in your
real-time renderer and still maintain
those all important frame rates.
The Intel Core i7-4700MQ CPU may
not be the fastest, but the excellent
500GB Samsung 840 Evo SSD gives
it a boost in our multithreaded
CAM and rendering tests. Its ability
to fetch data quickly means the CPU
can get to work much earlier.
As a smaller manufacturer,
Schenker is quick to respond to new
tech and is already offering the Intel
Core i7-4940MX (3.1GHz to 4.0GHz)
CPU and 1TB Samsung 840 Evo SSDs
in 2.5-inch and mSATA form factors.
Indeed, if high performance
storage is your obsession, the W503
is well equipped. Theres space for a
whopping 4TB thanks to two mSATAs
(which can be striped or mirrored in
RAID 0/1) and two 2.5-inch bays (one
replaces the DVD).
The downside of having 17-inch class
features in a 15-inch chassis is it does
feel slightly chunkier than its peers
and the power adapter is heavier.
From a design perspective, its also
less refned, though the keyboard and
touchpad are perfectly adequate.
The HD screen, despite boasting
a 95% colour gamut, doesnt excite
out of the box like the HP ZBook 15
or Lenovo ThinkPad W540. Investing
in a colour calibration tool might
change this. But then one mustnt
forget that to get your hands on
this 15-inch powerhouse
will only set
you back
1,531.
Schenker W503 Dell Precision M6800
C
onsidering the amount
of technology on offer in
this 17-inch model from
Scan, 3XS MGW-10 wins
hands down on value for money.
With an Intel Core i7-4800MQ CPU,
Nvidia Quadro K3000M GPU and
32GB RAM, it has a spec to rival a
mid-range desktop workstation.
A 250GB Samsung 840 Evo mSATA
SSD provides fast storage for OS and
apps, while a 2.5-inch 1TB Hitachi
Travelstar HDD will hold the bulk of
your CAD data. With room
for an additional 2.5-inch and mSATA
drive theres plenty scope to expand.
RAID 0/1 is supported in pairs.
The Clevo P170SM chassis (also
used by Workstation Specialists in its
WS-M1760) is plasticky in places and,
compared to the Dell Precision M6800
or HP ZBook 17, a little uninspiring.
Thats not to say it isnt well-
built, but when one can customise
the backlit keyboard with fashing
colours, its obvious Clevo only has
one eye on the professional user.
The Quadro K3000M is of a slightly
older generation of GPUs than the
K3100M and didnt reach the same
heights as Schenkers W503. Scan says
this is down to supplier availability
rather than cost, so its probably
worth waiting for the newer GPU to
come online, which should be soon
Overall, the machine offers solid
performance, good expandability
and great value for money,
making it a cost-
effective altern-
ative to a
mainstream
desktop CAD
workstation.
T
his 17-inch monster from
Derby-based Workstation
Specialists is by far the
most expensive mobile
workstation on test this month,
but its in a completely different
class in terms of its spec.
The high-end 8GB Quadro K5100M
GPU makes light work of throwing
texture-heavy design viz datasets
around the HD display. And, with
1,536 CUDA cores, it can also double
up as a powerful general-purpose
processor. This will be of interest to
users of CUDA-compatible ray trace
renderers or simulation solvers,
where the GPU can be used to
augment the Intel Core i7-4800MQ
CPU. And theres plenty of memory
to support such complex datasets:
the machine is maxed out with 32GB
PC3-1600MHz High Speed DDR-3.
To serve up the OS and apps
theres a 240GB Intel mSATA SSD
with a 750GB HDD for data. If
you need a more powerful
storage system, you
can double
up on both
mSATA and
2.5-inch drives.
The WS-M1760 uses the same Clevo
P170SM chassis as the Scan 3XS
MGW-10 so theres no docking port
or SmartCard reader, but you do get
a fngerprint reader, powered by
Truesuite keepsafe.
The HD display is a bit lacklustre.
Lines are sharp, but fre up a CAD
render and the colours appear a
little dull. The good news is there are
plenty of digital outputs to connect
to an external display, including
HDMi, DisplayPort, Mini DisplayPort,
which will be helpful to get the best
out of the high-end GPU.
Scan 3XS MGW-10
F
rom the outside the
17-inch Dell Precision
M6800 looks just like a
bigger version of the Dell
Precision M4800. And in many
ways it is. It features the same
trademark Dell styling, solid
chassis and easy maintenance
of its 15-inch sibling. The big
difference is whats inside.
The M6800 places a big emphasis
on high-performance graphics and
only has options for mid-range or
high-end GPUs. Our test machines
Quadro K3100M should be perfect
for power CAD users, but you can
take this all the way up to the
K5100M should you so desire.
The 4GB GPU is partnered with an
Intel Core i7-4800MQ CPU and 16GB
of RAM, which comes in 4 x 4GB
DIMMs. Unfortunately, this means
theres no room to upgrade to the
maximum 32GB without swapping
out memory.
Its criminal for a machine of
this class to be kitted out with
such prosaic storage but our
M6800s 750GB Hard Drive
is crying out for an SSD to
take the strain in day to
day operations.
And its not as if the
M6800 cant handle it. With
support for one solid state Mini-Card
and three 2.5-inch drives (one in the
optical bay caddy), there are plenty
of options. Drives can be confgured
in pairs for RAID 0 or 1 and, unlike
the WS and Scan, you can also
make a three drive RAID 5 array for
performance and redundancy.
The 17.3-inch UltraSharp HD display
is impressive, boasting crisp lines and
well-balanced colours. Unfortunately,
theres no upgrade to QHD+, which
is a shame as the M6800 is more
equipped than most to throw around
ultra hi-res models without unduly
impacting performance.
Its clear our test machine needs
some tweaks to get the most out of
the M6800, but it certainly has the
foundations for a solid, enterprise-
class desktop replacement.
H
IG
H
-E
N
D
1
7
-IN
C
H
MOBILE WORKSTATION BUYERS GUIDE
M
ID
R
A
N
G
E
1
5
-IN
C
H
H
IG
H
-E
N
D
1
7
-IN
C
H
H
IG
H
-E
N
D
1
7
-IN
C
H
H
IG
H
-E
N
D
1
7
-IN
C
H
WS-M1760
Mobile workstations.indd 51 4/3/14 19:32:26
52 MARCH 2014 DEVELOP3D.COM
DEVELOP3DSERVICES
Product
Design
Composites Design
& FE Analysis
Airbus
Boeing CS/FAR 25 Analysis
FIA F1/LMP Structures
R&D
Solutions
World class design
and analysis to the
Composites,
Aerospace and
Automotive
sectors.
www.fluidformdesign.co.uk
+44 (0)1243 840022
To adverTise YoUr services here conTacT sTeve KinG
sTeve@X3dMedia.coM | +44 (0) 20 3355 7314 | +44 (0)7850 507362
Welcome to DEVELOP3Ds professional
services section for product development
professionals.
To see your service advertised here,
please contact Steve King.
steve@x3dmedia.com
+44 (0)20 3355 7314 / +44 (0)7850 507362
p52_D3D_MARCH14_Services.indd 52 4/3/14 21:00:09
JOBS.DEVELOP3D.COM MARCH 2014 53
Welcome to DEVELOP3Ds jobs section.
Every issue we will bring you the latest product development
jobs to help you kick start your career.
In partnership with CADjobhunter.com we also have a dynamic
jobs website where you can nd your dream job by searching by location,
keyword or CAD/CAM/CAE software.
Alternatively upload your CV to help your future employer nd you.
Register your details at
jobs.develop3d.com
To advertise on the website or
inside the magazine contact
Matt Wells
matt@x3dmedia.com
+44 (0) 1252 414007
DEVELOP3DJOBS
To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 1252 414007
More deTails aT hTTp://goo.gl/dKxvQT
Mechanical Design Engineer
Peterborough
Olympus Automation is an engineering company of experienced, enthusiastic and motivated people.The company has been
trading since 1993 and has grown based on its track record of best in class process and automation solutions in the food and
beverage industry.
We are currently looking for a Mechanical Design Engineer to tackle the design and support of the delivery of capital contracts on
time and to or below budget in a range of food processing technologies.
THE JOB (Main Duties):
To provide design assistance, support and advice to other engineers during contract execution.
Support the management of contracts, both in the UK and overseas.
Be part of teams dealing with specific responsibilities for delivering projects
Liaise internally to support the delivery of profitable contracts on time and to or below budget.
Support the iternal sales tendering process and manage the transition from enquiry into contract.
Manage effectively the transition internally from order into contract, minimising commercial and technical risks.
To specify and requisition key technologies.
Prepare engineering equipment drawings and plant layouts using Solidworks drawing package.
CANDIDATE PROFILE:
A highly motivated, confident and dedicated professional.
An experienced engineer with an analytical approach to problem solving.
Able to understand equipment and process designs using the appropriate analytical tools.
Experience using Solidworks drawing package.
Able to work alone or as a member or the leader of a project team.
Able to travel both within the UK and throughout the world.
INTERESTED?
Send your CV and covering letter to
jobs@olympus-automation.co.uk
p53_54_55_56_57_D3D_MARCH14_jobs.indd 53 4/3/14 20:47:08
54 MARCH 2014 JOBS.DEVELOP3D.COM
JOBS.DEVELOP3D.COM
To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 1252 414007
More deTails aT hTTp://goo.gl/7fb2C
p53_54_55_56_57_D3D_MARCH14_jobs.indd 54 4/3/14 20:47:09
JOBS.DEVELOP3D.COM MARCH 2014 55 To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 1252 414007
JOBS.DEVELOP3D.COM
More deTails aT hTTp://goo.gl/T7nnuC
Where next?
Wherever you take us.
Whats next for Dyson? You tell us. Actually, you wont just tell us, youll show us. Because well give you
the freedom to invent, to pursue your ideas and to push technological boundaries.
Great things are happening here. Not only are we working on some incredible new projects, but were
continuing to invest heavily in our UK Research, Design and Development (RDD) centre. Which tells you
two things. Firstly, that were doing fantastically well as a global business. Secondly, just how vitally
important engineers are to us. In many ways, engineers are Dyson. Thats why were looking for more
like minds to join us and create the technology of the future.
So if youre unafraid to take risks and ready to turn conventional thinking on its head, we need to hear
from you. Your background could be mechanical engineering, technology, science.... were open to
ideas. Find out more at www.careers.dyson.com
DESIGN, MECHANICAL AND RESEARCH ENGINEERS
COMPETITIVE | WILTSHIRE, UK
p53_54_55_56_57_D3D_MARCH14_jobs.indd 55 4/3/14 20:47:09
56 MARCH 2014 JOBS.DEVELOP3D.COM To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 1252 414007
JOBS.DEVELOP3D.COM
More deTails aT hTTp://goo.gl/gpeseo
mechanical design engineer
andover, hampshire
3form Design is a well-established design consultancy with a passion and rep-
utation for creative designs that are engineered beautifully. We work from initial
strategy and concept design, engineering development and design detailing for
production, and if required, through to manufacturing on behalf of our clients
too. We have an operation in China.
3form Design is looking for a motivated Mechanical Design Engineer to join our
fast moving design consultancy. The role will be based in Andover, Hampshire.
Successful applicants will work on a huge scope of products: medical, consum-
er, industrial, architectural, structural.
You will be:
Passionate and enthusiastic
An experienced user of SolidWorks (or similar)
Have a strong understanding of engineering, mechanisms and manufacturing
processes
Able to develop a concept through to manufacture
Able to create engineering drawings
Able to provide technical assistance
Have at least 4 years experience in industry
How to Apply
If you think you have what it takes, please email through your CV and portfolio
to ally@3formdesign.com with a subject header Mechanical Design
Engineer or call (+44) 01264 326306.
www.3formdesign.com
p53_54_55_56_57_D3D_MARCH14_jobs.indd 56 4/3/14 20:47:09
JOBS.DEVELOP3D.COM MARCH 2014 57 To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 1252 414007
JOBS.DEVELOP3D.COM
More deTails aT hTTp://goo.gl/jvr830
p53_54_55_56_57_D3D_MARCH14_jobs.indd 57 4/3/14 20:47:09
I
t only seems right that we nish
o our 3D printing issue with a
back page article that addresses
one of the major issues thats
facing the industry at present.
The issue that most of the software
out there is crap at supporting this
fascinating technology to build parts
out of, guratively speaking, nothing
at all.
Lets face it. 3D printing is over hyped of
that, theres very little doubt. But its also
incredibly useful for professional designers
and engineers. A fact that most of us have
been aware of for the last two decades or
more.
What Ive noticed in the last year or so is
that more 3D software vendors are talking
about it. Its begun inltrating user events
and press conferences, and is starting to pop
up in webinars and case studies. 3D printing
is a hot topic and the software vendors are
trying to make the most of it.
Whats interesting is that the vast majority
have, until recently, completely ignored it.
When it was an output process from their
3D design systems, they treated it as pretty
much that. If they supported a half decent
STL output that wasnt 20 per cent ipped
triangles or an over bloated, plain text ASCII
le, then they were happy. Job done.
Of course, now the tables have been
turned. The 3D print industry is getting the
headlines and headlines that the software
vendors are, in some cases, downright
jealous of. When did you last see the CEO of
a 3D design software company on the cover
of Wired magazine? When did you last see
Jeremy Paxman staring ba ed at a NURBS
model on Newsnight?
EASY NOW TIGER
From the perspective of the user and one
with a decent amount of experience, I can
understand why theyre so keen to jump on
the bandwagon. If you can associate your
products with a technology thats hitting
the mainstream outside of your traditional
community, then you stand a better chance
of reaching those that youve not before.
My issue with this activity is that there
doesnt seem to be a lot of substance to
much of it. Yes, the 3D tools are essential
to build the geometry thats to be printed.
That much we all know. But when a company
58 MARCH 2014 DEVELOP3D.COM
THE LAST WORD
is linking that, but without following up on
providing better tools, more support and
understanding the workow and issues that
surround the professional user, you cant
help but think its all a bit of a con. The good
news is that things are starting to change.
LIP SERVICE vs REAL TOOLS
In the last year or so, weve seen the
mainstream 3D software vendors start to
add in tools that better support the process
of 3D printing. Anyone thats played with
one of these machines will know that its not
simply a case of loading up your 3D part and
hitting print.
Theres a layer of preparation involved.
You need to orient the model, ensure that
the features youre trying to build are
appropriate for the machine or process
youre building on. Yes, in many respects,
the ultimate is the ability to hit print and get
a geometrically exact replica of whats on
screen.
The reality is that its a more involved
process. Each machine and material has its
own requirements in terms of geometry.
When you then factor in aspects such as
shrinkage, post processing, resizing of
holes, adding support to tap holes some
adaptation is always needed.
This has typically been the preserve of the
set-up software for each machine. Sizing and
orientation are typically handled with ease
on a part level. If you then need to look at
adding support for thin walls, for resizing
of holes and such, then its down to the
generating software i.e. your CAD system.
Its been a pain in the arse and something
that comes with experience.
MORE INTELLIGENT TOOLS
Now were seeing tools to support these
processes and more introduced into our 3D
design systems. SpaceClaim has a whole
module that covers some of the basics,
Autodesk has recently updated its free
MeshMixer tool to bring in not only sizing
and orientation tools based on real machine
proles, but also support optimisation and
generation. Theres also talk of greater
support coming in SolidWorks 2015.
Alongside this, theres a range of
specialised tools that also have these type
of tools. These have been long adopted by
users in the know. One of the leading lights
Al still needs a bigger shed. But hes about done
writing about 3D printing... for a couple of
months, at least. al@x3dmedia.com
Get o the bandwagon and put down the
handbook sang Arctic Monkeys. Their
singer hit the headlines for his speech
at the Brits, but Al Dean thinks 3D tool
vendors should pay more attention
when it comes to 3D printing
1
is Magics, by Materialise. This system has
such mastery of the whole process that its a
thing to behold. Will these specialist vendors
leverage the hype in the same way or bring
out more economically viable tools for the
average user rather than the hardcore user?
I do hope so.
If were to put up with the hype and the
endlessly entertaining questions from
friends and family, then we might as well get
some benet on a professional basis at the
same time. The hype. Its annoying. But can
be benecial after all.
1 Materialise Magics
is a killer App for 3D
printing but it costs
2 SpaceClaims 3D
Print Prep module
brings new tools
1 Autodesk
MeshMixer solid
tools, for free
2
3
p58_D3D_MARCH14_Al..indd 58 4/3/14 20:58:32
17181920
JUNE 2014
LYON EUREXPO
C
e
d
o
c
u
m
e
n
t
e
s
t
d
i
t
p
a
r
3D PRINT,
the only show
spotlighting additive
manufacturing
technologies
for all industries.
Develop and
manufacture
diferently...
Your free access badge on
www.3dprint-exhibition.com