ME 290P -- October 2002Design is an Iterative ProcessA Specific ChallengeConceptual PrototypingNew Ways of Rapid PrototypingWhat SFF exists in COE ?SFF: Fused Deposition ModelingFused Deposition ModelingLooking into the FDM MachineLayered Fabrication of Klein BottleKlein Bottle Skeleton (FDM)Fused Deposition Modeling (FDM)What Can Go Wrong ?SFF: Solid ImagingSlide 15Slide 16Slide 179-Story Intertwined Double ToroidSlide 19Powder-based ApproachesSFF: 3D Printing -- Principle3D Printing: Some Key Players3D Printing: Z CorporationSlide 24Slide 25Optional Curing: 30 min. @ 200ºFSlide 27Slide 28120 Cell -- Close-up3D Color Printing: Z-Corporation3D Color Printing: Z CorporationSlide 32Slide 33Broken PartsSlide 35SFF: Stereolithography (SLA)Slide 37StereolithographySéquin’s “Minimal Saddle Trefoil”Slide 40Consumer Electronics PrototypesPrototyping Consumer ProductsModel  Prototype  Mold  PartArtistics Parts, Abstract Sculptures“Viae Globi” SculpturesSculpture Design: “Solar Arch”Competition in Breckenridge, COFDM Maquette of Solar ArchWhich Process Should You Pick?Informal Process Ratings MatrixCHSCHSUCBUCBME 290P -- October 2002ME 290P -- October 2002Rapid Prototyping and its Role in Product DevelopmentCarlo H. SéquinEECS Computer Science DivisionUniversity of California, BerkeleyCHSCHSUCBUCBDesign is an Iterative ProcessDesign is an Iterative ProcessFormal SpecificationsDetailed DescriptionClear Concept1st `hack'Demo PrototypeUsable Evaluation SeriesMarketable Systems ProductVague ideaRevision of artifact Experiments, get feedbackCHSCHSUCBUCBA Specific ChallengeA Specific ChallengeCreate as soon as possible a 3D "free-form" part(not a box-like thing that can be built from flat plates)for evaluation in its application context.This includes:visualizationtactile feedbackfunction verificationsimulation of final use.CHSCHSUCBUCBConceptual PrototypingConceptual PrototypingThe Traditional Options:Model from clayCarve from woodBend wire meshingCarve from styrofoam – perhaps with surface reinforcementMill from a block of plastic or aluminum (3- or 4-axes machines)CHSCHSUCBUCBNew Ways of Rapid PrototypingNew Ways of Rapid PrototypingBased on Layered Manufacturing:Build the part in a layered fashion-- typically from bottom up.Conceptually, like stacking many tailored pieces of cardboard on top of one another.Part geometry needs to be sliced, and the geometry of each slice determined.Computer controlled, fully automated.CHSCHSUCBUCBWhat SFF exists in COE ?What SFF exists in COE ?In Etcheverry:A Fused Deposition Modeling MachineA Z-Corp Color/Mono 3D PrinterIn Cory Hall:Solid Printing / Imaging (3D Systems)Stereolithography (3D Systems)You need to prepare:A “watertight” boundary representation with less than 100’000 trianglesIn .STL format.CHSCHSUCBUCBSFF: Fused Deposition ModelingSFF: Fused Deposition ModelingPrinciple:Beads of semi-liquid ABS* plastic get deposited by a head moving in x-y-plane.Supports are built from a separate nozzle. Schematic view ==>Key player: Stratasys: http://www.stratasys.com/* acrylonitrile-butadine-styreneCHSCHSUCBUCBFused Deposition ModelingFused Deposition ModelingCHSCHSUCBUCBLooking into the FDM MachineLooking into the FDM MachineCHSCHSUCBUCBLayered Fabrication of Klein BottleLayered Fabrication of Klein BottleSupport materialCHSCHSUCBUCBKlein Bottle Skeleton (FDM)Klein Bottle Skeleton (FDM)CHSCHSUCBUCBFused Deposition Modeling (FDM)Fused Deposition Modeling (FDM)An Informal EvaluationEasy to useRugged and robustCould have this in your officeGood transparent software (Quickslice)with multiple entry points: STL, SSL, SMLInexpensive to operateSlowThink about support removal !CHSCHSUCBUCBWhat Can Go Wrong ?What Can Go Wrong ?Black blobsToppled supportsCHSCHSUCBUCBSFF: Solid ImagingSFF: Solid ImagingDroplets of a thermoplastic material are sprayed from a moving print head onto a platform surface.Need to build a support structures where there are overhangs / bridges.These supports (of the same material) are given porous, fractal nature.They need to be removed (manually).Key player: 3D Systems: http://www.3dsystems.com/index_nav.aspCHSCHSUCBUCBSFF: Solid ImagingSFF: Solid ImagingSupports made from same material, but with a fractal structureCHSCHSUCBUCBSFF: Solid ImagingSFF: Solid ImagingThermojet Printer (3D Systems)Technology: Multi-Jet Modeling (MJM)Resolution (x,y,z): 300 x 400 x 600 DPIMaximum Model Size: 10 x 7.5 x 8 in (13 lb)Material: neutral, gray, black thermoplastic:ThermoJet 88: smooth surfaces for castingThermoJet 2000: more durable for handlingCHSCHSUCBUCBSFF: Solid ImagingSFF: Solid ImagingThat’s how partsemerge from theThermojet printerAfter partial removalof the supportingscaffoldingCHSCHSUCBUCB9-Story Intertwined Double Toroid9-Story Intertwined Double ToroidBronzeinvestment casting from wax original made on 3D Systems’“Thermojet”CHSCHSUCBUCBSFF: Solid ImagingSFF: Solid ImagingAn Informal EvaluationFastInexpensiveReliable, robustGood for investment castingSupport removal takes some care(refrigerate model beforehand)Thermojet 88 parts are fragileCHSCHSUCBUCBPowder-based ApproachesPowder-based ApproachesKey Properties:Needs no supports that must be removed!Uniform bed of powder acts as support.This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.CHSCHSUCBUCBSFF: 3D Printing -- PrincipleSFF: 3D Printing -- PrincipleSelectively deposit binder droplets onto a bed of powder to form locally solid parts.Powder Spreading PrintingBuildFeederPowderHeadCHSCHSUCBUCB3D Printing: Some Key Players3D Printing: Some Key PlayersZ Corporation: http://www.zcorp.com/Plaster and starch powders for visualization models.Soligen: http://www.zcorp.com/Metal and ceramic powdersfor operational prototypes.CHSCHSUCBUCB3D Printing:3D Printing: Z CorporationZ CorporationThe Z402 3D PrinterSpeed: 1-2 vertical inches per hourBuild Volume: 8" x 10" x 8" Thickness: 3 to 10 mils, selectableCHSCHSUCBUCB3D Printing:3D Printing: Z CorporationZ CorporationCHSCHSUCBUCB3D Printing:3D Printing: Z CorporationZ CorporationDigging outCHSCHSUCBUCBOptional Curing: 30 min. @ 200ºF Optional Curing: 30 min. @ 200ºF Keep some powder in place<-- Tray for transportCHSCHSUCBUCB3D Printing:3D Printing: Z