Modern Machine Shop: To See Machining Reality on a Tablet

Modern Machine Shop

Viewing the simulation of a live machining process in real time gives clear picture of what is happening at the moment inside the machine tool as it runs an NC program. SPRING Technologies’ NCSIMUL Player Synchro makes this happen on a wireless mobile tablet with an app called WYSIWYC.

Article From: 4/21/2015 Modern Machine Shop

NCSIMUL Player Synchro

One of the distinguishing aspects of the CNC programming aids from SPRING Technologies (U.S. offices in Cambridge, Massachusetts) is advanced use of 3D simulation of machining processes, which the company has taken in several new directions. One of the most interesting of these developments is a mobile application called WYSIWYC (what you see is what you cut) that puts its NCSIMUL Player Synchro on a tablet PC designed to withstand a harsh environment........
WYSIWYC

For the complete article go to: http://www.mmsonline.com/articles/to-see-machining-reality-on-a-tablet 

Best Linux distribution for 3D printing?

I researched a bit for a best Linux distribution focused on 3d printing and found CAE Linux. It is loaded with digital fabrication and 3d design software packages.

Here is the description for the project site:
Thanks to Open Source, now you just need to insert the CAELinux LiveDVD in your computer to turn it into a free and open engineering development workstation with CAD, CAM, CAE / FEA / CFD, electronic design and 3D printing features: no licence and even no installation is required !

Based on the open-source CAD/CAM software such as Freecad, LibreCAD, PyCAM and Cura and CAE softwares like Salomé, Code_Aster, Code_Saturne,OpenFOAM and Elmer , you can design your CAD geometry, perform multiphysics simulations to optimize your design, generate G-code for prototyping with 3D printing & milling, and even develop your own PCBs & microcontroller based electronic circuits for automation.  
For example, using Freecad, you can design your parametric CAD geometry with ease, generate a computation mesh and setup your simulation problem in Salome_Meca in a few minutes. After your design is checked you can go on preparing a G-Code for CNC milling a prototype with PyCAM or 3D printing it with Cura.
With the integrated open-source tools of CAELinux, you can simulate incredibly complex physics with the open-source FE & CFD solvers Code_Aster, Code-Saturne, OpenFOAM & Elmer: non-linear thermo-mechanics, coupled fluid-structure dynamics, seismic / non-linear explicit dynamics, contacts, visco-plasticity, fluid dynamics, heat exchange, convection heat transfer and radiation in other words nearly all physics problem can be addressed with the integrated solvers!! Then reload your results files in post-processing applications like Salomé, GMSH or Paraview to visualize your data in 3D... And don't forget all these features are based on open-source / free softwares, so now you don't have to pay for any expensive licenses and if you want, you can even improve it.
SALOME on CAE Linux

Here is a video overview of CAE Linux:



CAE Linux homepage: http://www.caelinux.com/CMS/

There is also good 3d printing support in Fedora 19 distribution.

Hopefully the CAE Linux team will update the distro soon since the last release is in 2013.

Here are series of video tutorials going into more details of the software installed by DrRMFithen. Great guides on how to use open source CAD and 3d design:









D-Coil handheld wax extruder for manual 3D printing




From project description:
D-Coil is a new digital 3D modeling approach using wax coiling to bring tangibility to the design of digital models. After defining a shape to extrude, the users follow the lead of a hand-held actuated extruder to instantiate the actual extrusion using wax. The tangibility of the wax extrusion sets the stage to create the next components until the digital model is completed.
The digital model affords all digital attributes (ease of transformation, distribution, and 3D printing) while the wax artifact can be discarded or kept as a one-of-a-kind memento.

We present a proof-of-concept implementation of D-Coil and showcase how this additive approach can also be extended to a subtractive process using a digitally actuated cutter. By adding a 6DOF mouse, users can also include scaling, rotation, and bending effects to create a wide variety of shapes often difficult for novices to produce in standard CAD software.








More information and detailed PDF paper:

http://dl.acm.org/citation.cfm?id=2702123.2702381

It reminds me of FreeD handheld fabrication tool or Human 3d printer projects.

Materialise 3D printing factory

This facility looks amazing. I wish I could work someplace like that.





... I wouldn't even mind working in quality control checking if holes are round ...
... I know its a corporate commercial video, but hey, I think it's cool ...


Random guy doing something cool ... I envy you dude ...





Digital Sculpting - Two Model Pose

Our sculpture group decided to take on the challenge of working with two models. Our first pose had one model on top of the other like this:

After trying that out for a session we changed to an embracing pose:

I tried something for the first time - posing skeletons before working up the sculpt in ZBrush. To pose the skeletons I used the animation software 3ds max. I took photos of the models in a T-pose and sized the bones to match each model.

Then the bones were rotated into position.This generates an aimation keyframe for each bone. I thought this would be fairly quick, but it turned out to be surprisingly painful! It took me two sessions with the models to get things into a reasonably close match. I think there are some inaccuracies in setting the bone lengths over a photo - even for a T-pose.

Here are a few views of the posed bones:


I then needed to generate a base mesh to sculpt from. So I used ZSpheres positioned on top of the posed skeletons. One could argue why not just pose the ZSpheres and skip posing the skeletons! In fact, having done it, I might argue that myself! :) Actually, one advantage is you can turn on the skeleton beneath the transparent figure forms. If the skeleton was perfectly posed that would be a huge advantage. But there are inaccuracies in the bone lengths and positions and it wasn't nearly as useful as I had hoped.



For the final output I was looking for something geometric. So I used the ZPlugin Decimation Master to experiment with lower and lower polygon counts. This tool lets you preprocess the high resolution mesh and then quickly regenerate lower resolution meshes very rapidly.

These meshes are 6000 polygons total. I really like this look.



Here's the model decimated to 2000 polygons:



Here's the model with 1000 polygons total:



All the way down to 600. Below this level limbs start dropping out :)



Looks like folded paper. That suggests Pepakura Designer. This software takes a SIMPLE (read low polygon count) models and generates a net. A net is an unfolded pattern which can be printed and cut out, then folded back up to create the 3D model. Pepakura generates the fold lines and tabs for gluing.



You-SLS open source desktop SLS 3d printer

German student Lukas Hoppe wants do develop cheapest SLS 3D printer which should be very affordable since it would be open sourced. Since it should use widely available parts it would cost under 2000 USD!



He has started a Indiegogo campaign where you can help him fund this project and get more information:

https://www.indiegogo.com/projects/you-sls-the-first-desktop-open-source-lasersinter

I wish him all the best since we ALL WANT A CHEAP DESKTOP SLS!!! :-)




Space Race with 3D Printed Rocket Engines Continues

Race for space is getting more heated and 3d printed parts are becoming present in every major project from rocket engines to 3d printed satellites. Everyone is competing: big government agencies, private companies, student groups and private citizens. We have even seen 3d printed open source liquid fuel rocket engine.
3D printed rocket engines can be very fast in production and affordable even as low as 500 USD for the open source version printed by external service provider.

Here are some new developments:

Vulcan 1 rocket engine developed by SEDS team


SEDS (Students for the Exploration and Development of Space) is well known for their previous successful Tri-D 3d printed rocket motor developments. Now they are crowd-funding further development of bigger Vulcan 1 3d printed rocket engine and launch their Vulcan 1 rocket over 10000 feet.



Check out their KS campaign:

https://www.kickstarter.com/projects/1054991011/vulcan-i-rocket-powered-by-3d-printed-engine

NASA has developed a full size 3d printed copper engine


NASA successfully laser sintered full scale copper rocket engine.



They write:
“Building the first full-scale, copper rocket part with additive manufacturing is a milestone for aerospace 3-D printing,” said Steve Jurczyk, associate administrator for the Space Technology Mission Directorate at NASA Headquarters in Washington. “Additive manufacturing is one of many technologies we are embracing to help us continue our journey to Mars and even sustain explorers living on the Red Planet.”

Numerous complex parts made of many different materials are assembled to make engines that provide the thrust that powers rockets. Additive manufacturing has the potential to reduce the time and cost of making rocket parts like the copper liner found in rocket combustion chambers where super-cold propellants are mixed and heated to the extreme temperatures needed to send rockets to space.

A selective laser melting machine in Marshall’s Materials and Processing Laboratory fused 8,255 layers of copper powder to make the chamber in 10 days and 18 hours. Before making the liner, materials engineers built several other test parts, characterized the material and created a process for additive manufacturing with copper.
“On the inside of the paper-edge-thin copper liner wall, temperatures soar to over 5,000 degrees Fahrenheit, and we have to keep it from melting by recirculating gases cooled to less than 100 degrees above absolute zero on the other side of the wall,” said Chris Singer, director of the Engineering Directorate at NASA’s Marshall Space Flight Center in Huntsville, Alabama, where the copper rocket engine liner was manufactured. “To circulate the gas, the combustion chamber liner has more than 200 intricate channels built between the inner and outer liner wall. Making these tiny passages with complex internal geometries challenged our additive manufacturing team.”

“Copper is extremely good at conducting heat,” explained Zach Jones, the materials engineer who led the manufacturing at Marshall. “That’s why copper is an ideal material for lining an engine combustion chamber and for other parts as well, but this property makes the additive manufacturing of copper challenging because the laser has difficulty continuously melting the copper powder.”
Source and more information:
http://www.nasa.gov/marshall/news/nasa-3-D-prints-first-full-scale-copper-rocket-engine-part.html


Rocket Lab Electron Launch Vehicle


Rocket Lab is a private company that wants to provide cheap satellite rocket launch system for small satellites. Their Electron Launch Vehicle  rocket is made with carbon fiber and uses electrically powered 3d printed motor.




Rocket Lab uses Rutherford rocket engine that is almost entirely 3d printed:



Rocket Lab’s flagship engine, the 4,600lbf Rutherford, is a turbo-pumped LOX/RP-1 engine specifically designed for the Electron Launch Vehicle.
Rutherford adopts an entirely new electric propulsion cycle, using electric motors to drive its turbopumps, and is the first oxygen/hydrocarbon engine to use 3D printing for all primary components.

China has tested a 3d printed rocket engine part


China is making a progress forward, according to the report by 3ders.org:
Engineers from Institute 41 (part of the China Aerospace Science and industry Corporation) have already successfully tested an engine ignition device that has been created using 3D printing technology.

This is reportedly the first time Chinese engineers tested a 3D printed rocket component, but it seems to be very suitable for the job. Shell structures typically used for the ignition components in rocket engines are very difficult to design and produce, and are very costly and time-consuming to create. Engineers felt themselves bottlenecked, so a team from the ignition technology research laboratory of Institute 41 began incorporating 3D printing into their R&D process.
In collaboration with local manufacturers of 3D printing equipment, these engineers eventually and successfully 3D printed the first set of shells for ignition devices. To ensure these shells met all design requirements, researchers produced hundreds of 3D printed test samples, which were submitted to various extensive testing sequences.

We live in very interesting times... where will you boldly go?

FilaFab filament extrusion system and filament winder




Here is a new filament extruder and winder system named FilaFab that will enable you to make your own filament from pellets. You can also recycle old prints and other plastics, experiment with colors and compounds, and extrude materials like ABS, PLA, EVA, HDPE, and nylon.

FilaFab Kickstarter campaign with more information:

https://www.kickstarter.com/projects/1574214560/filafab-first-professional-filament-extruder-and-w

FilaFab company page: http://www.filafab.co.uk/








Limitless 3d printer and CNC mill hybrid





Project description from the maker:
Limitless is a revolutionary new automated multi tool. With Limitless, projects and ideas can be brought to life using one of many methods. Inventors and engineers can bring projects to life using the milling machine, 3d printer and other tools we plan to add such as a laser cutter. Limitless is a dynamic platform which is always changing to suit the needs of its users.

Unlike all other personal platforms, Limitless uses a robust controller similar to the ones found in industrial machines. We do not use all-in-one controllers for our automation. Each one of our large stepper motors has its own motor driver with separate power supply. We also provide the largest work space out of any other brand! With a granty clearance of 14 inches and a table size of 23.5 x 33 inches, we are the largest most versatile CNC combo tool one can buy!
With Limitless real prototypes can be produced! Since we have such a large work area, projects often do not need to be scaled down. Buy upgrading to our 6 axis controller a lathe option can be added as well, adding even more versatility to the platform. Also, all of our tools (Spindle, 3d printer, and, potentially a laser) are always installed on the “Z” axis, so there is no need to swap out tool heads. You just choose the profile you plan on using and you are good to go!
Company and product page: http://advancetecheng.com/index-Automaiton.html

KS campaign:

https://www.kickstarter.com/projects/1866188127/limitless-0





SPRING Tech to exhibit at EASTEC in Massachusetts, USA on May 12th

Date: May 12 - 14 2015
Location:
West Springfield, Massachusetts, USA

EASTEC, New England’s premier manufacturing exposition, returns May 12-14, 2015 with nearly 600 exhibitors, complimentary conference sessions, industry keynotes and much more.

EASTEC is an event dedicated to keeping northeast manufacturers competitive.
If you’re already registered, be sure to visit our booth 5859.

If you haven’t registered yet, use promo code ETFREE for free registration. Learn more at easteconline.com

Visit linkfor more information


Emerging synergy of lasers and 3d printers with real-time scanning and cutting

What is cooler then lasers? Well, lasers and 3d printers combined! duh! At some time at past I have argued on some forums that lasers will become integral parts of 3d printers and I was met with lot of opposition. There have been some attempts to integrate laser based 3d scanners into 3d printers even in commercial products but it is far from wide acceptance.
Yet, adding a laser with sensing electronics can give you so much more then just cheap 3d scanning.

Here is a video by Claudio Di Leo, MIT student, who attached a Infiniter VLM-650-27 line laser to a Solidoodle which uses a 2MP web camera to scan printbed enabling it to 3d print on place object. The entire upgrade costs some 50 USD but increases the ability of the machine.




Now, what would happen if you turn up the power on the laser?

There are several simple DIY laser cutter projects based on replacing the extruder but what if a laser cutter would be a separate tool moving independently?

Here is a video demonstration of laser cutting 3d printed PLA object. As you can see it can be done easily.




Here is a project with detailed guide and software on how to make springs with a laser cutter from different materials but also features PLA 3d printed tube:



Here are detailed instructions for spring laser cutter:

http://www.instructables.com/id/Laser-Cut-Helical-Springs/?ALLSTEPS

So, what could we achieve if we integrate active lasers into 3d printers:

  1. 3d scanning
  2. real-time scanning of print volume for continuous 3d print calibration, sensing failure and continuation of aborted prints
  3. 3d printing on objects attached to a print surface
  4. laser cutting printed objects giving new dimensions to 3d printed objects
  5. "standard" laser cutting of sheet materials, engraving and PCB processing
This could be the next big thing :-)




Hack your FDM Delta into DLP 3D printer

As I was researching low cost DLP solutions I found this project by sirocco where he converted his old Delta into DLP SLA 3d printer by putting a projector on the top opening and adding vat resin. Delta configuration looks like good option due to hight.

I'm not sure how he moves his vat with salt water and resin, it could be done by separate mechanism or by some type of vat tray mounted on three points to the Delta frame and moved by existing motors.



Source, more details, but no clear instructions:

http://www.instructables.com/id/Delta-Robot-to-Sla-Printer-Top-Down/

Print results look decent:



TestrBot DIY static dynamic tension and compression tester

Ever wanted to test your printed parts? Michael developed this project that uses 3d printed parts and can perform tension and compression test on various objects. It is very useful to get real results for different 3d printing materials and printing techniques. As it is easy to make with affordable price of around 300 USD it will certainly find place in many workshops.

Project description:
TestrBot is a $300 Universal Test Machine (UTM) and can be used to perform any type of static or dynamic testing in tension or compression up to 200 lbs. It was designed to run a gamut of physical tests on 3D printed specimens. 
3D printing is still new enough that there are many questions that do not yet have definitive answers. While the basic physical properties of raw ABS & PLA have been well established, there are still many esoteric material properties that cannot be determined without doing actual mechanical testing.
TestrBot is going to help the 3D printing community by figuring out these properties. As of this writing, I am at the beginning of the testing process but you can among the first to hear about the results as they become available by following blog here: www.EngineerDog.com



Here is TestrBot in action with description:



Detailed build guide and all the files needed:

http://www.instructables.com/id/TestrBot-The-300-Universal-Test-Machine/

Simple and affordable DIY hot end building tutorial

Andy M made this great video tutorial on how to make a simple and cheap metal hot end from affordable common parts.


Great job Andy!

For a tutorial on how to make a nozzle out of a single brass nut look at:

http://diy3dprinting.blogspot.com/2013/09/how-to-make-3d-printing-hot-end-nozzle.html



Disney develops innovative textile 3D printer for soft objects

Disney researchers have developed a completely new 3d printing technology for making soft objects out of textile. They call it "Layered Fabric 3D Printer for Soft Interactive Objects". It works by laser cutting fabric layer form a continuous band and then binding them with heat sensitive glue.



Video of it in action:




Description from the project page:

We present a new type of 3D printer that can form precise, but soft and deformable 3D objects from layers of off-the-shelf fabric. Our printer employs an approach where a sheet of fabric forms each layer of a 3D object. The printer cuts this sheet along the 2D contour of the layer using a laser cutter and then bonds it to previously printed layers using a heat sensitive adhesive. Surrounding fabric in each layer is temporarily retained to provide a removable support structure for layers printed above it. This process is repeated to build up a 3D object layer by layer.
Our printer is capable of automatically feeding two separate fabric types into a single print. This allows specially cut layers of conductive fabric to be embedded in our soft prints. Using this capability we demonstrate 3D models with touch sensing capability built into a soft print in one complete printing process, and a simple LED display making use of a conductive fabric coil for wireless power reception.
Project homepage:


Detailed PDF paper:

Printrbot Play 3D printer (with review and Cura tutorial)

Printrbot just announced their new Printrbot Play 3D printer which is aiming towards low cost market but has full metal body and aluminum platform.

They posted on their Twitter:

Coming soon….. Printrbot Play. $399 assembled. 100x100x130mm. Metal construction. Mic6 Alu bed.


Here is the video presentation of Printrbot Play by Brook Drumm:



Still no third party reviews or tests ...

Update: here is a print result video...




Update:

here is a review by Thomas Sanladerer:




Update:

Here is a guide on how to use Cura with Printrbot Play:

How stupid laws regulating 3D printing are ruining fun for everyone in California

Now this is just absurd and shows the sad state of affairs. Libraries are the key place where 3d printers should be accessible to everyone and now the LIABILITY and INFRINGEMENT protection are going to make them impossible to use.

From the source:
Here's a new bill in the California Assembly, AB-37*, which would require libraries that have 3D printers to post stupid signs warning people not to do nasty infringy things with those printers:
This bill would require every public library that provides public access to a 3D printer, as defined, to post a notice on or near the 3D printer that would alert users of the 3D printer of the potential liability of the user for misuse of the 3D printer, as specified.
This bill would require the Department of Justice to draft and distribute this notice, as specified, and annually review and revise the notice for accuracy. By imposing additional duties upon local officials, this bill would create a state-mandated local program.
In the actual text of the law, they're explicit about how it's about not infringing intellectual property:
The Department of Justice shall prepare and distribute to a public library that provides public access to a 3D printer a notice that would alert users of the 3D printer of the potential liability of the user for misuse of the 3D printer. The notice shall do all of the following:

(A) Provide citations to the applicable state and federal laws that may impose civil liability or criminal penalties for misuse of a 3D printer, including laws regarding copyright infringement and trademark and patent protection.
Source and more detailed information:

https://www.techdirt.com/articles/20150415/06143030661/california-bill-would-require-libraries-post-scary-warning-signs-not-to-do-infringy-stuff-with-3d-printers.shtml


EPIC FAIL CALIFORNIA ASSEMBLY! Get your act together! Stupidity of this is beyond description!

Let people create and make stuff without fear of prosecution!


I am Groot

You can 3d print Groot on purpose like Marcel Meyer did:



Or you can get similar result by accident like Justin Soule did :-)


Great work guys! :-)

Hannover Messe - Keep up buzzing!

Hannover Messe

Address:
Messegelande, D-30521 Hannover
Booth B10 - Hall 8

Date:
April 13- 17, 2015 (Event Started today)



Ready to go.
...for ncs machine / NC doc / tool / dnc 



Visitors can come 


We are happy to start the first official SPRING Tech exhibition in Germany. 

CNC CODE

5 axis cnc mill,5 axis cnc router,cad cnc,cc machine,cnc cutter machine,cnc cutting system,cnc definition,cnc equipment manufacturers,cnc fabrication,cnc lathe retrofit,cnc machine accessories,cnc machine automation,cnc machine business,cnc machine companies,cnc machine description,cnc machine maker,cnc machine news,cnc machine repair,cnc machine services,cnc machine shop,cnc machiner,cnc maching,cnc machining companies,cnc machining equipment,cnc machining parts

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The machine should have X Create a 3D printed CNC tool creative CNC ideas creative commons creative tools Credit card fraud crime criminals Critical Loss Tracking croatia Cross-Shift Analysis CrossFire Review crowdfunding CRT to LCD CT cube cubejet cubesat cubex cubify cubify invent cubify.com cups cura curaengine custom car parts custom design Custom Design Custom Door Design Custom Fabrication Custom fixtures custom G-code custom machine movement Custom Metalwork Custom Parts custom parts production custom PCB customized cut cut acrylic Cutter Compensation cutting cutting depth Cutting Fluids Cutting Force cutting parameters cutting speed Cutting Tool Cutting tools Cutting Tools Cyber Security cyberpunk Cybersecurity Cycle Time Cycle Time Analysis Cycle Time Optimization cycle time reduction Cycle Time Tracking Cycloidal Gyro CypCut Tutorial Czech Republic d3d da vinci Daily Maintenance daily use dart gun Dashboard Dashboard Design Dashboard Health Dashboard Monitoring Dashboard Optimization Dashboard Performance Dashboard UI Dashboard UX Dashboards data Data Acquisition Data Aggregation Data Analysis Data analytics Data Analytics Data Architecture Data Automation Data Backup Data Burst Data Cleaning Data Collection Data Communication Data Consistency Data Efficiency Data Engineering Data Feedback Data Integration Data Integrity Data Latency Data Loss Prevention data management data matching tutorial Data Monitoring Data Normalization Data Pipeline Data Presentation Data Processing Data Protection Data Quality Data Redundancy Data Science data security Data Separation Data Standardization Data Streaming Data Structuring Data Synchronization Data Tracking data tree tutorial. 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Trends G Code G Code Basics G Code Programming G Codes g-code G-code G-Code G-code Analysis G-code automation G-code commands G-code Compatibility G-code conversion G-code data G-code Data G-Code Data G-code documentation G-code Editor G-code Efficiency G-code Errors G-code example G-code Fix G-Code Loops G-code optimization G-code preview G-code programming G-code Programming G-code simulation G-code simulator G-code subroutine G-code Tips G-Code Tips G-code training G-Code Tuning G-code tutorial G-Code Tutorial G-code Variables G-code Viewer G00 G01 G01 G02 G03 G02 G02 G03 G02.1 G03 G03.1 G04 G07.1 G17 G20 G21 G28 G32 G33 G40 G41 G41 G42 G42 G52 Code G54 G55 G70 G72 G73 G74 G75 G76 G76 Threading G77 G78 G79 G80 G81 G89 G83 G83 Tutorial G84 G84 Tapping G85 G87 G88 G89 G90 G91 G92 G94 gallium game gamechanger gaming Garage shop garage tool layout garden gartner GCode GDT ge gears geeks gemma Genmitsu PROVerXL Genmitsu PROVerXL 4030 V2 geodesic geomagic geometric tolerance Geometry 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