OpenSLS Laser Sintering 3D Printer Made From Hacked Laser Cutter

Rice University bioengineering researchers have hacked a cheap Chinese CO2 laser cutter into a low(er)-cost laser sintering 3d printer and used it to produce fine objects such as liver structures. They claim it can be made under 10000 USD.
Materials used on it are nylon, sand, Candelilla wax, polycaprolactone (PCL) and other. 
Since there is a 40-80 W of laser energy, they use custom build inter gas module to prevent burining of the material.  

They have also made it open source, which deserves some gratitude from the community! Thank you Rice team! Sharing is caring!



























Here is the short presentation video:




Here is the powder distribution mechanism in action:



Project has a very detailed and extensive documentation well worth reading if you are interested in laser sintering and bioprinting.

GitHub with all the files:

https://github.com/MillerLabFTW/OpenSLS

Rice Uni news article:

http://news.rice.edu/2016/02/22/modified-laser-cutter-prints-3-d-objects-from-powder/

Ver detailed RepRapWiki page:

http://reprap.org/wiki/OpenSLS

Detailed PLOS research paper:

http://journals.plos.org/plosone/article?id=10.1371/journal.pone.0147399

If you want to make something similar, do keep in mind that lasers are dangerous, and nylon powder and simillar micro-powder materials are flammable and can also go KA-BOOM. Stay safe kids.

Here is the photo gallery:



LiteFab Open Source DLP 3D Printer

LiteFab is an rugged open source DLP 3D printer you can build yourself at a low cost and which comes with an excellent step-by-stem construction guide.
The cost for this project is some 400-500 USD plus the DLP projector which you can buy new or used which will cost you some 50 - 1000 USD extra. For this build the developer used Acer h6510bd.

The supporting structure is made from CNC cut wood, aluminum rails and 3d printed parts. It looks very hackable, which is encouraged by the developer.

This machines is developed by Instructables user that goes by name of bongoboy23. Cool name bro! Thnx for this project!

Some of the features of this design:
  • Quick removable vat
  • FlexVat design means no secondary action needed for peeling parts off vat. For example, the Form1 pulls the vat down on one side to peel parts off the vat. The FEP film used in a flexvat, being flexible, peels as it flexes. This film also has a much longer lifetime then standard vats, which means less often replacement of the vat.
  • Quick removable bed
  • Adaptable for use with any projector 
  • Large vat allows for a large build area
  • Nice open area for easy access to components, for easier maintenance and modification
  • Opensource! All the design files are provided. 





























Resin vat with DLP projector underneath which solidifies the resin with UV light. 






























LiteFab has a very detailed build guide with all the files at:

http://www.instructables.com/id/The-LiteFab-the-Affordable-and-Rugged-DLP-Printer-/?ALLSTEPS


Knight and a Rook. Very detailed and fine. 




Objects printed on LiteFab. Looking good ...





Orbital Composites Advanced Carbon Fiber 3D Printing

Orbital Composites is a company which developed advanced carbon fiber and wire 3d printing with applications in space additive manufacturing. It should enable future missions to 3d print satellites and objects in orbit or to 3d print drones with carbon fiber structures.

Here is the interview with Orbital Composites Founder and CEO Cole Nielsen and presentation of their tech:



Orbital Composites homepage:

http://www.orbitalcomposites.com/


Coaxial extruder nozzle developed by Orbital Composites. It should deliver 10x increase in print speed. 

Coaxial extruder that can extrude carbon fiber,  plastic wire, solder epoxies and other materials.

DIY 3D Print Error Correction System

Chris Barr from Australia developed his own error correction system using magnetic encoders that recognizes that 3d print went wrong and then tries to correct the problem.

Chris writes:
At the moment, I’m using a linear magnetic encoder IC from AMS (the AS5311) on a small PCB I’ve designed, along with an ATmega328 to track the axis motion and implement I2C communication (also on the same IC).
This seems to be a relatively robust solution, and the encoder can track axis motions up to about 350mm/s – which I think covers speeds reached by most 3D printers.
Printer firmware is Marlin, with a few new bits I’ve thrown in to get this working.

Here you can see it working when Chris forcefully pushes the extruder by hand:





Project homepage:

http://chrisbarrbuilds.com/2016/04/3d-printer-error-detection/

You can find his code for this system at:

https://github.com/Aus3D/MarlinDev



3D Printed PMG Generator for DIY Wind Turbines

Brian developed a 3d printable DIY PMG generator ideal for producing electricity from small wind turbine.
You will need some disc magnets and copper wire, but you will get a functioning generator. It can produce up to 50 watts at high RPMs.

Here is the generator being assembled and tested:




Here are four generators mounted on a modular multi-blade wind turbine in a strong wind:



The files and manual are not free, but come at reasonable 35 USD:

http://www.energy-creator.com/3D-generator-1.php

There are several other non-printable DIY generators on that page so it's a good resource for anyone interested in home-made wind power.

If you are looking for larger DIY generator of the same type for bigger diameter wind turbines, there is a complete manual in PDF format that can be found at:

https://www.scoraigwind.com/pmgbooklet/itpmg.pdf (remember to click the captcha that you are not a robot).
It gives out much more power, but you will need some heavier woodworking, bigger magnets, resin and longer blades and higher tower.



Thermaltake 3D Printed Modding Accessories

As 3d printing is going mainstream, many companies see the potential using it as user involvement tool. Thermaltake, PC parts manufacturer, started their 3d printing site to help PC modders 3d print components for their cases, fans, LED lightning, drives and other peripherals.

Here are some fan grills:


See the models at:

http://3dmakers.thermaltake.com/download.aspx

Zortrax Inventure Compact Prosumer 3D Printer from Poland

Zortax Inventure is a new 3d printer from well known Polish company that is compact in size and print volume, but features many professional solutions.
I generally don't like move towards proprietary cartridges with chip "protection" marketed as a feature ...

Presentation video:



Video focusing more on key features, such as ability to print two materials from a single nozzle:




Tech specs:


  • Printing Technology:  LPD Plus – advanced technology with DSS system
  • Build volume: 140 x 140 x 140 mm, 5.5 x 5.5 x 5.5 in
  • Resolution: 90-400 microns
  • Material container: Cartridge
  • Wall thickness Minimal: 400 microns
  • Optimal: 800 microns
  • Resolution of single printable point: 400 microns
  • Material diameter: 1.75 mm (0.069 in)
  • Nozzle diameter: 0.4 mm (0.014 in)
  • Minimum single positioning: 1.5 microns
  • Positioning precision (X/Y): 1.5 microns
  • Z-axis single step: 1.25 microns
  • Extruder maximum temperature: 380° C (716° F)
  • Heated chamber: Yes
  • Chamber maximum temperature: 90° C
  • Ambient operation temperature: 15°-35° C (60°-95° F)
  • Storage temperature: 0°-35° C (32°-95° F)
  • 3D Printer Support: Dissolvable – printed from a different material than the model
  • HEPA filter: Yes
  • Material consumption sensor: Yes
  • Chip with information about material (type, color, consumption): Yes
  • Extruder: Single with double nozzle
  • Connectivity: SD Card (included)
  • Available materials: Z-ULTRAT Plus, Z-SUPPORT
  • Electrical AC input: 110/240V ~ 2 A 50/60 Hz
  • Power requirements: 24 V DC @ 11 A
  • Power consumption: 160W
  • Software bundle: Z-SUITE
  • File types: .stl .obj .dxf
  • Supports: Mac OS X / Windows XP and newer versions
  • Physical Dimensions: 350 x 350 x 400 mm, 13.7 x 13.7 x 15.7 in

Price is yet unknown ...

Learn more about it at:

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

Brochure is available at:

https://zortrax.com/wp-content/uploads/2015/05/Zortrax-Inventure-brochure2.pdf
I am, as always waiting for independent reviews and tests.



nUnitled 3D Printer and Giova's Extruder from Italy

nUnitled 3d printer and Giova's extruder are DIY  machines developed in 2015 from Italy which are low cost and feature some interesting solutions.
The main feature of this project is its anti-wobble system which consists in the separation of Y and Z axis from Z screws. Y axis can moves freely on Z axis, because it's leaning on Z screws. This innovation avoids the transmission of Z screws wobble to Z axis.
This machines has wooden support structures.
Giova's extruder aims to be light and low-cost extruder based on the cheap 28BYJ-48 motor. It is relatively weak but it works.
Third party reviews are not yet available.

Here is the presentation video:




You can find all the files for the printer and extruder:

http://www.thingiverse.com/thing:1434161

http://www.thingiverse.com/thing:1434128



3D Printing Custom Car Audio Speakers

As I was searching to find what can I print for my car, I found Mark and his company. It is an excellent example how 3d printing can help a small company to make custom products. They use 3d printing to make custom car audio speaker boxes, pods and attachments that look vary cool.
They may run out of business when 3d printing spreads and Maker / DIY culture becomes mainstream ;-) Probably not, as they certainly have creative spirit which will enable them to thrive on the market.

3D printed A-pillar speaker pod:



3D printed car subwoofer box:




Here is the company page:

http://www.caraudiofabrication.com/


SPRING Technologies attends COE 2016, San Antonio Texas


SPRING proudly attended ‪#‎COE2016‬ in San Antonio, Texas to showcase NCSIMUL SOLUTIONS and our newest award winning module, NCSIMUL CAM.

Capable of reading native CATIA files, NCSIMUL SOLUTUIONS offers a simple and easy way to integrate the two. Our software works to considerably reduce manufacturing costs, secure the shop floor, and improve the fluidity in the machining operations, making it the best CAM complement available.

Thanks to all who visited our booth!




CNC Router Machines for Statues

The OMNI CNC router is a fine example of turning materials on a router. The process is very simple. A rotary device works as 4th axis on a conventional 3-axis router. The CNC router can carve exquisite newel posts, chair jambs, crown molding, statue profiling, modillion engraving, and wall moldings. The applications can only stretch the imagination

The rotary device works as a 4th axis indexer that allows machining of parts in the round profile. Free form ornamental turning is revolutionizing statue profiling. The Omni CNC router is making master craftsmen out of ordinary souls.

This also calls for introspection on a disappearing art of master carpenter. But technology is no more the servant of man rather it is breaking new grounds and with the advent of the Chinese company OMNI-CNC, new ground breaking technology is now available at an affordable price. The 4th axis with the rotary device makes the job of carving newel post and statues like 3d carving on Buddha.























The machine frame is of robust build quality. There are 12 spindles which can be employed on various materials like MDF (medium density fiberboard is an engineered wood product), solid woods, plastics and acrylics. The rotary device can process irregular objects as well as different columns. The digital servo brushless motor on all the axes is maintenance free and gives unmatched routing flexibility.  Sometimes this Omni CNC machine is dubbed as statues CNC router.


The design process for carving a statue profile will need the visualization of the concept. For this 3D modelling software or 3D CAD (Computer Aided Design) is required. Instead of drawing the object via lines (by a pencil) the 3d object is built up by inserting and changing fundamental 3D shapes. OMNI CNC router machines for profiling statues come with the right software tools to execute a tool path for the visualized 3D shape and allow the CNC router to trace the tool path. The technical word is called creating the Part file for the CNC router to cut the profile. The Omni CNC router for statue profiling is fast and to watch it in action is itself breathtaking.


5:25 AM

Low-cost Easy 3D Printed RC Flying Wing

Samm Sheperd demonstrates how easy and cheap it is to develop and 3d print a flying wing pod that houses first person camera, transmitter, controls, motor, batter, drive shaft and propeller for a RC plane.

Her is a video of his design flying:



Here is a Thingiverse with all the files you need to print it yourself:

http://www.thingiverse.com/thing:1412963



When someone re-invents the wheel with some 3D printing help

OK, it's a skateboard wheel, but it is designed as a strange combination o cube and sphere and other stuff ... they were 3d printed and polyurethane casted 
I'm not even sure how they work and I never rode a skateboard in my life :-) but they look cool!




From video description:
A fascinating interview with David Patrick from Shark Wheels. David explains how the latest techniques in Rapid Prototyping helped him in the process of developing his unique product; Shark Wheels.
It's a wheel that comes from a cube: the Shark Wheel shape is a perfect cube and a perfect circle and a perfect sine wave!
The Shark Wheel geometry is the intersection of a cube, a sphere, and a three-dimensional sine wave. It is based on the shape of shark jaws and is a pattern found all throughout nature. David M. Patrick discovered the shape while studying natural sciences, and has since been developing the Shark Wheel to be a more efficient wheel with superior performance in many ways. David's passion for skateboarding coupled with his interest of the natural world have led to the discovery of the Shark Wheel.
BJB offers a complete line-up of Castable Polyurethanes, Epoxy Systems, Silicone Casting Rubbers, Polyurethane Foam Systems, Aliphatic Water Clear Urethanes, Sprayable Polyurethanes, Pigments and Release.
Shark wheels homepage:





"Super Make Something" Tutorial On How To Build a Simple 3D Scanner

This youtube channel gives a step-by-step tutorial on how to make a simple 3d scanner with 3d printed parts and IR sensors. It outputs the scan data on a SD card which you can then turn into 3d model using MATLAB. The results are somewhat rough and you will need one custom electronic board but it is a nice learning projects.

Here is the tutorial video:



STL files can be found here:

http://www.thingiverse.com/thing:1413891

Full code and board design can be found in video description.



CRACUNS flying and diving 3D printed drone

Johns Hopkins University developed 3d printed quadcopter drone that can both fly and be submerged under water. Since it was developed in cooperation with the military it will be probably be used as a weapon system sometime in the future. Cool technology, but we need more food delivery drones and less war-bots. It is named CRACUNS, which stands for "Corrosion Resistant Aerial Covert Unmanned Nautical System".




From the news article:
“Engineers at APL have long worked on both Navy submarine systems and autonomous UAVs,” said Jason Stipes of APL’s Sea Control Mission Area, project manager for CRACUNS. “In response to evolving sponsor challenges, we were inspired to develop a vehicle that could operate both underwater and in the air.” The resulting CRACUNS prototype system was developed and tested using internal research and development funding.

CRACUNS enables new capabilities not possible with existing UAV or UUV platforms. Its ability to operate in the harsh littoral (shore) environment, as well as its payload flexibility, enables a wide array of potential missions.
The most innovative feature of CRACUNS is that it can remain at and launch from a significant depth without needing structural metal parts or machined surfaces.To make that possible, the team needed to overcome two big challenges. First, the APL team leveraged advances in additive manufacturing and novel fabrication techniques available at the Laboratory’s extensive fabrication facilities. The team fabricated a lightweight, submersible, composite airframe able to withstand the water pressure experienced while submerged.
The second significant challenge was to ensure CRACUNS could not just survive, but operate effectively in a corrosive saltwater environment. To do that, the APL team sealed the most sensitive components in a dry pressure vessel. For the motors that are exposed to salt water, APL applied commercially available protective coatings. The team tested the performance of the motors by submerging them in salt water. Two months later, they showed no sign of corrosion and continued to operate while submerged.
Full press release:

http://www.jhuapl.edu/newscenter/pressreleases/2016/160317.asp


Syknet will know how to use this little guy

Hydraulic 3D Printed Insectoid Robot

Researchers at MIT CSAIL developed a 3d printing process named "printable hydraulics" where you can 3d print with soft and hard materials at the same time. This creates articulated objects which can move when pressure is applied.
They demonstrated it by 3d printing an insectoid robot that moves when motor and battery is added. Other robotic accessories such as hydraulic grippers can also be 3d printed.

Hydraulic hexapod in action with other flexible parts demonstrated:



Learn more at:

http://groups.csail.mit.edu/drl/wiki/index.php?title=Printable_Hydraulics

https://news.mit.edu/2016/first-3d-printed-robots-made-of-both-solids-and-liquids-0406

Full paper in PDF format:

http://groups.csail.mit.edu/drl/wiki/images/7/7c/2016_MacCurdy-Printable_Hydraulics-A_methods_for_fabricating.pdf


How to build an Ultimaker2Go low cost clone

PaulSS made a build log on Instructables about his Ultimaker2 Go DIY clone. It is much cheaper then the 1600 USD original at some 500 - 600 USD. The frame is made on a CNC from plywood.
The machine is named Ultifaker2Go :-)









Detailed instructions and files can be found at:

http://www.instructables.com/id/UltiFakerGo-3D-Printer/?ALLSTEPS

How to make a simple 3d printed snake robot

Nikodem from Poland made a very good tutorial on how to make a 3d printed snake robot. It actualy uses a worm equivalent movement , but hey snake sounds cooler :-)

Here is the build instruction video:



Detailed step-by-step guide and all the files can be found at:

http://www.instructables.com/id/Snake-Robot/?ALLSTEPS



DIY Power Hacksaw made with 3D Printed Parts

Bruno made his own DIY powered hacksaw with many 3d printed parts. it is a low cost home tool which can even cut some metal. The total cost for the project is some 50 USD.

Bill Of Materials

  • 6x – 608 Roller skate bearings 
  • 2x -100mm 8mm all thread rod. 
  • 5x - M8 bolts. 
  • 1x - 40mm M8 bolt 
  • 2x – 6mm ID. 15mm OD bearing (had these laying around) find what you can, modify the files as necessary. 
  • 1x - 60mm shaft (matches the bearings) 
  • 12x - wood screws 
  • 1x plank of wood. Approx. 300mm x 450m 
  • 3x Spacer wood 2x4 is what I used. ~ 50mmx100mm 
  • 1x – Geared Globe Motors Model number 409A502 
  • 1x – 19v PSU 
  • 1x – 5A switch 
  • 1x – Ikea $7 table leg, or 50mmx50mmx400mm chunk of wood.

Here is the saw in action:




Here it is cutting steel:




Bruno's homepage:

http://engineerd3d.ddns.net/

You can get all the files here:

https://www.youmagine.com/designs/power-hacksaw-3d-printed





A Great End to a Great Conference Industries Paris 2016


A Great Thank you to the entire team of SPRING Tech for sticking together the entire conference and being there for their current customers and future ones.


CEO Gilles Battier and Corporate Marketing Director Philippe Solignac in a pose to celebrate the great achievement of winning Industries Paris 2016 Innovation Award

For further details on the award go to: http://www.industrie-expo.com/trophees-innovation/ 

"A Big Picture Look at Simulation" Case Study with Utley's Inc and their use of NCSIMUL MACHINE, published by Modern Machine Shop

        SPRING Technologies is proud to be featured along side Utley's Co. Inc. (Queens, NY) in a new Case Study of this month's Modern Machine Shop publication.

        In "A Big Picture Look at Simulation",  CNC programmer Antonios Karoustos at Utley's says, “We’re making some pretty key investments in our CNC department to help us get our parts out to our customers as fast as possible,” Mr. Karoustos says. “We are planning to do a lot of work on the Okuma and will have NCSIMUL test any programs for the new machine, because it is very expensive and we want to avoid damaging it. We’re going to make sure that we run everything through NCSIMUL.”

Visit SPRING Technologies Booth C104 at INDUSTRIE PARIS to see first-hand the award-nominated solution NCSIMUL CAM

 Paris Salon Industry

INDUSTRIE PARIS started yesterday with great success. Lots of customers approached the
SPRING Technologies booth to get a glimpse of the Innovation Award-Nominated Solution


Show opened and a crowd formed in minutes.


Everyone at the booth got engaged in amazing discussions with existing and potential new clients

  

For more information about NCSIMUL CAM. Click here

Come visit us at Booth C104 and see a live demonstration of the product.

Getting Started with ZBrush - For Rhino Users

This post contains the basic information you need to know to begin sculpting with ZBrush. This post is specifically for Rhino users who want to import and sculpt models, then export them as meshes back into Rhino. There are a many tutorials online, but sorting through what's important and reviewing the material can be time consuming. This post is a concise subset of the tools to get you going quickly.

If you work your way through this post you'll be able to do quite a bit in ZBrush. At the end I'll point you to more tutorials to further help you develop your skills.

The ZBrush User Interface

When you first look at the ZBrush user interface it may seem different/complex/confusing. It is different. And it may be complex. But it does not need to be confusing. In fact, you can do quite a bit of detailed sculpting with only a few tools. The user interface is tuned for artists and designers. The workflow in using the program is really excellent and once you get comfortable it it fades into the background. You feel you are sculpting clay rather than interacting with a computer program. So don't be put off by the uniqueness of the UI. It is well worth diving into!

Creating a First Object to Sculpt On

When you first start ZBrush a dialog appears across the top of the screen. This is the LightBox. You can think of it as an asset browser. By assets I mean, objects, textures, materials, brushes, etc. You can use LightBox to quickly load an object to sculpt on. Double-click one of the spheres shown - I'd suggest DefaultDynaWax64.

This replaces the current file with a new sphere, at 64,000 polygons, using a wax material. We'll sculpt this very shortly!

For experience CAD users it may seem strange but ZBrush does not deal in conventional drawing units (inches, mm, etc). Everything is visual - you work by eye. When you finish a model you can scale it to size before exporting it. But inside ZBrush forget about units and drawing with typed coordinate precision. Just sculpt visually and enjoy the freedom.

File Opening / Saving

Working with files is pretty much as expected. To save a project use the File > Save As button. To open a project use the File > Open button.

When you need to start a new document use the Document > New Document button. This will clear the canvas and let you start over.

You can also use LightBox to browse for files to open.

Viewport Navigation

The first thing you need to learn to do is manipulate the viewport; Rotate, Pan and Zoom the view of your model.
  • Rotate: Left-click in an open area (where there isn't an object to sculpt), then drag. The view will rotate. Note: You can hold the Shift-key when you rotate the view. Doing so will snap the model into Front, Back, Left Side, Right Side, Top and Bottom alignments. 
  • Pan: Hold the Alt-key and left-click and drag. The view moves laterally. 
  • Zoom: Follow this sequence: 1) Hold the Alt-key, 2) Left-click and hold, 3) Release the Alt-key, 4) Drag. This zooms in and out. You have to keep the left click held as you release the Alt-key. 
These may seem strange at first (especially Zoom!), but once you get used to them they become quite natural and fluid. So spend some time early practicing these and getting comfortable.

You can press the F key to "Zoom Extents". You can press Shift+F to toggle wireframe display on and off. And don't forget using Shift with rotate to lock into the orthogonal views.

Common and Useful Sculpting Tools

The choice of which brushes to use in ZBrush is key to effective sculpting. When you click the Brush icon you are presented with a large palette of loaded brushes:

There are many to choose from but you can do a great deal with just a few. Before you can use the brushes effectively there are a few controls you need to be aware of and adjust as you work the brushes. A convenient way to access these controls is by pressing the Spacebar. This menu appears:

These most important control in here are:
  • Draw Size: Sets the size of all brush strokes or editing actions. The draw size is shown as the outer circle when you hover over your sculpt. Adjust this often - making the brush the proper size is key to getting good results. 
  • Focal Shift: This shifts the affect of the tool closer to the center or away from the center. This size is shown as the inner circle. 
  • Z Intensity: Sets the amount of depth information of the current tool. The higher the intensity the greater the effect of the sculpting tool. If you find the tool is too sensitive (particularly on low resolution models) turn this way down. 
With those settings understood you can get to sculpting. Here are the most common brushes I work with. Try them out on the sphere you loaded as you read about them below. 



Move Topological: Moves vertices on the mesh around without affecting those not directly attached to the brush area. Coupled with sizing the brush and focal shift I use this all the time to adjust the sculpt.


Clay Buildup: Very useful for building up layers of virtual clay. This brush will fill in low areas before it builds up higher area. This is kind of like smoothing clay onto the surface - it'll squish into the recesses first. As you stroke back and forth it'll build up. The alpha channel is used so it gives good control of how the stroke falls off. Note: You can hold the Alt-key to reverse the effect and have the tool push into the surface rather than build out from it.


Smooth: Takes a rough surface and smooths it out by averaging the level of the surface. I usually turn the intensity way down to make the effect more controllable. Important Note: Simply press the Shift-key to activate this mode. You don't need to change tools to do so.


Inflate: Expands an area of the sculpt by pushing vertices along their normals. Great for adding volume to a feature which is too small. It can also be used to deflate - pushing the sculpt in the opposite direction. The Alt-key works here to invert the effect.


Slash3: This brush is used to cut into a surface to create a tight crease or slash. I find the default intensity too high so consider turning it down. The brush size has an important impact on this brush's effect so experiment with the size as well. As usual you can hold the Alt-key to pull out a "slash" stroke.


Pinch: This brush pulls vertices together effectively pinching the surface along your stroke. The brush optionally allows the verts to be pulled up or pushed down.

You can accomplish a lot of sculpting with just those brushes. I think it's interesting to note that these are the tools available in Sculptris (the simpler, free version of ZBrush).

Alphas

Alphas are grayscale images used to control the deformation of the mesh as you draw out brushstrokes. The brightness of the alpha determines the low areas versus high areas. Dark areas in the image deform the mesh less than bright areas which deform it to the full Z Intensity.

Experiment with a few alphas and you'll quickly get a feel for this.

Stroke

The stroke controls how the mouse or stylus applies the effect of the brush to the sculpt. For example there is a stroke which acts like spray paint. For most use you'll want the Dots or FreeHand stroke active. If you are using alphas to apply detail to your mesh you may want the DragRect stroke. This lets you drag out a rectangular area and the alpha gets applied in that area like a decal.

Experiment with these to test their effect on the mesh.

Note: At times you may find that the back side of a mesh is being deformed by a brush. In thin areas of the sculpt this can happen. Here's an example - the front is sculpted. But the back is pulled forward as well:
 

You can prevent this by enabling the AutoMasking / BackfaceMask button. This is a setting in the Brush menu:

Now when you apply that stroke the faces facing away are unaffected:

Symmetry

It's sometimes desirable to want to work symmetrically. Changes to one side of the objects are mirrored to the other side.

The most common symmetry is easily toggled using the X key. This mirrors about the X axis of the model. For more detailed control of symmetry open the Transform pull-down menu and work with the controls in the Activate Symmetry area:

You can have X, Y, and Z on in any combination. You can also click the (R) button to toggle Radial symmetry and set the RadialCount. Try it - it's lots of fun :)

DynaMesh

This features lets you sculpt away without having to worry about your underlying geometry. You can stretch, pull and manipulate the sculpt in any way you choose. If it becomes too stretched out or low resolution in spots, simply re-dynamesh.

If you started with the DefaultDynaWax64 model then Dynamesh is already on. If not, you can easily turn it on. This feature is in the Geometry panel, in the Dynamesh tab:

Using the Resolution slider you set the number of polygons you desire (in K). So 64 means approximately 64,000 polygons in the regenerated model. If you set the Polish button on the mesh will be smoothed during the remeshing. Then press the DynaMesh button. This will regenerate the model. You only need to press the button once. It stays lit up in orange.

Once DynaMesh is on you simple hold the Ctrl-key then drag downward in an open area of the viewport. This action gives you a newly generated mesh with an even polygon distribution. Do this whenever you feel the mesh is stretched or the topology isn't looking smooth or uniform.

Before - modifications have really stretched the mesh topology:

After - no problem! Ctrl+drag = Fixed:

Masking

Masking is a powerful tool to limit the area of the sculpt that's affected by the brush. To create a mask hold the Ctrl key and "paint" with the brush. The Draw Size and Focal Shift settings apply to masking so set those properly. Masked areas will turn dark gray. If you brush over these areas they remain unaffected by the tool.

The mask usually falls off near the edge so the effect of the mask is softened.

You can hold the Ctrl-key and tap on the mask area to further the softening of the mask. This makes the transition from masked to unmasked even smoother.

You can hold Ctrl+Alt and tap on the mask area to make it tighter:

You can Ctrl+click in an open area of the viewport to invert the mask.

Getting Ready to Export to Rhino

ZBrush supports very high resolution meshes. If you try to export these to Rhino you'll likely overwhelm it! Therefore you need to use the decimation tools to reduce the mesh complexity without dramatically compromising the form. ZBrush has some great tools for this.

Decimation Methods

Decimation refers to rebuilding the mesh with a lower vertex/face count. There are three ways to do this:
  • Dynamesh (discussed above): Nearly instantly regenerate the topology of your mesh with a controlled resolution. But because it is so fast, the topology generated is not as refined as the other methods. For final export use the next two methods. 
  • Decimation Master: This is a plug-in which lets you rapidly experiment with different mesh polygon counts. You pre-process the model once, then you can quickly test out different resolutions of the mesh to get it to your liking. This tool does a remarkably good job. 
  • ZRemesher: This tool lets you create a new polygonal model of your sculpt where you can specify a count of the number of polygons. It quickly retopologizes the model in a manner that follows the surface in a natural way. This method is the slowest, but produces the best results. You also have control over the topology (areas of higher and lower detail) as well as some control over how the edge loops flow. That is not possible in the other methods. So for best results use this method. 

Decimation Master

This is the original plug-in to reduce mesh complexity while maintaining the overall form. It still has advantages, mainly speed in getting results and exploring different mesh resolution settings.

It's available from the pull-down menus: Zplugin > Decimation Master. The interface is shown below:

After you click the UI often disappears. So you have to bring it up repeatedly from the pull-down menus. (Yeah I don't know why either... anyway...)  The process to use it is very simple. First, press the Pre-process All button. This will take a little time as it generates a file to allow you to quickly decimate in the future. A progress bar scrolls across the top of the screen. Once it's done set the number of polygons you desire with the k Polys slider. For example if you want to decimate to 20,000 polygons set the slider to 20. Then press the Decimate All button. ZBrush will rapidly regenerate the model with the desired resolution and the viewport will update. If you are happy with the result you can save the model. If not, bring up the UI again and try a different value and press Decimate All again.

You can also set the % of decimation slider. So 10% will make it much smaller, 90% will only reduce it a little.

It's as easy as that, and the results are really good.

ZRemesher

This is the latest technology from Pixologic. It's easy, fast, and does a amazing job. It's also controllable. You can use Polypaint to control the tesselation adding more detail in areas and less in others. You can also use what are called ZRemesherGuides to control the flow in ZRemesher.

You get to it in the Geometry panel under ZRemesher. Here's the UI:
 

The simplest thing to do is enter a value in the Target Polygons Count slider. 5 is 5,000 polygons. Then press the ZRemesher button. It takes a little time, the progress bar along the top shows the status. When done the model is remeshed.

Extra control is provided by PolyPaint. Enable the Use Polypaint button. Then adjust the ColorDensity slider to paint on specific areas. How PolyPaint affects the density is determined by the color used:

  • Red specifies a higher polygon density within the painted area.
  • Blue specifies a lower polygon density within the painted area.
  • White (no PolyPaint) gives ZRemesher total control over polygon density.

A ColorDensity setting of 2 doubles the polygon density. A a setting of 0.50 halves the density.

You can also use the ZRemesherGuide brush to draw curves on the model which guide the remeshing. This only works if you turn the Curve Strength slider quite high (near 100). Otherwise the normal algorithm takes precedence.

The written documentation is here. Also, this video covers the other controls quite nicely.


Sizing the Model for Export then Exporting

Assuming you have decimated your mesh you are now nearly ready to export. But what about the size of the model? ZBrush doesn't deal with conventional modeling units of feet, meters, etc. However, when you get ready to export your model you can set a size that will be correct on export. You do this Zplugin pull-down menu. Then open the 3D Print Exporter panel:
 

Here you set if you want to export in inches or millimeters. You set one of the X, Y or Z size sliders then press the Update Size Ratios button. This will update the other two to keep the proportions the same. For a sculpt at building scale this notion of inches or mm is kind of small! However, you can easily scale up in Rhino so it's no problem.

Once the size is to your liking you press the STL, VRML, or OBJ buttons to export to that format. Rhino will import all of these formats so you may choose whichever you like.

Importing Rhino Models into ZBrush

Importing into ZBrush means exporting out of Rhino. So let's start there. In Rhino use the File > SaveAs... command.  Use OBJ as the file format. The next image shows the settings to use - underlined are key ones:

You want a polygon mesh, you want the vertices welded, and you want to swap Z and Y. Rhino uses Z up and ZBrush uses Y up. That settings keeps the orientation the same between the two programs.

Inside ZBrush you use the Import button on the Tool palette to bring in your model. After you import you'll have a new tool which is your mesh. You can select that tool and drag it onto the canvas. If you are starting a new document be sure to immediately press the Edit button (or press the T key). This puts you in edit mode so you can use the sculpting brushes to manipulate your model.

Further Learning - Video Tutorials

The following tutorials are also very helpful in developing your ZBrush skills.

First, the ZClassroom has a large library of very well put together, succinct videos.

For hard-edge modeling a fantastic tool is the ZModeler Brush using QMesh. Here's a video on the basics of it's use - be sure to check it out: Poly QMesh. Another video on the ZModeler Brush is more detailed and proceeds at a faster pace. It's really good. If the first one captured your interest be sure to check this one out.



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