My First Impressions With Using ViaCAD

I had some time to play around with ViaCAD and it looks really interesting. I've downloaded the 14-day trial version and used a few simple daily tasks to see how it performs.

First steps in the program interface are very easy and you are greeted with a simple video tutorial on how to create a 3D goblet from 2D drawing in 60 seconds:





From the beginning, I wanted to focus on 3D printing tools which are a part of this CADs features.

The toolbar with 3D Printing tools can be activated in the "Window" menu.
























The interface is fast and fluid.

You can define your printer settings from a list of the pre-defined machine or set it manually:



































To see how other functions work, I imported the Voronoi "Broken benchy" by T-E-C from Thingiverse. It is a more complicated and harder version of the standard Benchy.





























You can check the printability of your model with "3D Print Check" tool. Here is the output screen with some of the errors found, with several being my mistakes of not properly aligning the object or setting the parameters correctly (like print volume).
Very useful!































"Surface normals" tool shows, you guessed it, surface normals :-)






























There are tools to show overhangs and wall thickness.

"Slices" tools will show animated slices base on several parameters, they can be saved into several formats. This is not a slicer which generates g-code for printing.





























"Support structures" tool enables you to create support pieces and attach them with a mouse click.

































With the "Position" tool you can place the object anywhere in selected print volume coordinate manually or with the automatic positions like "Center".

These basic tools were easy to use at this level, time will show how they perform in everyday work during a longer period. For now, I'm satisfied with this CAD software and will continue to us it.


You can get ViaCAD here and test it yourself and download a trial version from PunchCAD homepage:


PunchCAD.com


There are additional 3D Printing "power packs" for ViaCAD with 70+ 3d printing tools, you can see them here:

Punch! PowerPack v10

Here is a video demo:


Maybe I'll get them also in the future. The pack seems to have many tools in one place instead of using multiple apps and sites.

In next post, I'll describe some of my experiences with actual design and learning curve.

Printrbot Printrbelt

Printrbot just teased their Printrbelt 3D printer with the heated conveyor belt print surface or "Infinite Z" as they described it.  The belt is a steel belt covered in Kapton with adjustable bed height and tension.
It is a direct competitor to BlackBelt 3D printer (which has a bigger print surface) and knowing Printrbot, it should be low cost and open source.

Brook responded in a Tweet:
Yes, Printrbelt will be open source & affordable. I'll do larger sizes. Already have bits designed for 12"x12" window, but this first.
So we can expect larger models in the future.

Short teaser:





More detailed presentation by Brook:




Brook writes:
The Printrbot Printrbelt allows for very long prints, multiple copies of one print, or a whole project of files to be printed in one shot. It is a beta, but too fun to keep to ourselves.
We are working with Polar3D, who has already hacked a printer like this onto an existing printer frame. They are working on the firmware magic in a cloud service to make this mind-bending twist on 3d printing easy for anyone. This will be a neat partnership that takes an important step forward in desktop manufacturing.
Stay tuned for more on this wild 3d printer that brings a new superpower to your desktop at an affordable price. 

printrbot.com


Looks like we will see much more conveyor belt 3d printers coming up! Competition is great.





























Update (02.07.2017.):

Here are videos of Printrbelt working.








NCSIMUL Will See You at WESTEC 2017

SPRING Technologies, developer of software for the optimal and flexible use of CNC machines, including simulation and optimizing CAM programs, will demonstrate its flagship NCSIMUL SOLUTIONS package at WESTEC 2017, Booth 2538. The manufacturing event will be held September 12 – 14 in Los Angeles. The latest 2017 version of NCSIMUL Solutions sets a new benchmark for comprehensive control of the machining process, providing ease of use, flexibility and automation for manufacturers to move towards Industry 4.0. The two main modules, NCSIMUL MACHINE and NCSIMUL 4CAM will be highlighted at the show.

"For manufacturers requiring 5-axis simulation software for machining centers or complex mill-turn multi-axis simulation, we are hopeful they will put us on their "must see" list at WESTC," Silvère Proisy, North American Operations Director for SPRING Technologies.
Among the new features of NCSIMUL SOLUTIONS 2017 and the NCSIMUL 4CAM module are: New probing strategies; support for turning after milling, for one-click NC machine turnaround; cutting tool management with 3D definitions; one-click project update; project export/import; automatic performance analysis; automatic graphic detection of machining risk zones and less than optimal cutting conditions, and more.
NCSIMUL MACHINE is an innovative CNC software solution providing realistic CNC simulation of the machining process. Users can simulate, verify, optimize and review machine programs based on the actual characteristics of the machine tools. Three-dimensional graphics help to avoid machining crashes while powerful algorithms and embedded process-based knowledge enable cutting conditions to be optimized. NCSIMUL MACHINE provides machining verification in three steps: investigates and corrects coding errors, simulates to locate collisions and correct motion errors, and validates the program. The benefits are many, including reducing the time spent on debugging programs; preventing the costly risk of spindle collision, tool breakage and scrap; and improving cycle times and process optimization efficiencies.
Further, SPRING has focused its R&D over the last year on optimizing the performance of NCSIMUL 4CAM, the award-winning CAM add-on module that can be integrated with the software package. Based on SPRING's expertise in the field, NCSIMUL 4CAM 2017 effectively brings users more efficient processes and supports their best practices with existing CAM software products. With the new version of NCSIMUL 4CAM, manufacturers now have a decision-making tool that is reliable, flexible, secured and automated for selecting the production resources they want to deploy.
ABOUT SPRING TECHNOLOGIES
SPRING Technologies develops software solutions designed to optimize manufacturing companies' CNC machines to reduce costs and maximize productivity.
Its product NCSIMUL SOLUTIONS® provides a complete and integrated mastery of the production process from Methods departments to Workshop including NC programming, machining simulation, cutting tool management, CNC program management and real time machine status monitoring.
This unique approach simplifies the digital chain and provides needed tools and flexibility for the implementation of automated factories.
Based in France, Germany, PR China and the USA, the company was founded in 1983 and collaborates with manufacturers in aerospace and defense, transportation, energy, industrial equipment and medical devices, using CAM software's such as CATIA, NX, CREO, TOPSOLIDCAM, MASTERCAM,... Through its global network of resellers, SPRING supports its customers all over the world.
NCEXPERIENCE, NCSIMUL, Optitool and NCdoc are registered trademarks of SPRING Technologies.
2:49 PM

Maslow $350 Open Source CNC Cutting Machine

Maslow CNC is a novel approach to the cutting of large material sheets. It is a hanging or suspended CNC router.
It is open sourced and it comes at $350 price point.

Tech specs:
  • Work Space: 4' X 8' 
  • Encoder Resolution: 8148 steps/rev
  • Repeatability: +- 1/64th inch (.4 mm) or better
  • Max feed rate 48 inches/minute
  • AC Voltage: 110-250 volts
  • DC Voltage: 12 volts
  • Connection: USB
  • OS for Software: Mac, Windows, Linux
  • Size: H: 6' 8" W: 10' D: 1' 7"

Here is the design overview:




Video showing Maslow cutting out an OpenDesk chair:




On Tested show:




Maslow CNC homepage:

http://www.maslowcnc.com/



Desktop Metal 3D Printing with Microwave Enhanced Sintering

Here is another revolutionary step forward in 3D printing: the desktop metal 3d printer. It deposits metal "paste" made from metal powder with a polymer binder in a similar way as any common FDM machine and the parts are then sintered in a microwave enhanced furnace chamber.
The price is comparable to higher-end professional FDM machine from a few years ago. They also sell production cell that has much higher capacity for more demanding production facilities.


Tech specs:

  •  Build volume: 12 in x 8 in x 8 in (305 mm x 205 mm x 205 mm)
  •  Materials:  Steel, Titanium, Aluminum, Copper and other undisclosed materials
  •  Layer height: 50 μm (minimum)
  •  Dimensions: 60 in x 49 in x 30 in (1500 mm x 1250 mm x 750 mm)
  •  Technology: Microwave Enhanced Sintering
  •  Price: $120,000 for the desktop version, $250,000+ for manufacturing cell production system


Desktop Metal presentation video:




Here is a much more in-depth video by GoEngineer with many details about the machines, materials, and the process:




Company homepage:

https://www.desktopmetal.com/



New DIY CO2 Laser Cutter Project

Here is a new DIY CO2 laser cutter project from Instructables. It was developed by Michiel Deschout and uses relatively available materials and parts like 3030 aluminum T-slot profiles, Arduino and some 3d printed parts. The total cost was some 1900 Euro.
The presented setup uses 40W laser, but the power could probably be increased.






Very detailed step-by-step build guide with all the files can be found at:

https://www.instructables.com/id/Make-Your-Own-High-Quality-CO2-Lasercutter-With-To/



Here is the back side with 3d printed holders for the CO2 laser tube:


The latest fashion trend for all you 3d printing geeks

If you are into 3d printing then this is THE style of jacket you should wear!









































Detailed project description:

This jacket has 40 neopixels sewn to the back to display the status of the 40 3D Printers in Duke’s Innovation Co-Lab Studio. Each light corresponds to one printer and is either blue (in use), green (available), or red (offline) to show the real-time status of the printer. The printer status is retrieved via Duke’s Innovation Co-Lab’s 3D printer status API, documented here: http://apidocs.colab.duke.edu/.


Instructables page with all the steps and code:

https://www.instructables.com/id/3D-Printer-Status-Jacket/

3D Printable Parametric Slew Bearings

Christoph Laimer published  another very useful project. He developed a fully 3D printable and working parametric slew bearings. Since they are developed to be sturdy they can be used in many different project where a simpler 3D printed ball bearing would fail.
Since the design is parametric, you can adapt it to fit your needs. One version even has conical bearings.



























Project description:
Ball-bearings are very popular for 3d-printing. However they often fail for real applications. Using Fusion 360 I've created a parametric design of a "Crossed Roller Slew Bearing". The result is a pretty accurate and robust bearing. The bearing including the rollers is 3d-printed in separate parts. There are a few screws needed to clamp the two halves of the inner race together.

Here is the full video:





Thingiverse page:

https://www.thingiverse.com/thing:2375124

A360 download page:

http://a360.co/2r9MFf5

http://a360.co/2r9JnZf

THERO project

THERO is a privacy project developed by Román Torre and Ángeles Angulo, that uses a Raspberry Pi with TOR routing. By moving the front panel you change your connection to the external Internet and your privacy.
It uses 3d printing to make the full enclosure and mold for the concrete encased version.


Here are two videos showing how the project was developed:








Source:

http://3dadept.com/manage-your-online-privacy-with-thero-a-3d-printed-desktop-device/

Project homepage (in Spanish):

http://www.romantorre.net/portfolio-item/thero/



PrusaControl - a new software interface from Prusa3D

Prusa released a new software aimed at beginners: the PrusaControl, which is a simplified interface for Slic3r Prusa Edition.

Here is the description from the news release:
PrusaControl is an alternative user interface for Slic3r Prusa Edition.
Slic3r Prusa Edition was the first step with a great success and we are extremely proud when people mention they switched back from S3D. But Slic3r has one problem, it is rather complex and intimidating for new users. We cannot do much about this, it is its nature. And that is why PrusaControl was born. It is parallel to Slic3r PE for newcomers to 3D printing, we distil the settings down for the user and put our knowledge to the backend to get the same results. The main goal is to open an object and hit print. PrusaControl is simple, novice friendly and smart.























PrusaControl home page:

http://prusacontrol.org/

Source news article:

http://www.prusaprinters.org/prusacontrol-release/

Garage Shop

I reorganized my garage shop this weekend. While it's all clean and tidy I took some pictures. So in a week or so I can remember what it was like when it was all clean and tidy.

Here's the view coming in the garage door. Most tools are on wheels by necessity. This lets me move them as needed when working with larger parts.


Starting in the back corner against the garage door... clamp rack in front of router table. Sharpening storage and bench:

Router table setup - this is the Bench Dog station with a Porter Cable router installed on a lift. The fence is a nice adjustable model from a Fine Woodworking magazine article by Patrick Warner.

Veritas Carver's Bench. This bench is great for carving as it tilts, swivels and the dogs and clamps rotate so they can grip irregular shaped work.


Bench area. CNC router computer cart in foreground: 

Bench details:


CNC router laptop computer cart:


CNC Router. Router 4-axis below table. Hand saw storage behind:



Jointer and table saw:

Table saw and mitre saw in background:


Various fences, jigs and tools on shelf below table saw:

DeWalt sliding compound mitre saw. Anyone recognize that table? It's a New Yankee Workshop Chop Saw Station project. As part of my clean-up I order one of the FastCap Chop Saw hoods to install behind this. I've needed better dust collection for years!

Planar, shaper, sanding tools, cordless drills and chargers, shop vac:

Drill press and band saw with riser block:

I designed and built the plane cart years ago.

Plane cart closeup. Rolling cart in the corner is another New Yankee Workshop Rolling Shop Cabinet project:

Formlabs Fuse 1 Desktop SLS 3D Printer

Formlabs just released their Fuse 1 3D printer which is a desktop selective laser sintering machine priced at 9,999 USD. It has a 165 x 165 x 320 mm build volume and uses nylon powder.

This is a small revolution on the market and a big step forward in 3D printing availability and affordability!!! Laser sintering machines used to cost in hundreds of thousands and were very large. This will push the competition to respond and lower the prices even more in the future.


Fuse 1 introduction video:




Here is a different promotional "The Human Touch" video:




Fuse 1 homepage:

https://formlabs.com/3d-printers/fuse-1/


Here you can see the Fuse 1 size on a table next to a Form 2 SLA machine:



I wonder what will the price of the powder material be? Will it be recyclable and reusable? Will it come in proprietary cartridges with chip control unit?

Source:

https://formlabs.com/blog/digital-factory-announcing-fuse-1-and-form-cell/

Update:

Here is a much more detailed review by Tested. It shows how the Fuse 1 works and accompanying equipment like recovery station and material mixer. The material is recyclable and the mix of new and used material is determined by the user to get different print qualities.
The material is gray to absorb more energy from 10 watts fiber laser.


ViaCAD by Punch!CAD

I'm always on a search for the new and interesting software tools and when I received a tweet from Punch!CAD about their ViaCAD product I decided to take a look.

ViaCAD looks like an easy to use CAD that has an acceptable learning curve and feature set. You can start from the easy models and move into more complex stuff as you learn. Since it has support for many file formats I was able to open and edit things from various sources. The community behind it and support/tutorials available helped me find answers quickly.

The price seems very affordable and there are no additional fees or vendor lock-in features. It runs both on Windows and Mac machines.


ViaCAD has some powerful 3D printing features and tools:

  • 3D Print Check: This tool checks a part for print viability, displaying warnings or errors to the user.
  • Surface Normals Check: Facet normals define the inside and outside areas of a part. If facet normals are pointing the wrong way, the 3D printer may have problems creating the part. If you have a normals issue, there are several commands that can help you fix this problem.
  • Overhang Analysis: The Overhang Analysis tool provides a means to visually inspect modeling areas that may require structural support for 3D printing. Meshes, surfaces, and solids facets normals are compared to the work plane direction. Angles that are less or equal to 45 degrees are highlighted as red.
  • Wall Thickness: The Wall Thickness Analysis tool provides a means to visually inspect modeling areas that may be too thin for 3D printing. Meshes, surfaces, and solids facets are examined using ray intersections. 
  • Preview Slices: The Preview Slices tool provides a user interface to slice models given a direction and thickness. The dialog box allows for animation through the slices and single stepping. One use of the Preview Slice tool is to verify a part has closed, non-overlapping sections, a requirement for 3D printing. The Save Slices option provides several options to save slices to DXF, STL or adds the results directly into your drawing.
  • Auto Position: The Auto Position tool translates the model to the positive x, y coordinate system at z=0.
  • Support Structure: Manually adds geometry to support material as it is created by the 3D printer. Support structures controls, include Attach Radius, Midpoint Radius, Base Radius, Base Thickness and Drag base and midpoints to modify structure location.
  • Show Printer Volume: Toggles the boundary of the default 3D Printer. The volume is defined within the Printer Definitions dialog box.
  • Printer Definitions: Sets key parameters of the 3D printer, including length, width, and height of the volume accessible by the printer. The parameters in the Printer Definitions dialog box are used for commands such as 3D Print Check and Auto Position.

Here is the ViaCAD presentation video:




For much more information go and check out the company website:

http://www.punchcad.com/



In the future, I'm going to explore ViaCAd further and see if it can bring a CAD noob like myself on to the next skill level.

Aluminum Profiles DIY 3D Printer by Thomas Workshop

I always like to see new 3D printer designs and builds by different people. Recently I found this larger volume (40cm3) machine by "Thomas Workshop" on Instructables. It is fully made from common aluminum profiles and Thomas did put some effort to document and present his work process.
Test prints look good and the frame seems sturdy.

























Here is the final video from three part series showing electronics and printing:




Here is the detailed step-by-step build guide with videos, documentation, and picture construction log:

https://www.instructables.com/id/3D-Printer-Working-Area-40x40x40cm/

Make a DIY Waterjet Cutter From a Cheap Pressure Cleaner

In my youth, I used to work at a local car wash place. If you traveled trough Balkans you probably saw many of them, and they all use handheld pressure washers. When I saw this video it reminded me of that time and I thought you guys would enjoy and find something useful in this project.

Ben Krasnow used a very cheap pressure washer and attached a DIY abrasive sand container combined with AccuStream professional cutter head to make a low-cost DIY waterjet cutter.
It can cut thin aluminum, wood, and plastics. it looks like the cuts are very precise and controllable. In water only mode it cuts trough soft materials like foam.


Here is the full video with all the details.





Next step would probably be to mount this cutter on a CNC gantry and turn it into a fully computer controlled machine.
Since there are much more powerful pressure washers, like the Karchers I used, this could be made into a more capable device.
With right settings, it could potentially cut plastic 3d printed parts or use it as a sand blasting device for surface finishing.

Applied Science YouTube channel:

https://www.youtube.com/channel/UCivA7_KLKWo43tFcCkFvydw

Ben's blog:

http://benkrasnow.blogspot.com/



Steam Powered 3D Printed Mechanical Computer

Here is something you don't see every day: a steam-powered mechanical computer with nylon 3d printed parts.
It is a version of a Babbage Engine from the 19th century.





Project description:
A simplified version of Charles Babbage's Difference Engine no. 2 has been constructed by Piers Plummer as part of a project with the Computer Science Department at Royal Holloway University of London, funded by The Leverhulme Foundation. In this video, it is performing calculations while being powered by steam!


I just love the looks of it, with all the pipes, valves, and a steam boiler! Even a hand crank!





























Source:

https://www.youtube.com/channel/UCGib9sASZ5MUPpQM6t3krUQ


Acrylic Figure Sculpture

I recently completed a new figure sculpture. This one was produced from CNC router cut 0.22" thick acrylic sheets.

Modeling

The form was sculpted in ZBrush from a live model as part of my work with the West Huron Sculptors.

Given the simplification about to happen it was kept loose. It was decimated down to 200K polygons. It is then sized and exported to Rhino where the ReduceMesh command further brings it down.

Next, a Grasshopper definition was run which contours the form and lays out the form for fabrication. Grasshopper is a visual programming editor which runs inside the Rhino modeler. Here's the full program, called a definition. Obviously you can't see anything - but you can get an idea of complexity:

It's broken up into small chunks of functionality. 1) Contour the form 2) Get rid of small contours 3) Rebuild the curves, 4) Group together with neighboring piece, 5) Layout flat for cutting.

Here the contours have been extruded to visualize the result:


When Grasshopper contours a mesh it puts control vertices at every triangle intersection. That's a lot of verts which makes extruding slow and faceted.

In order to speed things up and smooth them out a little the Grasshopper definition rebuilds the curves. The number of control vertices used in based on the curve length. These are smooth but nicely represent the form.

Layout for Fabrication

The contours are then laid out and distributed on the ground plane. Each contour is drawn on top of the previous contour in the stack. This provides guidance of alignment from layer to layer. One obvious solution is to drill holes between the pieces and align them with a dowel. I didn't want to use acrylic dowels in the alignment because I didn't want them showing up piercing the piece - ouch! So the alignment diagrams were plotted on cheap bond paper and cut out. In the end this turned out to be less useful than I thought.

In order to CNC route these the nesting of parts needs to be much more efficient! Here are the contours laid out for cutting using RhinoNest:

Three sheets - each 48" x 46" (which I got from the off cut section of Alro Plastics). They look reasonably well packed, yeah? Actually it's about 48-50% efficient per sheet. Not great - but - a really good nesting is usually about 60% efficient. And that's not great. If you want it better - larger sheets, more small parts!

Cutting

The parts are cut with a plastic cutting endmill, one flute, sharp point, scalloped back edge - specially made for acrylic and other hard plastics - available here: Spiral O Flute from Tools Today. The single flute is useful so the plastic doesn't melt during cutting. Some advice: Wear a dust mask and sealed eye protection. Even with good dust collection I find this stuff pretty nasty to cut.

After cutting the parts were number by hand. Better would be to make a simple tool holder for a Sharpie and let the machine label them.

Starting to sort them.

Trimming off the tabs at the router table with a piloted straight cutting bit. That's super easy on the big parts. The smallest parts I had to do at the sander.

An oscillating spindle sander tended to break the tabs off too easily. So instead I clamped a random orbit sander into my bench, hooked up the dust collection and held the parts over 80 grit paper. That makes pretty quick work of it. It's messy though. Again, dust mask and eye protection essential!

After too much of that I switched to using a Dremel tool. This is much more localized and leaves the surface looking closer to the router cut edge. Much better.

Assembly

With all the parts cut and sanded they just need to be layered up and glued just like the computer model. That should be easy, right?!

Here we go... feet upward...

I kept the computer handy. One side view and one perspective on the monitor are helpful to figure out who is going where.

Drawings showing a small stack of layers are also extremely useful:

I could usually stack 3 or 4 pieces, glue them up, then glue on the previous stack:

Once the form starts to tuck under itself I need to mirror the drawings and build the other way. That allows them to be glued together with generally smaller parts on top of larger ones.

Last to go in was the arm going beneath her hair and against her neck. The last piece was too tight for 0.22" acrylic. I cut pieces at 0.125 and 0.1875" and went with the latter which was a nice fit.

Assembled

Whew! All put together, no clean-up of ANY kind! Some Dremel tool assisted polishing is in order.
 





LED Lights 

Here's an updated post about adding LED lights to this piece.

Lessons Learned

Well that was easy to cut but hard to assemble. Here are a few things I'd do differently next time:
  • I should have used a 1/8" diameter bit instead of 1/4" to cut the contours. In some spots, in particular the face, the added definition to the form would have been worth it. My thought at the time was keeping the resolution the same in every direction (1/4" thick acrylic) would look best. Having seen it I don't think so. 
  • The tabs need to be trimmed off with a cutter similar to the one used to cut the edges. Otherwise the surface looks different where the tabs were. This is apparent on the finished form. This would require making a custom router bit - basically adding a bearing to the existing tool. Of course if you have a large laser cutter you don't need tabs and the edges will all be polished!
  • Initially I used a feed of 150 with a spindle speed of 18000. Later I used 80 and 7500 and I prefer the later. The chips are much bigger and less sliver-y. 

CNC CODE

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