Showing posts with label stratasys. Show all posts
Showing posts with label stratasys. Show all posts

How to make translucent 3d printed parts transparent?

Do you know the difference between translucent and transparent? I didn't, but I got it after watching this video.
This free webinar will teach you how to get 3d objects optically clean by polishing, buffing, photobleaching, sanding, clear coating and applying other techniques. It is focused on Stratasys VeroClear material but it can be applied on other surfaces to get better finish.




Webinar is presented by Tyler Reid of GoEngineer.



Aurora Flight Sciences 3D Printed UAV with Jet Power




Project description:
Aurora Flight Sciences, a Virginia-based manufacturer specializing in advanced UAV systems, is pushing the envelope of UAV design by teaming up with Stratasys to create the world’s first jet-powered, 3D printed aircraft.
Using 80% 3D printed parts, the UAV is composed of Stratasys’ ULTEM™ 9085 lightweight material to achieve flight speeds of over 150 Mph. The high-speed system boasts an impressive 9 ft wingspan and weighs in at only 33 lbs.



Press release with much more information:

http://www.aurora.aero/wp-content/uploads/2015/11/SSYS_News_2015_11_9_Stratasys_Corporate.pdf


How are large city and terrain map models 3d printed and assembled?

Here are two projects that demonstrate how you can make very large models of cities or terrain by connecting smaller pieces in larger frame.


3D Printed Model of San Francisco





Video description:

Behind the scenes 3D printed model of San Francisco:
Connex 500 printed 3d model of a portion of San Francisco. The model was created to aid real-estate developer Tishman Speyer in telling the story of urban development in the rapidly changing SOMA neighborhood. It can help with urban planning and building construction decisions that are better understood with the kind of physicality that only a real-world 3D replica offers compared to digital images or digital models.



























3D Printed terrain map of Canton Bern in Switzerland


3drucken.ch printed this terrain map of Canton Bern in Switzerland, made in scale 1:25'000 out of 340 tiles. 4.9 x 4.5 x 0.17 m. ca. 75kg PLA used, 12'000h total print time on 7 Ultimaker printers during 7 months.





Hexacopter Rapid Development with 3D Printers

One day soon there will be thousands and thousands of different models of DIY copters and robots moving around. What is now in hands of hackers, makers and hobbyists will become ubiquitous like bicycles...

This is just a preview of things to come and you will probably be able to make on your low cost home machine.



Description:
Students at Wentworth Institute of Technology were challenged to develop a functional hexacopter using six different manufacturing processes, including 3D printing. 95% of the 3D printed components were produced using the Stratasys uPrint SE and Objet30 3D Printers.

GrabCAD CubeSat Challenge

Here is a great contest for all you guys interested in 3d printed satellites and space. It has some great awards also.

One of the contest entries. 

The contest is organized by Stratasys, MakerBot and GrabCAD.

About This Challenge

The goal of this challenge is to design a small satellite frame optimized for additive manufacturing. By using the benefits of design for additive manufacturing (DFAM) principles:
  • Mass distributions and materials can be rethought to minimize weight 
  • Part count can be reduced to improve producibility 
and ultimately, cost can be reduced.

Awards for TOP 10 places:

1st Place

- $2,500 cash
- Your design printed by Stratasys Direct Manufacturing
- Makerbot® Replicator® and material pack.
- Featured story in Stratasys online communication and use of your design as an example part in Stratasys trade show and conference appearances.


2nd Place

- $1,000 cash
- Your design printed by Stratasys Direct Manufacturing
- Makerbot® Replicator® and material pack


3rd Place

- $500 cash
- Makerbot® Replicator® and material pack.


4th - 10th Place

- $100 cash
- Makerbot T-Shirt
- 3D Printed Sample Part


Challenge homepage:

https://grabcad.com/challenges/the-additive-cubesat-challenge

also don't forget about NASA 3d printed habitat contest:


Good luck people! 


DIY Stirling heat difference engine with 3d printed parts

Doug Conner developed a 3d printable homemade Stirling engine, a type of motor that creates mechanical motion from temperature differential of a medium which is air in this case. The engine is made in ABS on a Stratasys FDM printer.

This engine has some metal (brass, aluminum) parts, couple of metal screws and some rubber O-rings, but that is unavoidable due to the nature of the technology and ABS material limitations.

It takes some 50 deg F (or 28 deg C) of heat differential to move at stable speed at about 300 rpm without additional weight or load.
Project homepage:

http://www.solarheatengines.com/2012/10/29/3d-printed-stirling-engine/

All the 3d files and plans to make this Stirling engine can be found at:

http://www.thingiverse.com/thing:34709

Here is video demonstration of the engine in action:




Doug's DIY 3d printed Stirling engine from the project homepage

Free webinar on 3d printed car parts and car mods

Here is new free webinar from GoEngineer focusing on 3d printed car parts, car accessories and car modifications.

If you are interested in cars, car hacking, car repair, hypermiling, modding, car tuning and have access to any type of 3d printer this video will give you lots of useful tips, information and practical examples. You could theoretically make any plastic part needed for your car and customize it to fit your needs.

Webinar is presented by Tyler Reid, it is focused on Stratasys technology but the knowledge and is applicable to other 3d printers.

3d printed car parts presented here are:

  • gauge bezel
  • firewall feedtrough
  • wire tee box
  • throttle body spacer
  • battery charging box
Here is video webinar, one hour well spent ;-):



Here is a picture of installed wire tee box:



























Great tutorial, thank you for the content Tyler and GoEngineer team!

There are many more similar high quality tutorials, like:

3d printed jigs and fixtures:

http://diy3dprinting.blogspot.com/2014/08/free-webinar-on-3d-printing-jigs-and.html

or 3d printed end user parts:

http://diy3dprinting.blogspot.com/2014/07/free-webinar-of-3d-printed-end-use-parts.html

Here you can see another example of home 3d printers being used to make small replacement parts like AC button and cargo cover holder:

http://diy3dprinting.blogspot.com/2014/08/repairing-ford-focus-cargo-cover.html

Update:

Here is a new webinar about complex geometry and 3d printing:

http://diy3dprinting.blogspot.com/2014/12/free-webinar-on-3d-printing-and.html




Free webinar of 3d printed end-use parts





Here is another great free video webinar by Tyler Reid of GoEngineer. It is a hour long exploration of many different projects and products which are 3d printed to be used under realistic conditions in very demanding environments and not just protoyped.
It is 201 level webinar.




For other educational videos by GoEngineer see:

http://diy3dprinting.blogspot.com/2014/07/free-webinar-on-fdm-and-polyjet-3d.html

http://diy3dprinting.blogspot.com/2014/04/free-webinar-on-industrial-3d-printing.html

Update:

New 201 webinar on injection molding:

http://diy3dprinting.blogspot.com/2014/08/free-webinar-on-3d-printing-and.html







Cost reduction and time saving blow mold production with 3d printing





Blow molding is process mostly used for manufacturing of various containers such as bottles. With the help of 3d printers the time of mold production is reduced by 90% and cost are cut by 94%.

Blow molding is a manufacturing process used to produce hollow plastic parts, such as bottles and other containers. Blow mold design and the specification of process parameters require skill and precision. A small change in the pinch--off or vent design, die temperature or blow pressure can dramatically affect the molding results.

Prototyping enables designers to validate these parameters and accelerate design approval. But up till now, high costs and long lead times have deterred blow mold prototyping.

Additive manufacturing, or 3D printing, makes prototyping a viable option. In this brief video you will learn how to produce cost-effective blow molds using PolyJet-based 3D printing from Stratasys.

3d printed vs. cnc machined aluminum blow molds
















Source: http://blog.stratasys.com/2014/06/30/3d-printed-blow-molds-plasel

Free webinar on FDM and PolyJet 3d printing basics




It is 30 minutes worth watching if you are starting with FDM and PolyJet commercial grade 3d printers. It gives the technologies overview, advantages and disadvantages, applications and materials.  It is based on Stratasys machines, but it the knowledge is mostly universal.
This webinar is made by Tyler Reid of GoEngineer. You can go to his channel and see many more interesting videos on various 3d printing / CAD / CAM topics.

FDM and PloyJet applications examples and intersections 




















Source: https://www.youtube.com/watch?v=BAJMi8n2wso

Fully functional AirDog drone prototype developed with 3d printing




AirDog is innovative quadcopter drone that will follow you automatically and record video of your activity guided with electronic bracelet "leash" or smartphone app. The fully functional prototype is 3d printed in ULTEM 9085 production grade thermoplastics.

Currently it has several flight patterns that can be expanded in future:
  1. Auto-follow. Will work with almost any sports. In this mode AirDog will follow you repeating exactly your movement trajectory while maintaining its position in preset distance and altitude from you. It will follow you at speeds up to 40 mph.
  2. Relative position follow. In this mode AirDog will maintain constant offset relative to magnetic north from the rider. For example, you can set it to keep a 10 meter distance at 4 meters high to the east from your position. Even when you change your direction, the AirDog will stay at the same preset angle from you. We suggest this mode for straight line wakeboard cable parks, surfing, and some other sports.
  3. Follow track. This is the safest way to operate AirDog. Simply go for one lap with AirLeash and it will record your track. Then adjust AirDogs trajectory to your liking in smartphone app. AirDog will repeatedly fly over the exact set trajectory and the camera will be continually adjusted to aim at the rider.This is the most creative mode where you can become a true director of your movie. Adjust AirDog's trajectory to avoid obstacles like buildings or trees. You can even make it to shoot you from different angle on different spots/kickers in the track. It might sound complicated, but its a simple few tap process in AirDog smartphone app.
  4. Hover and Aim. The Hover and Aim setting allows AirDog to stay in one position above the ground, but constantly directing the camera at the AirLeash. This setting is perfect for tight places such as smaller skateparks, narrow forest trails, or for activities such as bungee jumping or base jumping, where clearance from equipment is important.
  5. Circle. In this setting, AirDog makes circular rotations on a set radius and altitude, keeping the camera aimed at the AirLeash. This for slow speed or static shots to show impressive view around you.
  6. Look down. The most simple mode but can produce very stunning results. Simply "walk" your AirDog above a ramp or kicker where you are about to throw some epic tricks and with push of a button it will freeze its position and aim camera straight down. Now make sure you don't go too high.
  7. When it goes into production it will be produced with injection molding and it is clearly indicated on the timeline.

It was developed with Stratasys:

From Stratasys blog post:
The working prototype, currently flying in demonstrations over the United States, was produced using 3D printing technologies from Stratasys, with guidance from Stratasys’ Latvian partner, Baltic3D, and Polish reseller Bibus Menos.
“As the world’s first auto-follow action sports drone, AirDog not only grants end-users their own affordable and personal aerial video crew, but goes one step further in providing thrilling footage from distances and angles previously inaccessible to such consumers,” explained Edgars Rozentals, Co-founder and CEO of Helico Aerospace Industries.
A production-grade thermoplastic (ULTEM 9085), popular in the aerospace industry for its high strength-to-weight ratio, was used to create the AirDog quadcopter. “We were particularly impressed by how far we could push the boundaries of the ULTEM material,” said Rozentals. “The material’s functional stability enabled us to 3D print very thin walls that further reduced AirDog’s overall weight.
For the AirLeash, Helico chose to use rubber-like as well as rigid materials in a single prototype, relying on Stratasys’ PolyJet 3D printing technology, which allows for the incorporation of multiple materials in a single go.
“I’m not sure how we would have arrived at the stage of having a functional part, were it not for Stratasys 3D printing technology. I founded the company two years ago and we’re a staff of three, so for start-ups like Helico, this technology isn’t just a game-changer, but the ticket to the game itself,” ventured Rozentals.

AirDog Kickstarter:

https://www.kickstarter.com/projects/airdog/airdog-worlds-first-auto-follow-action-sports-dron

Source blog post from Stratasys:

http://blog.stratasys.com/2014/06/25/3d-printed-sports-drone-airdog/























Prototyping large tanks for space industry with 3d printing by RedEye




Here is an example of large scale prototyping for space industry. Large fuel tanks for satellite deployment were prototyped by RedEye saving lot of money and time.




























From source post:
Validation of design
In early 2012, Lockheed Martin SSC began looking at ways to improve and add value to their satellite design. The goal was to design a satellite that would make more efficient use of space and increase the satellite’s payload. It would require testing many assembly configurations and producing several simulators and prototypes to validate design changes. One change that needed to be validated was in the satellite’s fuel tanks.
Before building the actual fuel tanks for final use, Lockheed would need to test form, fit and function and assembly with tank simulators. Producing test parts with traditional manufacturing methods would not be realistic given the deadline and costs. Machining the larger tank at 6.75’x3.8’x3.8’ and the second tank at 3.8’x3.8’x3.8’ would take over 6 months and around $250,000. The recent advancements in large-scale 3D printing motivated Lockheed to apply Stratasys’ Fused Deposition Modeling (FDM) to the tank simulators.
Lockheed Martin is no stranger to 3D printing technology. In fact, they are considered a 3D printing leader for aerospace applications and own several additive manufacturing machines. But this particular application, part size, post processing requirements and project deadline posed a challenge for their in-house capacity. The parts would have to be built in many pieces and bonded together, requiring an army of machines and a team of FDM finishing experts. That’s when they turned to RedEye’s aerospace team.
Constructing the tanks
Lockheed Martin has partnered with RedEye over the last several years to manufacture parts and often comes to RedEye when size, material or machine capacity limit their in-house additive manufacturing systems. Lockheed knew RedEye would deliver high quality parts on time and offered the engineering thermoplastic and finishing processes required for the form, fit and function tests.
“We chose RedEye because they have the machines and finishing capabilities to build tanks of this size,” said Andrew Bushell, senior manufacturing engineer at Lockheed Martin SSC. “We also decided to go with RedEye for their speed and engineering support we had received on past projects.”
When the RedEye’s aerospace team received design files from Lockheed’s engineers, they were stunned with the size of the tanks. “These are the largest parts we’ve ever built using FDM,” said Joel Smith, the strategic account manager for aerospace and defense at RedEye. The project required many preliminary meetings between Lockheed and the RedEye team as it was the first time building a design of this magnitude. “We completed an extensive design review to determine the best orientation and slice height to ensure we could accurately build and bond the sections together in post processing and meet Lockheed’s dimensional requirements,” said Smith. RedEye landed on building the larger tank in 10 sections and the smaller tank in 6 sections in polycarbonate (PC) on the Fortus 900mcs.
RedEye and Lockheed had to adapt and make adjustments to the plan along the way to meet tolerances. “We decided to alter the orientation of the exterior clocking rings that go around the tanks and increase their wall thicknesses to support inserts,” said Trevor Stolhanske, aerospace and defense project engineer at RedEye. Each section of the tanks took 150 hours to build, but even so, RedEye was able to build multiple sections at once, maximizing lead times and controlling costs. After all of the sections were complete, the support material was washed away and the sections were sent to finishing services for bonding.
Because of their round shape and weight, the only way RedEye could successfully bond the tanks was to build customized fixtures to hold the sections while fusing pieces together. After several hours of welding each section together, RedEye sanded the tank seams and surfaces. After finishing, the tanks and rings were sent to Hutchinson Manufacturing, Inc. to be machined to the design’s critical dimensions. When RedEye received the tanks from Hutchinson, they added brass inserts to the rings and assembled the tanks per Lockheed’s specifications.
Final assembly
“These tanks were built in a fraction of the time it would have taken with traditional manufacturing methods. Even with the machining process and design changes made along the way, we were able to deliver these parts ahead of schedule” said Smith.
The tanks went through a number of quality assurance and accuracy measurements and were approved for the first concept assembly. Lockheed Martin’s Space Systems Company performed form, fit and function testing as well as process development, in order to validate the proposed design changes.
Next, Lockheed will take what they learned from the first phase and use the information to optimize the design and assembly to print the second iteration of tanks.

Source and more information:

http://www.redeyeondemand.com/3d-printing-case-studies/lockheed-martin-3d-printing/

So this is the "serious" industry, while they are doing that, students are developing fully functional 3d printed rocket engines:

http://diy3dprinting.blogspot.com/2013/10/students-developed-and-successfully.html


Endur simulated Polypropylene commercial 3d printing material by Stratasys




Endur is an advanced simulated polypropylene material for PolyJet technology commercial 3D Printers. It is durable and flexible with both high impact resistance and elongation at break, resulting in tough parts with great surface finish.
More info: http://www.stratasys.com/materials/polyjet/simulated-polypropylene

























Stratasys shows fully functional 3d printed skis




From video description:

Check out Stratasys founder, chairman and head of innovation Scott Crump braving the slopes as he tests what could be the world's first 3D printed skis. These skis are fully functional, built on a Fortus 3D Production System using Fused Deposition Modeling (FDM) Technology and ULTEM 9085 resin.
Stratasys Engineer Dominic Mannella designed and built the skis at our Skunkworks facility. He picked ULTEM because it's a strong and stable thermoplastic that endures a wide range of temperature and moisture conditions -- even a Minnesota hillside in a polar-vortex winter.
The ability to 3D print low-volume end-use parts could be a boon in industries like sporting goods, where personalized ergonomics and custom aesthetics are attractive.

More details with entire build process can be found at:

http://blog.stratasys.com/2014/02/13/3d-printed-skis/


Here is first 3d printed snowboard, differences in technology level are obvious:

http://diy3dprinting.blogspot.com/2013/03/first-3d-printed-snowboard.html



Stratasys Objet500 Connex3 World's First Color Multi-material 3D Printer








This powerhouse is priced around 300,000 USD.


Technical specifications:

Model materials:
  • Vero family of opaque materials, including color
  • Tango family rubber-like flexible materials
  • Medical: MED610
  • Digital ABS and Digital ABS2 in ivory and green
  • DurusWhite RGD430
  • High Temperature RGD525 white
  • Transparent: VeroClear and RGD720

Digital model materials:
  • Hundreds of composite materials can be manufactured on the fly including:
  • Vibrant blended colors in rigid opaque
  • Translucent colored tints
  • Rubber-like materials in a variety of Shore A values
  • Polypropylene-like materials with improved thermal resistance

Support material:
  • SUP705 non-toxic gel-like photopolymer support

Tray size:
  • 500 × 400 × 200 mm (19.7 × 15.7 × 7.9 in.)

Net build size:
  • 490 × 390 × 200 mm (19.3 × 15.4 × 7.9 in.)

Layer thickness:
  • Horizontal build layers down to 16 microns (0.0006 in.)

Build resolution:
  • X-axis: 600 dpi; Y-axis: 600 dpi; Z-axis: 1600 dpi

Printing Modes:
  • Digital material: 30-micron (0.001 in.) resolution
  • High quality: 16-micron (0.0006 in.) resolution
  • High speed: 30-micron (0.001 in.) resolution

Accuracy:
  • 20-85 micron for features below 50 mm; up to 200 micron for full model size (for rigid materials only, depending on geometry, build parameters and model orientation)

Input Format:
  • STL, OBJDF and SLC File

Workstation compatibility:
  • Windows 7 64-bit or Windows 8 64-bit

Network connectivity:
  • LAN – TCP/IP

Size and weight:
Objet500 Connex3:
  • 1400 (w) x 1260 (h) x 1100 (d) mm
  • (55.1 x 49.6 x 43.3 in.)
  • 430 Kg (948 lbs.)

Material Cabinet:
  • 330 (w) x 1170 (h) x 640 (d) mm
  • (13 x 46.1 x 26.2 in.)
  • 76 Kg (168 lbs.)

Print heads:
  • 8 units

Power Requirements:
  • 110–240 VAC 50/60 Hz; 1.5 KW single phase

Operational Environment:
  • Temperature 18 C-25 C (64 F-77 F); relative humidity 30-70 percent (non-condensing)

Stratasys product page:

http://www.stratasys.com/3d-printers/design-series/precision/objet500-connex3


PDF technical specification sheet:

http://www.stratasys.com/~/media/Main/Secure/Material%20Specs%20MS/PolyJet-Material-Specs/Objet500%20Connex3_Design_SellSheet_low%20res%20R3.pdf














Peppermint Energy FORTY2 suitcase solar generator developed with 3d printing prototyping




From video description:
Peppermint Energy, based in a South Dakota, has developed a portable, plug-and-play solar generator called the FORTY2.

Described as a solar plant in a suitcase, the FORTY2 draws enough juice from the sun to power lights, laptops — even a dorm fridge. A battery stashes power and delivers it after sundown.
Originally a cool product idea for tailgaters and campers, this quickly became a potential life changing source of energy for developing countries where three billion people live without reliable electricity. That means medicine that requires refrigeration could reach places it couldn't go before. The device could also spark commerce in remote areas as entrepreneurs find ways to monetize free reliable power.
Watch the story behind this remarkable device and how Stratasys 3D printing based on FDM™ technology using ABS plastic delivered a durable full scale prototype. Just one of the prototyping benefits - Peppermint decided to make the whole device even smaller than intended after carrying the first prototype proved awkward.

http://www.peppermintenergy.com/

FORTY2 video:



Source:

http://blog.stratasys.com/2014/01/10/peppermint-energy-3d-printed-solar-generator/




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