Date post: | 14-Sep-2014 |
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3D Printing: A Bridge Between 3D Printing: A Bridge Between Engineers, Designers and Innovation?Engineers, Designers and Innovation?
Olaf Diegel
From A to Z
Life before academia
Subtractive Manufacturing 101
The really old way: Take a block of material and carve it out
You want to make a bust of yourself...
The more modern way •Generate 3D model•Generate CNC program•Machine away unwanted material•If possible, recycle waste
Additive Manufacturing 101
• Generate a 3D CAD model• Software slices the 3D
model into thin slices• Machine builds it layer by
layer• The thinner the slices, the
better the quality of the model
The Past For most of the 90s, Additive Manufacturing was
known as Rapid Prototyping, and mostly used for prototyping engineering parts.
In the last decade AM has begun to make appearances in real, commercially available, products, ie. moved beyond prototypes.
Why Additive Manufacturing?
1. Complexity for Free2. Mass-Customisation3. Complete products in one print4. Trying Ideas with minimal risk5. Encourages Innovation6. Supply-Chain Reduction / On-demand
manufacturing
Advantage 1: Complexity for Free
• The more complex the part, the better it is suited to Additive Manufacturing (AM).
• If a part is relatively simple, there are, generally, more cost-effective ways of manufacturing it than AM.
• Many simple parts can often be consolidated into one much more complex parts as no assembly is required (so less assembly labour).
Art & Design Objects
Freedom of Creation
Joshua Harker
Jewellery
Marketing
Advantage 2: Mass customisation
• A small production run of parts can be undertaken in which each part is uniquely customized to suit the user
• It costs no more to do 100 different components than 100 of the same component
• This opens up a whole new area of business for products that are mass-custom-made for the user
Medical Applications
Knee replacement, EOS
Hip socket, Ala Ortho, Italy, made on Arcam machine
Laser Sintered Hearing Aids, EOS/Materialise
Dental Crowns and Bridges, EOS
Lighting
MGX Design
Printing People
Know your baby before its born…
Tomohiro Kinoshita , of FASOTEC, the company offering the 'Shape of an Angel' model, even offers parents a miniature version which could be a 'nice adornment to a mobile phone strap or key chain.'
Advantage 3: Complete Products
• AM allows the production of complete products with moving parts. This can greatly reduce the amount of assembly (ergo labour) required to make products.
Textile & Fashion Applications
Continuum Design
Freedom of Creation
Francis Bitonti & Michael Schmidt Studios
Joshua DeMonte
3D printed airplane
University of South Hampton
Advantage 4: Try Ideas at No Risk
• Testing the market with an idea, using traditional manufacturing methods, can often be extremely expensive. AM allows small production runs of product to be taken to market with very little capital risk.
• This allows many more inventors to realize their inventions and test their market validity.
Galantai Soap Dispenser
Short production run of 100 units undertaken for Australian market. Cost ~US$2000
Adding Aesthetics to Utility
People who feel good about how they look are likely to be happier than people who are uncomfortable. Bespoke Innovations has taken this to heart and, through the power of AM, has created what they call prosthetic Fairings.
3D Printed Musical Instruments
Challenges
• Body configuration without flex• CAD files suited for mass-customisations,
aesthetics, neck scale/style, pickups, bridge, electronics, tremolo, etc.
• Colour on SLS
Where to from here?
• Have sold around 30 instruments since July 2012
• Americana won Best in Show at NAMM 2013• Licensed designs to 3D Systems in November
2012. They are now working to take over sales and manufacturing.
• Working on app that allows customer to design their own 3D printed guitars in an intuitive ‘gaming’ style
The Goal“Spore” Guitar Creator online customer co-creation software
Advantage 5: Encouraging Innovation
• The relatively low-cost ability to easily try out ideas generates many innovations that would just not have seen the light of day with conventional manufacturing.
• AM has seen children returning to making things. Where, over the past 20 years, they have slowly drifted into a digital entertainment age, 3D printing is now allowing them to move back from digital into reality.
Beauty and the beak
Miles Lightwood
Innovative Applications
FabCafe in the Shibuya, Tokyo offers custom-printed chocolate, that resemble a customer’s face. It’s done with 3D printing technology
“Eat Your Face Machine” (EYFM) is a 3D printer developed by David Carr and the MIT Media Lab
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May 2013: 3-D Printer Makes A Bionic Ear
The “inks” consisted of hydrogels mixed with calf cells and silver nanoparticles.Michael McAlpine, Princeton University
Baby's Life Saved with 3D Printing
Researchers built a 3D printed device that saved the life of Kaiba Gionfriddo, born with a rare condition, tracheobronchomalacia, that caused life-threatening breathing problems.
polycaprolactone splint, Dr. Glenn Green and Scott Hollister, PhD,
University of Michigan
Prototype engagement ring, in case she says “No”
Innovative use of power sources
Markus Kayser’s “Solar Sinter” 3D printer
And, of course, it was only a matter of time…
The Justin Bieber
Virginia tech’s 3D printing vending machine
The DreamVendor is an interactive 3D printing vending machine for Virginia Tech students to enable them to quickly make prototypes for their academic, or personal, design projects. Insert an SD card with the 3D model into the machine; the DreamVendor then prints your 3D part and dispenses it into a bin when it's finished.
The Challenge: Innovation vs Engineering vs Design
Don’t be stupid! You cant do that…
What do you mean you can’t make it like
this?
Engineer
Designer/Artist
Additive Manufacturing missionary
AM Reporter
Innovation and AM
• Yes! We absolutely need more engineering research into the technical aspects of AM
• Design for AM is fantastic!• But let’s not forget about the innovations
that are often brought about by those who know nothing of the engineering constraints of AM.
• So avoid telling people what cannot be done with AM!
The Catch-22
How do you avoid telling people what cannot be done with AM while, at the same time, dispelling the many myths created by bad reporting, and by us giving people bad advice by telling them that anything can, and should, be made with AM?In other words, Is it time that we now start a much more effective and responsible education program around AM and it’s uses?
The opportunity
Because it crosses all disciplines, from hard-core engineering, to art & design, to social sciences, to business, additive manufacturing gives us an unprecedented opportunity for all disciplines to work in much closer synergy than ever before, and to innovate in an extraordinary manner.
USE IT!