3D Printing in O & P: Foundations

Transcription

1 3D Printing in O & P: Foundation Rick E. Sevier BOCO C.Ped. CPOA Steampunk Bionic Academy Module Objective The objective of thi module i to familiarize the learner with the baic workflow, component, hardware and oftware utilized to fabricate O & P device from conception to delivery utilizing 3D printing Me Rick E. Sevier - Owner Steampunk Bionic Academy / CFS Allied Health Education BS Ed., AAS Orthotic, AAS Prothetic Oklahoma State BOCO, C. Ped., CPOA Uing CAD ince 1983 Teaching CAD/CAM/Engineering ince 1985 pot-econdary Worked for Autodek a Intructor Fmr. Full time CAD Dept Head - De Moine Area CC Advanced Technology Center Fmr. O&P Faculty at OK State 1

2 We do not ell hardware or oftware. Our only product i education! You Several type of learner attend 3D printing lecture The Curiou 3D printing i a curioity Thoe folk are here jut to figure out if there i any viability to it Stay tuned 2

3 The Anxiou 3D printing threaten ome who are good at what they do traditionally Thee folk are here to gather intel for the eemingly inevitable battle againt the machine The Seriou 3D printing i a viable option Thee folk are committed to making thi work, and are here to get a much info a they can take home The Ambitiou Courtey LifeNabled, INC 3D printing i here to tay and we are uing it! Thee are the folk that ee 3D printing a a way to not only upplement their exiting device offering, but to puh thing to the next level through deign and rapid prototyping With 3D printing, you can imagine it in the morning and have it on your patient by afternoon 3

4 and finally The Unconciou What cla i thi? Only another hour of thi guy. Why the hat? Hmmm, that wa kinda cool Wow! Thee are the folk who walk in jut looking for point and walk out a believer 3D Printing The Proce The Proce To truly undertand 3D printing, we have to undertand the PROCESS of 3D printing FIRST 4

5 The Proce Scan CAD CAM 3DP P o t The proce of 3D printing (Additive Manufacturing) i traight forward and hare ome component with CNC (Subtractive Manufacturing) CAM CNC P r o c e i n g The Proce - Scanning Scan CAD CAM 3DP Scanning i the firt tep in the proce of creating a cutom device for the patient Thi i where the initial topographical data i obtained in it raw form Little to no editing i done at thi tage P o t P r o c e i n g The Proce - CAD Scan CAD CAM 3DP The canned data i imported into the CAD (Computer-aided Deign) program Thi i where the canned data i cleaned up by deleting unwanted object (artifact) The canned object i then modified to meet the practitioner pecification and any mechanical component accommodation added P o t P r o c e i n g 5

6 The Proce - CAM Scan CAD CAM 3DP Once the data ha been edited in CAD, it i imported into the CAM (Computer-aided Manufacturing) application Some CAM application are contained within the CAD application Here the CAD data i tranlated from 3D coordinate into machine movement intruction to be read by the 3D printer (or CNC machine) P o t P r o c e i n g The Proce 3D Printing Scan CAD CAM 3DP The machine intruction tranlated from the CAD are read by the 3D printer The 3D printer follow the intruction and create the model layer by layer until complete Note that there may be ome pot-proceing required P o t P r o c e i n g The Proce Scan CAD CAM 3DP So, let take a cloer look at each of thee tep, beginning with canning P o t P r o c e i n g 6

7 Scanner Scanner come in different ize, connectivitie, qualitie, brand and price tag Commercial Scanner Commercial canner are widely available. Mot are eay to ue, reliable and turnkey. Cot i uually omewhere between $2500 and $25,000. There are lower cot alternative that will do the ame job. New Generation Scanner The Structure Senor paired with an Ipad Pro i a great option to expenive canner. The Ipad Pro provide the proceing power and better optic required for quality capture for under $400 (Plu Ipad) 7

8 Homebrew Scanner The Kinect V2, a enor for Xbox One, can be paired with free Kcan oftware, a Microoft Window converter cable, a laptop with a USB 3.0 connection and a mobile cart to create a very functional (although a bit bulky) canner for around $100 (Plu laptop) Scanning There are two type of canner commonly ued in the O & P indutry Laer Structured Light Laer Scanner Laer canner work by ending a laer beam all over the field of view 8

9 Laer Scanner Whenever the laer beam hit a reflective urface, it i reflected back into the direction of the canner, onto a enor Laer Scanner The urface information i aved a group of point in an X, Y and Z coordinate format referred to a a point cloud Infrared / Structured Light Scanner Infrared, or Structured Light 3D Scanner, ue the proce of projecting a known pattern (often grid or horizontal bar) on to a cene 9

10 Infrared / Structured Light Scanner The way that thi pattern deform when triking urface allow viion ytem to calculate the depth and urface information of the object in the cene Infrared / Structured Light Scanner Thi urface information i aved a a point cloud Caveat The caveat to uing either of thee type of canner i that they depend upon the reflectivity of the object being canned, in thi cae, the patient kin, clothe or liner 10

11 Caveat Scanner do not like to work with very dark colored object and material, and a ock or light colored covering may be required Caveat Good room lighting i eential when uing Infrared or Structured Light canning The Point Cloud The point cloud data i generally tored by the canner a one of two file format PLY OBJ 11

12 PLY File PLY i a computer file format principally deigned to tore threedimenional data from 3D canner a X,Y,Z point connected with a triangular meh with no color information tored OBJ File OBJ i a geometry definition file format deigned to tore three-dimenional data a X,Y,Z point connected with a triangular meh The OBJ file can utilize JPEG color capture to map the color image to the meh, thu creating a color can The Proce Scan CAD CAM 3DP P o t The next tep i importing and editing the model in a CAD application Let take a look at the different type of model utilized in O & P along with the two type of CAD application ued to create them P r o c e i n g 12

13 Type of CAD Modelling There are three type of CAD model that are utilized in O & P Organic Mechanical Hybrid Organic Model Organic model deign contain only modified organic can data, with no mechanical deign component Example would be Foot Orthotic, Scoli Jacket and Tet Socket Mechanical Model Mechanical model deign contain only mechanical deign without organic integration Example would be Knee Joint, Ankle Joint and Halo Ring 13

14 Hybrid Model Hybrid model deign contain mechanical component integrated with organic deign Example would be Socket with mechanical component attached, or integrated, and articulated orthotic Two Type of CAD Application There are two type of CAD application ued by O & P profeional O & P Specific CAD Solid Modelling O & P Specific CAD Pleae viit our O & P pecific CAD vendor in the exhibit hall There are everal different O & P pecific CAD application available to the O & P practitioner, with more available every day 14

15 O & P Specific CAD Thee CAD application are deigned to do a pecific tak: Produce ready-to-fabricate mold and final device ready to 3D print or CNC mill O & P Specific CAD O & P Specific CAD application provide a turnkey olution for buy practice, and are reaonably eay to learn and ue O & P Specific CAD Thee turnkey olution uually come with a ubtantial initial price tag, along with training and yearly maintenance fee 15

16 O & P Specific CAD Although they do what they were deigned to do, that i all they do They do have limit O & P Specific CAD An example of a familiar indutry pecific type of CAD program i the Deck Deigner application available online at your home improvement tore webite O & P Specific CAD Ye, it i great to deign your deck with, but it waffle when you try to integrate your Texa haped hot tub into the deign. Why? It jut not deigned to do nonnormal tak like that Plu it jut wrong 16

17 A Thought Don t get me wrong here I think thee O & P Specific CAD application are a great olution! Nextgen Deign I jut think that we, a practitioner, need to have ALL of the tool in our toolbox to allow u to deign and create well anything innovative and novel that help our patient achieve their peronal bet That bring u to Solid Modelling application Solid Modelling Solid Modelling application have all of the tool that allow u to deign everything that O&P pecific CAD doe and much more! 17

18 Solid Modelling There are two type of olid modelling application Organic Meh Modeller Parametric Deign (Mechanical/Hybrid) Organic Meh Modeller Organic Meh Modelling i the cloet thing to working in plater Organic Meh Modeller It ue culpting tool to make change to the model 18

19 Mehmixer One meh modelling application in O & P i Mehmixer by Autodek Mehmixer It i free for download at Autodek webite Mehmixer Ye free 19

20 Mehmixer So, what the catch? Yup there are a couple Mehmixer Mehmixer wa not developed to be a dedicated O & P application It i an R&D andbox for the Maker community to tet function for pay-me application Lucky u! Mehmixer It WAS developed to deign little evil bunnie What i funny i that many of you can ee a hint of prothetic fairing and colioi jacket in them bunnie I did 20

21 Mehmixer I and other took the time to coax O&P deign out of them little evil bunnie Mehmixer Did I mention it free Mehmixer Since it i free, upport i motly limited to uer group and Autodek employee that monitor them Uer number in the million Worldwide Many of their name begin with Dr 21

22 Mehmixer Demo So, let take a quick look at Mehmixer jut to get your feet wet Mehmixer In our Workhop, during the next eion, we are going to do a live can and do an FO and a BK ocket Parametric Solid Modelling Next we are going to look at Parametric Solid Modelling ued to create mechanical component a well a hybrid organic/machine fuion Credit: Georgia Tech 22

23 Parametric Solid Modelling Parametric Solid Modelling application are commonly ued to deign mechanical component in variou indutrie Parametric Solid Modelling The term Solid Modelling i what it ound like: Creating three dimenional model in an electronic format Parametric Solid Modelling What make thi intriguing to mot, i the olid part of that decription 23

24 Parametric Solid Modelling Solid implie an object with ma, material characteritic and the ability to analyze thoe characteritic in variou ituation Parametric Solid Modelling With Parametric Solid Modelling, we can create intelligent component and even more exciting, aemblie that we can analyze Parametric Solid Modelling Then there i that peky Parametric 24

25 Parametric Solid Modelling Parametric imply mean dimenionally driven Parametric Solid Modelling Every feature of every component ha information attached to it, including dimenion Parametric Solid Modelling If you change a dimenion, the volume and ma of the object change That i Parametric Solid Modelling 25

26 Parametric Solid Modelling Thi make it uper eay to create a one-ize-fit-all becaue it can be intelligently caled up or down, maintaining hole ize for hardware, etc Parametric Solid Modelling There are a couple of well known Parametric Solid Modelling application out there Catia ($65K plu $6500 / Year) Solidwork ($5000 / Year) Fuion 360 ($300 / Year) Other Choice We tried lot of other CAD application to ee if they could be adapted to O & P, but did not get the reult we were after 26

27 Fuion 360 We choe Fuion 360 becaue it work o well with Mehmixer, both being Autodek product Fuion 360 So, the quetion I get mot often i What all can I deign in Fuion 360? Fuion 360 Short anwer i Ye The long anwer i A long a it i not a liquid or ga, you can deign it in Fuion

28 Fuion 360 The Fuion in Fuion 360 mean to fue mechanical deign with free flowing organic topology, not omething that traditional CAD application can do Fuion 360 Thi made it a perfect choice to ee if it could be adapted to O & P Fuion Demo So, let take Fuion 360 for a quick pin around the block 28

29 Fuion 360 A you can ee, Fuion 360 i pretty eay to ue once you get a feel for it That one of the reaon why we choe to teach it Review of Deign I know we pent a lot of time here, but a good deign i the mot important apect of 3D printing Bad deign i jut bad Getting Ready to 3D Print After we have our deign where we want it, we need to export the file to a CAM application 29

30 Getting Ready to 3D Print The format that we ue to do thi i called an STL file Getting Ready to 3D Print STL, or Stereo Lithography, i a file format native to CAD oftware It ha become the univeral CAD format for tranferring between different CAD ytem Getting Ready to 3D Print STL file contain all of the information to rebuild your deign from X,Y,Z coordinate, a one big 3D object 30

31 Getting Ready to 3D Print Therefore, we need to have an application that can take our deign and lice it into the layer needed, add the appropriate parameter for material need and output it in a language that the 3D printer undertand Getting Ready to 3D Print The application that doe thi for u i generically referred to a the CAM application But the cool kid call it the Slicer The Proce Scan CAD CAM 3DP The next tep i importing the STL file into the CAM application There are both free and commercial CAM application available P o t P r o c e i n g 31

32 The Slicer The licer take the STL file and tranlate the 3D model into individual layer The Slicer The Slicer then generate the machine code that the printer will ue for printing Thi code i formatted a GCODE, a common machine code format ued by CNC milling machine and 3D printer The Slicer The licer application alo allow the uer to calibrate variou printer etting Let take a look at thee 32

33 Material Material etting include peed and temperature We have many material to chooe from in O & P and each ha it own unique etting We will talk more about pecific material in the afternoon eion Quality / Layer Height Think of layer height a the reolution of your print Thi etting pecifie the height of each filament layer in your print Shell / Wall Thickne Shell or wall thickne refer to the number of time the outer wall of the deign are traced by the 3D printer before tarting the hollow inner ection of the deign It i one of the factor that determine trength 33

34 Infill Denity Infill refer to the denity of the pace inide the outer hell of an object The higher the percentage of infill, the tronger and more rigid the object will be, and the more time and filament it will take to print Infill Pattern Infill pattern et the geometric pattern to be ued a infill, from linear to full honeycomb More complex pattern take longer, but are tronger Raft A Raft i a horizontal grid that i printed under the object that act a a platform to tick to the bed and build on top of It i eaily removed from the print after completion 34

35 Support Support are tructure that help hold up 3D object that don t have enough bae material to build off of a they are being printed Support Since object are printed in layer, part of an object that extend pat a 45 degree angle will have nothing for the firt layer of filament to build on Thi i referred to a the 45 degree rule Support Some licer automatically place upport, not allowing you to edit quantity or placement 35

36 Support Only one Slicer allow you to edit placement and quantity of upport Simplify3D ($150) Simplify3D When dealing with organic hape like we do, we need the ability to upport the hape at will Simplify3D - Demo So, let take a quick look at Simplify3D 36

37 Next So, now that we have a liced deign, and G-Code ready to go to the printer, let get it et up The Proce Scan CAD CAM 3DP The next tep i etting up the 3D printer to print and ending the G-Code file to the 3D printer P o t P r o c e i n g Fued Depoition Modeling Fued Depoition Modeling (FDM) 3D printer are currently the mot commonly ued type in the O & P community becaue of availability and cot 37

38 Fued Depoition Modeling With FDM technology, the 3-D printer i eentially acting a a very precie hot-glue gun Fued Depoition Modeling It fabricate the device by extruding a thermoplatic material through a heated nozzle onto a flat urface, where the material then cool and harden again Fued Depoition Modeling The nozzle ha the ability to move in the X, Y and Z direction, allowing for the creation of a 3-D object 38

39 Fued Depoition Modeling The reult i a finihed device, fabricated layer by layer More later We will take a cloer look at thi thi afternoon Next, let cloe thi by looking at a quick 3D printer etup procedure Powering On With the power off, make ure that the print bed i clean and all mechanical component are in good repair Power on the printer 39

40 Control 3D printer can be controlled through a mall on-board control creen or through the Slicer application and a USB interface to the PC Select Filament The filament that wa pecified in the Slicer hould be elected Loading Filament Load the filament per the 3D printer intruction Thi often require preheating the extruder head 40

41 Preparing the Print Bed Depending on the material to be printed, the bed can be prepared with the following: Gla bed can be left clean and empty Blue Painter Tape Aquanet Hairpray Kapton Tape Purple Glue Stick Levelling the Print Bed Depending upon the printer capabilitie, the print bed hould be manually levelled, or the Auto-level routine run G-Code Tranfer G-Code file can be tranferred directly to the 3D printer via memory card, or directly through the Slicer and USB connection 41

42 Click Print Once the G-Code i loaded, the lat tep i to hit PRINT and watch the action A few hour later Thi can be the mot enjoyable, rewarding moment or not. 42

43 3D Printing I tell all of my tudent The hardet thing about 3D printing i 3D printing 3D Printing We will talk, in-depth, about the 3D printing component of the proce, and bet practice for O & P, in our 3:15-4:30 dicuion: Material, Machine and Method Summary The objective of thi module wa to familiarize the learner with the baic workflow, component, hardware and oftware utilized to fabricate O & P device from conception to delivery utilizing 3D printing 43

44 Next Seion: Workhop 1:30 3:00 Workhop: We will do ome 3D printing, along with ome canning and deign of an FO and a BK ocket with lock 3:15-4:30 Dicuion: Material, Machine and Method What work, What hot and not 4:30-5:30 Roundtable with the Expert Pleae join u! 44