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1 Download slides at TEST SLIDE Is this text readable in the back? Are the corner dots visible?

2 ITERATING FASTER WITH A 3D PRINTER More of a 3d printing overview

3 SLIDES WILL BE ON MY BLOG

4 Q'S FOR AUDIENCE Have you watched a 3d printer work? Can you handle millimeters?

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6 I made these SB STARTUP WEEKEND TROPHIES 2014

7 VIRTUAL REALITY DISPLAY USING IPAD MINI My first 3d printing based project Completed before the delivery for the Oculus Rift

8 Another dumb project of mine The ratchet locks the screen in place so the motor can be turned off.

9 Santa Barbara Hackerspace is a Non-Profit to help educate the community and help them build stuff. Members can use the space, wifi and tools including 2 FDM 3d printers, laser cutter, electronics bench and more. We re open to everyone on Saturday afternoons after 2PM so stop by and see what we re working on or ask us questions.

10 ZAR PLOTTER Early Prototype Notice the motors hose clamped down to a board.

11 ZAR PLOTTER DRAWING BANNER

12 RANDY SZARZYNSKI

13 SUBTRACTIVE MANUFACTURING Make a part by removing (subtracting) material Nobody calls it that.

14 SUBTRACTIVE ShopBot Desktop at Crash Space in Culver City

15 This part shows up later

16 ADDITIVE MANUFACTURING Build up part by adding material Video is time lapse of Zortrax M200 print starting

17 CAN'T MILL THIS Herringbone planetary gear skateboard wheels Yes I know these are a dumb idea.

18 Download slides at UV SENSITIVE RESIN PRINTING Selectively cure layers of resin, using laser or DLP projector Little RP Form Labs many more

19 [pre-release machine shown] [projector not shown] ENTRY LEVEL RESIN PRINTER KITS $800 INCLUDING THE PROJECTOR LittleRP

20 Super high detail Limited build volume Expensive material ($90/liter or more)

21 Download slides at SLS (LASER SINTERING) On each layer, spread a new layer of powder, and selectively melt it with laser or heat. Various materials and costs: Nylon is cheaper, machine costs [lots] Metals like titanium are possible but machines would cost over $500,000 Video introduction to nylon SLS printer The patent covering this is about to, or just expired so things are going to get fun here.

22 SLS INTRODUCTION Clip by Solid Concepts Video clip from Solid Concepts (now Stratasys)

23 SLS RESULTS Raw (grainy) or Sanded (Shapeways Strong and Flexible) Layers are.12mm SLS patents have started expiring so others will start making these machines

24 Download slides at NO "STANDARD" METAL PRINTING PROCESS Do lost-wax casting from resin, plastic, or jet process print Glue metal powder together, move into bed of sand, then use as mold Laser welding then post-machining Standard welding then post-machining [Glued metal powder casting process video] Also additive laser welding

25 FDM is a Stratasys trademark FUSED DEPOSITION MODELING (FDM) / FUSED FILAMENT FABRICATION (FFF) Draw part by drawing lines of plastic layer by layer

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28 answered in future slides WHY ARE 3D PRINTERS A POPULAR THING NOW?

29 REPRAP PROJECT Make a machine that replicates itself when supplied raw materials

30 OPEN SOURCE

31 Download slides at TYPICAL OPEN SOURCE LICENSE You can use this and create derivatives as long as: You make the source files available for others to build on. And your derivative works are also available under the terms of this license Paraphrased GPL Available means include them with your copy or have a process to get them for the cost of media and postage

32 FEBRUARY 2008 DARWIN First model to replicate it s major parts University of Bath (England)

33 OCTOBER 2009 MENDEL

34 MAKERBOT CUPCAKE April 2009 Photo by Bre Pettis (Founder of MakerBot) Wow this thing is terrible. Repeating wobble due to riding on Z threaded rods which aren t straight. Motors VERY loud because current/voltage is wrong. Extruder calibration is nearly impossible because it s driving a DC motor without an encoder. Later models had a stepper driven extruder. You can yell over one. Here s the SB hackerspace s printing Photo by Bre Pettis CC-BY 2.0

35 MAKERBOT REPLICATOR January

36 MAKERBOT REPLICATOR 2 September 2012 End of open source updates from MakerBot, likely in response to clones.

37 Hey look, a MakerBot clone. NOW

38 Download slides at CONSUMER FDM/FFF MATERIALS PLA ABS PET variants Nylon

39 Download slides at CONSUMER FANCY FDM/FFF MATERIALS Co-Polyester-based plastics Flexible Urethane based plastic (Ninjaflex) PLA with metal powder (Bronze, Copper, Iron, Stainless)

40 Download slides at EXOTIC FDM/FFF MATERIALS These require higher temperature nozzle, and a controlled temperature chamber. Polycarbonate (Print 300 C in 100 C chamber) PEEK (About 350 C nozzle in 100 C chamber)

41 HEATED BED Lulzbot TAZ 5 printing HIPS on 110 C bed

42 WITHOUT SUPPORT MATERIAL This is one of our most successful makerbot cupcake prints. Yes I know it looks terrible.

43 SUPPORT MATERIAL (REMOVABLE)

44 Support removed in left photo, sitting behind part. Lower right photo shows interior of object is hollow.

45 SUPPORT MATERIAL (DISSOLVABLE) PLA dissolves PLA caustic soda in ultrasonic water bath HIPS: Dissolve HIPS with Limonene PVA: Dissolve PVA in water Pictured: HIPS (White) support ABS (Black) print material Print is the comet the Rosetta space probe landed on.

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47 Create a plaster mold around the original 3d printed part, with vent and pour inlet Burn/melt out printed material Pour in molten metal When cool, brake plaster to get part. Then trim spout+vents and polish. This perfectly replicated our print defects.

48 Download slides at TYPICAL PRINTING WORKFLOW Design in a computer, export STL file Load STL file in "Slicer" to generate g-code. Choose options like layer height, fill density, and support material. Send g-code to printer to print file.

49 CAD or whatever Export STL Load into Slicer and nearly instantly get result

50 OPTIONS Only really need two of these Support material on/off is about the only setting I change If I m switching between printing strong parts and ones that look good, I may change shell thickness and layer height

51 Download slides at DESIGN APPROACHES Solidworks, OnShape or other solid modeling packages Sculpting 3d Scanning

52 Download slides at DESIGN CONSTRAINTS Solids Thin features Thin walls Overhangs Shapeways description pages do a good job of describing each of these but I don t want to read you the material pages for a full hour.

53 OVERHANGS Nice beard

54 NON-MANIFOLD Usually the opposite of Watertight I expect this was intended for video games where the inside of the car didn t need to be solid.

55 CURA (SLICER) TRIES ITS BEST

56 CURA X-RAY PREVIEW Highlights problems in red

57 Download slides at TOLERANCES (CHEAP FDM/ FFF MACHINES) Small holes tend to be 0.4mm too small in diameter. Outer shapes tend to be 0.2mm too large Layer heights of mm are typical

58 Download slides at FDM LIMITATIONS Temperature for printed part. PLA gets soft at 65 C (149 F) Strength and durability isn t as good as molded or metal Parts weaker between layers then along their length

59 Download slides at PRINTING SPEED Typical speed of moving print head is 30mm-80mm/sec ( inches per minute) Typical layer height 0.1mm-0.3mm A part 4 inches long, 2 inches wide, and 1 inch tall may print in 2-6 hours.

60 PRINTING FASTER Increasing federate has limits: Melting plastic Under extrusion (from )

61 MOVING FASTER IS HARD Mechanics can only look nice moving so fast

62 INFILL DENSITY To reduce print time and required materials, objects are not printed solid. I m told stratasys doesn t let you adjust this :-(

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64 PRINTING FASTER There are heaters/nozzles for extruding plastic at a higher volume for thicker layers e3d volcano

65 Don t need to print EVERYTHING if you have other tools. Laser cut reel holder Mixed Laser/plastic VESA mount for tablet

66 "WIRE" PRINT

67 Don t try this. PRINTED PARTS ARE NOT FOR EVERYTHING

68 BRAKE CALIPERS PRESS HARD The gray part was also 3d printed Both lime and gray parts are 3d printed. The car was not moved while these brake pads were installed.

69 ZORTRAX M200 $ x200x180mm build volume Slow but good prints

70 LULZBOT TAZ 5 $ x725x250mm build volume Fully open source machine, prints well

71 "REQUEST A QUOTE" Hobbyists need not apply Screenshot is

72 STRATASYS MOJO

73 MOJO Approximately $5000 Soluble support by default $250/kilogram spools of plastic and support 127x127x127mm build volume Spools are probably $200/44 cubic inches The comparison $250/kilogram compares to reputable consumer suppliers selling ABS or PLA for $30/kilogram

74 UPRINT SE PLUS $22,000 Machine 203x152x152mm build volume Soluble Support by default price from

75 SHAPEWAYS Most approachable 3d print service

76 Strong & Flexible Nylon round trip time is about 2 weeks AUTOMATED INSTANT QUOTE

77 There are some edges highlighted in yellow for being where the part is too thin WEB BASED ERROR DISPLAY

78 LOTS OF MATERIALS

79 Download slides at PRINTING SERVICES Shapeways i.materialise Stratasys Direct 3d Systems:

80 Download slides at MORE LOCAL, POTENTIALLY FASTER TURN AROUND I haven t tried these but: Go Engineer has office in SB, offers FDM printing services Stratasys Direct (formerly Solid Concepts) has office in Valencia Steve Bond Design in Camarillo FDM Hollywood FDM, SLA resin or wax (detail) Gardena Resin or FDM Request a quote means not in my hobbyist budget so I haven't tried any of these

81 Download slides at MORE Los Angeles, range of materials from resin to metal Los Angeles resin-based materials that act like plastics Los Angeles for jewelry masters Los Angeles full color gypsum (not durable) Irvine Resin (polyjet) or FDM

82 BONUS SLIDES

83 3D SCANNING

84 PARALLAX FROM LINE LASER ($3000 NEXTENGINE) more links, photos, videos on

85 PHOTOGRAMMETRY ($180 PHOTOSCAN, FREE 123D CATCH) phtoscan: 123d catch: Image above from 123d catch video, doesn't show software in use but shows how to arrange photos:

86 STRUCTURE SENSOR ($380) Reconstruct the world using a Primesense Depth Camera Picture is screenshot of scanning using Skanect from

87 3D SCANNING PREP Get rid of glossy parts of what you intend to scan Unscented might be better.

88 source: REMOVE EXTRA SCANNED MATERIAL

89 FILL HOLES

90 WHY STEPPER MOTORS IN 2016? (MakerBot Mini)

91 because they re cheap These are the one-of prices on

92 GOING VERTICAL

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96 3D PRINTED VUVUZELA 3d Printed Vuvuzela for if you missed during the 2010 South Africa World Cup