Wednesday, 2 December 2015

Top 4 Reasons to Use 3D Printing Services

If your business needs 3D printed or additive manufactured parts. You have two options: invest in 3D printing equipment or order parts through a 3D printing service provider. Each has its benefits, and often companies will use both for different reasons. In a recent Stratasys survey of 700 professional 3D printing users, we examined the top reasons why companies outsource 3D printing, top benefits of having 3D printers in-house, what processes they would want to outsource and what processes they plan to take in-house.



The most common responses to the benefits of outsourcing 3D printing to a service provider were:

Access to advanced equipment and materials
Over the last few years 3D printing service providers have evolved from rapid prototyping with a few plastic 3D printing technologies to contract manufacturing with a broader service offering. Customers don’t just need plastics anymore; their 3D printing applications have evolved. They need a wide variety of materials from rigid and elastomeric plastics to metals and alloys, 3D printing processes, finishing services and assembly—all under one roof—and don’t have the budget or expertise to take those operations in-house.

Less investment risk
Investing in 3D printing equipment isn’t just a matter of buying equipment, plugging it in and pressing print. It involves investments in training staff, setting up software, maintenance, purchasing consumables (meaning material, print heads, etc.) and even disruptions in overall operations. With such a big investment, you may want to try 3D printing out first and take meditative steps – that’s where 3D printing service providers come in.

Produce parts not able to be manufactured internally
3D printing and manufacturing services can be a great complement to in-house operations. 3D printer owners will often come to Objective3D Service Bureau to try a new materials or process they don’t have in-house. Or conventional manufacturing equipment owners will come to Objective3D Service Bureau for custom 3D printed tooling, jigs and fixtures to improve efficiency on the manufacturing floor.

Access to expertise
Learning how to design for the various 3D printing technologies doesn’t happen overnight and getting it right takes practice. 3D printing service providers have experience working with multiple industries and applications and have developed process controls and a wealth of tribal knowledge to share with customers. One of the main reasons customers order parts through Objective3D Service Bureau is our seasoned project engineers and their expertise in formatting design files for additive manufacturing.

The Stratasys survey also found companies are especially attracted to outsourcing technologies that require more post processing and supplemental equipment, particularly Direct Metal Laser Sintering and Laser Sintering. Overall respondents indicated outsourcing part production is valued as a way to minimize risk and compensate for resources or expertise that doesn’t exist internally.

Australian and New Zealand companies are choosing to work with Objective3D Service Bureau not because they have to, but because they want to. Not only does outsourcing help companies meet production shortfalls, but service providers may have experience with a company’s application type and may be better suited to help them realize additive manufacturing’s full potential. The interest in ongoing access to expertise, spanning across the entire spectrum of product development and technology adoption, helps explain why survey respondents expressed interest in working with service providers even after they’ve purchased additive manufacturing equipment.

It’s an exciting time to be in this challenging and rewarding industry. While the future holds incredible potential, the expanded adoption of 3D printing for end-use parts does not happen in the blink of an eye—it happens one application at a time. It’s our job to take your amazing new ideas for products and technologies and champion them into real applications, one-by-one, by identifying ways 3D printing can bring them to life faster and easier. While it doesn’t happen overnight, it’s something we at Objective3D Service Bureau are uniquely and exceptionally good at. We get to know each part and project at a level that transcends the customer’s company or industry needs, allowing us to create unique solutions using a variety of tools.

Download the full report to find more reasons to use 3D printing services.

The Objective3D Service Bureau is certified ISO 9001:2008 compliant and is powered by Stratasys Direct Manufacturing with 16 commercial grade machines providing the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions. With more than 1500 orders received and over 100,000 parts produced annually, Objective3D Service Bureau is helping companies in diverse industries create extraordinary new products at every phase of the production process.

Have parts to build? Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

7 Questions to Ask Yourself When Choosing a 3D Printing Technology and Material

Additive metals, laser sintering, extruded filament, powdered plastics, alloys, photopolymers – the list goes on and on. Today there are a plethora of 3D printing processes and materials to choose from and it’s only growing. The dynamic additive manufacturing market is often difficult to navigate, especially if you’re still learning about the processes. At the Objective3D Service Bureau, our project and applications engineers try to learn as much as they can about customer’s part application to accurately guide them to the best technology and materials. To help you start to filter out certain processes and materials, we put together a selection methodology:




Application – What is the purpose of the end product? You may need to build a small volume of complex end-use parts which would require strong materials, dimensional accuracy and repeatability. Whereas a sacrificial investment casting pattern is one-time use and needs to burnout clean.

Function – What does the part need to do? It may just serve aesthetic purposes in which it just needs to look and feel like an end-use part. Or perhaps you have a hard-working part that needs to hinge, snap, or bear a load which requires an accurate process and stronger materials.

Stability – Where does the part need to function? For example, holding up and maintaining strength in high temperatures rules out a lot of processes and materials. Does it need to function outdoors? In that case you would need a UV-stable material. Will the part interact with the human body? Then your application requires a bio-compatible material.

Durability – How long does the part need to last? Consider the number of use cycles and the application duration. For example, a mold or tool may need to go through hundreds of cycles and prolonged friction, but may only need to last a week for prototyping. Some 3D printing materials are very functional over a short period of time and others can maintain mechanical properties for years.

Aesthetics – How does the part need to look and feel? Photopolymer processes, such Stereolithography (SL) and PolyJet, can produce smooth parts right off of the machine, but aren’t the most stable and durable materials. While thermoplastic and powdered plastic processes like Laser Sintering (LS) and Fused Deposition Modeling (FDM) can create stronger and more durable parts, they often require finishing processes to achieve a smooth surface.

Economics – What is your budget and timeline? If you have a set budget and need to get a part for X amount, then your decision will weigh on price more than value. Time and quality can often contradict one another as well – if you need a quick-turnaround, it may be at the expense of a certain level of quality. However we have found ways to reduce lead time and cost without sacrificing quality, including batching, nesting, scaling, sectioning, shelling, ID-Light builds and adjusting orientation to reduce material consumption.

Priorities – What is the most important decision-making factor? Consider the primary objective and ultimate project goals. Often there are multiple, but your main priorities should drive your decision tree and filter the 3D printing technology and material options.

Choosing the right additive manufacturing technology and material for your application is critical to part performance and results. The main thing to remember is “one-size-fits-all” doesn’t apply to additive manufacturing. It’s imperative to know the pros and cons of each process and material or partner with an expert who does. Asking yourself these qualifying questions will help you start to navigate the dynamic market.

Download our latest white paper to gain more in-depth knowledge on 3D printing material selection.

Direct 3D Printing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre is powered by Stratasys Direct Manufacturing with 16 commercial grade machines providing the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions. With more than 1500 orders received and over 100,000 parts produced in a year, Objective3D Service Bureau is helping companies in diverse industries create extraordinary new products at every phase of the production process. 

Have parts to build? Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Tuesday, 17 November 2015

The New Face of Advanced Manufacturing


Objective3D Service Bureau is transforming the manufacturing landscape through revolutionary 3D printing and custom manufacturing solutions that allow organizations to innovate rapidly, move to market quickly, and compete in a dynamically changing world.


Powered by Stratasys Direct Manufacturing, we cemented ourselves as a powerful technology leader, encouraging designers and engineers to challenge conventional approaches to manufacturing. Additive manufacturing allows for new approaches to design—something our team of engineers has spent more than a decade perfecting.


With 16 commercial grade machines providing the widest range of 3D printing technologies and materials and together with the help of our manufacturing capabilities and expertise, our customers are able to produce complex designs, previously impossible via conventional manufacturing methods, which in turn result in more advanced and higher performing products.


With more than 1500 orders received and over 100,000 parts produced in a year, Objective3D Service Bureau is helping companies in diverse industries create extraordinary new products at every phase of the production process. Our dedicated engineers are experts in their fields, from aerospace and medical to consumer products and entertainment. 




Contact us today at 03-9785 2333 (AUS)  09-801 0380 (NZ) to learn how you can empower your business with 3D printing and advanced manufacturing solutions. Alternatively, try out our INSTANT ONLINE QUOTING SYSTEM.



Tuesday, 10 November 2015

Canberra para-athlete Scott Reardon wins gold with 3D Printed Spike Plates

Canberra para-athlete Scott Reardon has sprinted his way to gold at the IPC Athletics World Championships in Doha with victory in the T42 100m for leg amputees.


The fastest qualifier coming into the finals, Reardon, using a 3D Printed Spike Plate, got his nose in front to stop the clock in a time of 12.13 seconds - a mere one-hundredth of a second in front of Russia's Anton Prokhorov.

It was sweet revenge for Reardon, the 25-year-old having to share the gold medal two years ago at the world championships in Lyon in 2013 with Germany's Heinrich Popow​.

"You come to championships to win championships and that's the most important thing," Reardon said.

"I probably didn't get the time I wanted, but when people look back, how I got there won't matter.
"It will just show me as world champion, and that's so exciting."

The result is the culmination of more than a decade of determination and training.


The Spike Plates which Reardon used in the Championships were 3D printed by Objective3D Service Bureau. This was made possible when Matthew Crawford from the the Australian Institute of Sport (AIS) approached Objectvie3D in search of a solution for their Paralympic athletes. 

According to Hugh Tevelein, Operations Manager at Objective3D, "We were able to use our Objet Connex3 to print a rubber like spike pad with PP like spikes using Endur material, although through testing we quickly found the rubber was tearing away from the Endur spikes under load while running. We needed a hard plastic that was able to withstand a small amount of flex without fracturing. We printed a whole spike pad using the Endur material which worked a treat, just enough flex while maintaining excellent impact resistance. We have since also printed spike plates in Digital ABS material on the Objet printer as well as Nylon printed plates from our EOS SLS machine. For the world championships Scott took away three different plates to see what worked best in the conditions."


  
"16 commercial grade machines and a broad range of material combinations readily available at Objectvie3D Service Bureau allowed for a smooth Research and Development process which provided a definite advantage in determining what worked and felt the best for Scott."


In 2002, Reardon severed his right leg through the knee when his shoelace caught in the power take off shaft of a tractor.

He spent a month in hospital recovering and amazed doctors by re-learning to walk in just one week.

Reardon continued to water-ski on one leg, representing Australia three times at the water-skiing world championships and winning the world title twice in 2007 and 2009.

He attended a Paralympic Talent Search day in 2006 and was immediately identified as having the potential to run on the track at the London 2012 Paralympic Games.

Reardon won a silver in the 100m at the London Games and narrowly missed a medal in the 200m, finishing fourth, spurring him on to next year's Paralympic Games in Rio.

"I train my backside off to achieve the best," Reardon said.

"This is just a motivator for even more.

"The standard out there was crazy.

"Two of the faster guys in this event couldn't be here, but everybody else really stood up and made the race a challenge for us toward the front.

"I want to take the next step and believe that I can do that, break the 12-second barrier, and hopefully become a Paralympic champion."

After juggling water skiing and athletics for a while, Reardon - who hails from Temora in country NSW - moved to Canberra in 2009 to train at the AIS and focus on his athletics career.

At the AIS, he trained alongside his sporting heroes, former track star and gold medallist Heath Francis and gold medallist and world record holder Evan O'Hanlon.

Direct 3D Printing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.direct3dprinting.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

News Source: Sydney Morning Herald




Tuesday, 27 October 2015

Scientists invent antimicrobial 3D printing material that can kill 99% of bacteria

The 3D printed plastic material that can kill 99% of bacteria could revolutionise dental implants

Scientists from the University of Groningen in the Netherlands have invented a type of 3D printed plastic that can kill 99% of bacteria that touches it, which could pave the way for a multitude of medical, dental, food hygiene and child safety applications.

The researchers took the dental resin polymers that are used to make artificial teeth implants and embedded antimicrobial quaternary ammonium salts inside the polymers. The salts are positively charged, which causes negatively charged bacterial membranes to burst and die.

The polymer was then put into a 3D printer and used to print out a range of dental items, including replacement teeth implants and orthodontic braces, with the objects hardened using ultraviolet light.

When the objects were coated in a mix of saliva and Streptococcus mutans, the bacterium that causes tooth decay, the researchers found that the new material was able to kill over 99% of the bacteria, whereas the dental resin polymer on its own could only kill 1% of bacteria.

Teeth implants are expensive and just like with real teeth, bacteria can cause a great deal of damage to false teeth and infect the gums and teeth around the implants. But this problem could become a thing of the past using antimicrobial plastic.

For now, the material is still being tested, as the experiments only tested the effects of the saliva and bacteria on dental samples coated with the mix over a period of six days, and the researchers have yet to ascertain whether the material is compatible with toothpaste.

However, once the material is conclusively tested, as dental resin is already considered to be safe for humans, the new material could be used in a wide range of non-dental applications – such as for children's toys, to improve food packaging or in water purification.

Stratasys 3D Printers and Materials are available in Australia and New Zealand from Objective3D, a complete 3D Printing Solutions provider. From 3D Printers, 3D Parts, 3D Scanners including Printer Maintenance services and consumables for Stratasys 3D printers, Objective3D is the largest distributor of Stratasys 3D Printers across Australia and New Zealand, and were recently awarded the Stratasys Customer Satisfaction and Support Award for 2013 for the Asia Pacific region. 

Objective3D is also a total solutions provider of 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

For more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ) or try out our INSTANT ONLINE QUOTING SYSTEM if you have need a 3D Part Printed.



The future of digital dental technology

Matthew Garnett, owner and MD of Merseyside-based orthodontic dental laboratory, Thermadent Ltd, has something to say about the future of digital dental technology.



"Let's get digital..."

Matthew has 25 years experience in dental technology, beginning as an apprentice in 1990. he went on to Liverpool Community College where he qualified in 1996 with distinctions and won the "Student of the Year Award for Excellence" in dental technology. His passion for perfection remains undimmed and he believes we must never rest on our laurels.

Before launching Thermadent in 2011 he worked in a number of laboratories right across the North West as an orthodontic technician, gathering valuable experience in all aspects of the craft. He took a lot of pride in his work and he made every appliance to the best of his ability, preparing each one as if it was for one of his own children. This level of commitment runs through the work of every member of the Thermadent team and is at the core of their success, that and their willingness to invest in the best, cutting edge technology.

Thanks to strong client recommendations our client list increased rapidly over the first few months after opening. As a result the Thermadent team had to move to bigger and better premises and increase staff levels. Now, as an established and well known orthodontic laboratory, it employs 10 staff and have plans to expand to new premises within the near future.

Since February 2014, NHS Dental Services has been requesting that the submissions of pre-treatment and post-treatment study models be submitted digitally. In a nutshell this means that instead of submitting the actual plaster models for your completed cases, you now need to submit digital scan files instead.

Because of this Matthew felt he needed to invest in a digital scanner to ensure he could service all his clients’ needs and he can now convert all plaster study models to 3D digital models, which makes a lot of sense for many orthodontic practices. As any technician knows all too well, plaster study models are bulky and can be difficult to store. They can also become mislaid and broken, and sometimes, if stored in damp environments, they can even become mouldy and unusable. It is old technology and Matthew felt it was time for change.

Using 3D digital study models means there’s no longer any need to store the physical study models − and he no longer need to worry about plaster model disposal, which can be costly and time expensive. What’s more, thanks to new GDC regulations, every orthodontic practice now has to keep a record of each patient’s tooth movement indefinitely. To store each patient’s physical plaster study models would quickly become an impossibility. Think of the cost for one thing, that and the fact that over a period of time, plaster study models will begin to decompose. With digital study models all you need is a safe, secure place to store the CD’s that contain the files.

Why choose an Objet30 OrthoDesk 3D printer?
Once we had the scanner in place Matthew thought it would make sense to move into the clear aligners sector because he was halfway there already. However, this move would mean he would now have to invest in a 3D digital printer. Thinking things through he realised that any investments in digital technology now will help drive Thermadent’s success in the very near future. His aim has been to not only provide clients with a fully digital service regarding study models, but also to create a product to rival the leading clear aligner manufacturers. He studied the 3D print market and plumped for an Objet30 OrthoDesk printer.

Stratasys Reseller in the UK helped Matthew decide which 3D printer was best for his needs thanks to their informed and impartial advice. Their help with installation and integration of the new machine with his existing equipment meant he could get on with the training they provided straight away, which reduced set-up time for the new Objet30 to an absolute minimum. They provided a first-class service all round.

Thanks to the precise tolerances and extreme accuracy provided by the Objet30 printer (28 microns detail, much better than other leading printers) our aligners are more accurate and provide a much better fit. Using the printer in-house also reduces lead times significantly. There is also a greatly reduced environmental impact compared to traditional and alternative CAD/CAM methods because the printing process produces a lot less waste.

The Objet30 is the first 3D printer of its kind, combining supreme accuracy with a surprisingly small footprint. It is easy to use, and includes specialized dental printing materials in convenient sealed cartridges. Using this new desktop model, and thanks to its patented PolyJet 3D printing technology, the Thermadent team can fabricate orthodontic appliances, delivery and positioning trays, models for clear aligners, retainers and surgical guides − with predictably consistent, high quality outcomes every time.

The Objet30 has been specifically designed for small to medium-sized orthodontic dental labs like Thermadent. It helps Matthew and his team to digitize their workflow from digital file to model, accelerate their production times and increase production capacity cleanly and efficiently. And there’s more. Now they enjoy a digital workflow we are able to convert chairside oral scans into precisely accurate 3D printed models. However, what this actually means to the work process is just one facet of the overall, digital breakthrough the Objet30 provides to both the lab and its customers.



Profits and savings
Matthew refers to a recent case study in which a practitioner took a patient’s normal alginate impression, and then made a chairside intraoral digital scan creating an STL file. Both were sent to their usual laboratory where the alginate impression was cast using Crystacal plaster (said to be the best, most accurate in its class). The digital STL file was printed using an OrthoDesk 3D printer. The results were astounding. The chairside digital scan, once converted into a 3D printed model, was the more accurate of the two by far.

If practitioners were to take a good look at their annual costs, including traditional lab bills, they would soon realise that investing in a chairside, intra-oral scanner and working with a fully functioning digital laboratory would have a massive impact on improving overall profits. And say goodbye to expensive recalls. Currently, how often does your lab phone to reappoint a patient because of a distorted impression? Consider that and then add in the fact that complaints regarding dental devices are on the increase. Taking the possibility of a distorted impression/recall/complaint out of the equation by going digital becomes a no-brainer. It makes economic sense and adds to quality control, win, win.

"We talk about the technology of the future, but thanks to continuous advances in CAD/CAM the future is here, now. Imagine the modern digital pathway leading from chairside scan to fast, accurate, 3D printed model. Private dental clients can have their intra-oral scans stored digitally. These scans can be taken quickly and cleanly then emailed direct to the lab. There’s no chance for distortions, mistakes, accidents or breakages. At Thermadent we can print a very accurate representation of the patient’s oral anatomy and also keep it on a digital file, plus the sheer speed of 3D printing means we can get to work straight away.

Fast, clean and accurate, the digital pathway means the patient spends less time in the chair and there’s less time spent waiting for the appliance afterwards. The results fit better, there are reduced material and staff costs and patient consultations are quicker and more animated. Going digital is surely the only route for affordable dental technology, and I see it as a must for all forward-thinking dental practitioners."....Matthew Garnett, MD Thermadent Ltd.

Stratasys 3D Printers including the Objet30 Orthodesk are available in Australia and New Zealand from Objective3D, a complete 3D Printing Solutions provider. From 3D Printers, 3D Parts, 3D Scanners including Printer Maintenance services and consumables for Stratasys 3D printers, Objective3D is the largest distributor of Stratasys 3D Printers across Australia and New Zealand, and were recently awarded the Stratasys Customer Satisfaction and Support Award for 2013 for the Asia Pacific region. 

Objective3D is also a total solutions provider of 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.


For more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Article Source: Dental Review news

3D Printed Spoon Gives Visually Impaired Child New Handle on Independence

When 4 year old Anthony of Shelbyville, Kentucky lost his vision after an operation to remove a brain tumor, Wayne Whitworth, a family friend and former United States marine, offered a solution to help the little boy regain his independence. Whitworth turned to 3D printing to develop a customized spoon on the Stratasys uPrint SE Plus 3D Printer at UPS store 0830, located in Louisville, Kentucky.

Simple daily functions like self-feeding posed frustrating challenges for Anthony and his family. “Anthony is blind so finding a spoon that he liked was a real challenge,” said Anthony’s mother, Cierra Brettnacher.


 Anthony celebrated his 4th birthday last month using his Stratasys 3D printed spoon to eat a piece of birthday cake

Anthony was drawn to a particular spoon he encountered during physical therapy. The special curvatures and features help visually impaired children like Anthony adapt to feeding themselves. Reproducing a utensil with a unique shape would require a process with greater design freedom and durable material options to withstand the stress of daily use—that process was additive manufacturing.


Stratasys 3D printing was crucial to the design of Anthony's spoon, as it gave Whitworth and The UPS Store the flexibility to change their approach throughout the design process

Whitworth came across United Problem Solvers™ campaign, a UPS initiative which helps customers find solutions to unique problems. UPS store 0830 franchisee, Debbie Adams, along with her graphic designer, Doug Seelbach, worked with Whitmore to develop a spoon that closely resembled the original.

Because they lacked a material that was FDA-approved and food safe, they shifted their design approach to develop a customized handle that would attach to disposable kitchen utensils. Adams and Seelbach developed two handles using durable ABSplus 3D printing material, branding one with a small square on top so Anthony could identify a fork from a spoon.

uPrint SE Plus 3D Printer from Stratasys

Whitworth and the UPS team’s kind-hearted gesture has gone a long way for Anthony and his family.
“When I gave the spoon to Anthony it made a huge difference,” said Cierra. “I was having to sit and feed two kids at the same time. So Anthony having a spoon where he could feed himself not only gave him independence and confidence but it also helped me so I don’t have to sit and feed him myself.”

Anthony’s 3D printed spoon device has made an enormous difference in the family’s daily routine. According to Cierra, the spoon has effectively introduced Anthony to many different types of food, a common headache for most parents of young eaters. “Since he’s able to feed himself these foods, he’s much more open to them,” added Cierra. “This spoon has truly impacted our lives in a variety of ways.”

Stratasys 3D Printers are available in Australia and New Zealand from Objective3D, a complete 3D Printing Solutions provider. From 3D Printers, 3D Parts, 3D Scanners including Printer Maintenance services and consumables for Stratasys 3D printers, Objective3D is the largest distributor of Stratasys 3D Printers across Australia and New Zealand, and were recently awarded the Stratasys Customer Satisfaction and Support Award for 2013 for the Asia Pacific region. 

Objective3D is also a total solutions provider of 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

For more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ) or try out our INSTANT ONLINE QUOTING SYSTEM if you have need a 3D Part Printed.

Daniel Widrig’s New 3D Printed Art Collection Explores Futuristic Human Form

Acclaimed artist and designer Daniel Widrig collaborated with Stratasys to create a futuristic 3D printed art collection. The collection, entitled Descendants, was unveiled at the ‘GLOBALE: Exo-Evolution’ exhibition, at ZKM | Center for Art and Media, Karlsruhe, Germany, on October 30.

DESCENDANTS by Daniel Widrig in collaboration with Stratasys produced using Stratasys’ PolyJet 3D printing technology. Size: 1751 x 452 x 292mm (Female), 1848 x 627 x 342mm (Male). Photo credit: Yoram Reshef

Exploring a futuristic context where technological development and computational capacities continue to spiral, Descendants addresses the increasing possibility of superior artificial intelligence and technological singularity, and how future synthetic bodies might look and feel. “With advanced technologies, such as 3D printing, already facilitating the customization and enhancement of the human form, the concepts of a post-human era of non-biological intelligence is now much more conceivable,” explains Widrig. “It is an inevitable yet exciting design challenge to begin to speculate on how new material bodies might be formed to face the real-world constraints of the future.”

The elaborate humanoid figures were developed by overlapping high-resolution 3D scans of male and female figures with intricate digital compositions. Bringing the digital images to life, the pieces were 3D printed using Stratasys’ color, multi-material 3D printing technology. This enabled Widrig to produce the complex geometries of each piece in a range of materials, in life-size human scale (size: 1751 x 452 x 292mm [Female], 1848 x 627 x 342mm [Male]). Drawing inspiration from both human form and abstract futuristic structures, Widrig combined color with rigid and flexible materials - achievable through Stratasys’ color, multi-material 3D printing technology - to create the fluid, human-like characteristics of the pieces, while also enabling Widrig to portray an alien presence.

DESCENDANTS by Daniel Widrig in collaboration with Stratasys produced using Stratasys’ PolyJet 3D printing technology. Size (Female): 1751 x 452 x 292. Photo credit: Yoram Reshef

“Having used 3D printing for almost a decade, it is now a natural part of my studio’s workflow, and the intricate geometries of the sculptures simply could not have been produced on this scale in any other way,” continues Widrig. “There was a unique synergy in employing Stratasys’ cutting-edge multi-material 3D printing capabilities and production techniques on a project that focuses on synthetic lifeforms and advanced technologies, which adds a real sense of authenticity and depth to the collection. Working with Stratasys has provided us a great opportunity to design and realize an ambitious project that otherwise would never have been possible.”

“Widrig’s artwork forms part of Stratasys’ 3D printed collection that will be showcased at the ‘GLOBALE: Exo-Evolution’ exhibition, which focuses on the artistic use of the latest technologies and the new realities being shaped by the ongoing technological evolution,” says Naomi Kaempfer, Creative Director, Art Fashion Design, Stratasys. “Descendants is yet another perfect example of Stratasys’ core purpose in revolutionizing the way things are made.”

Stratasys 3D Printers are available in Australia and New Zealand from Objective3D, a complete 3D Printing Solutions provider. From 3D Printers, 3D Parts, 3D Scanners including Printer Maintenance services and consumables for Stratasys 3D printers, Objective3D is the largest distributor of Stratasys 3D Printers across Australia and New Zealand, and were recently awarded the Stratasys Customer Satisfaction and Support Award for 2013 for the Asia Pacific region. 

Objective3D is also a total solutions provider of 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

For more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ) or try out our INSTANT ONLINE QUOTING SYSTEM if you have need a 3D Part Printed.

Monday, 19 October 2015

Jay Leno Uses 3D Printing to Replace Parts for His Huge Antique Car Collection

Jay Leno has a lot of old cars with a lot of obsolete parts. When he needs to replace these parts, he skips the error-prone machinist and goes to his rapid prototyping 3D printer. Simply scan, print and repeat.


Learn the benefits of 3D Printing for the classic car industry. Come visit Objective3D at stand 107 at the Motor Classica and you stand a chance to win $300 worth of 3D Printed Parts

One of the hardships of owning an old car is rebuilding rare parts when there are simply no replacements available. My 1907 White Steamer has a feedwater heater, a part that bolts onto the cylinders. It's made of aluminum, and over the 100-plus years it's been in use, the metal has become so porous you can see steam and oil seeping through. I thought we could just weld it up. But it's badly impregnated with oil and can't be repaired. If we tried, the metal would just come apart.


So, rather than have a machinist try to copy the heater and then build it, we decided to redesign the original using a 3D scanner and Stratasys Dimension 3D printer. These incredible devices allow you to make the form you need to create almost any part. The scanner creates a highly detailed digital model. The 3D printer makes an exact copy of a part in plastic, which we then send out to create a mold. Some machines can even make a replacement part in cobalt-chrome with the direct laser sintering process. Just feed a plastic wire--for a steel part you use metal wire--into the appropriate laser cutter.

Inside the printer, the print head goes back and forth, back and forth, putting on layer after layer of plastic to form a 3D part. If there are any irregularities in the originals, you can remove them using software. Once the model is finished, any excess support material between moving parts is dissolved in a water-based solution. Complexity doesn't matter, but the size of the object does determine the length of the process. Making a little part might take 5 hours. The White's feedwater heater required 33 hours.


Any antique car part can be reproduced with these machines--pieces of trim, elaborately etched and even scrolled door handles. If you have an original, you can copy it. Or you can design a replacement on the computer, and the 3D printer makes it for you.

People say, "Why not just give the part to your machinist to make?" Well, if the machinist makes it wrong, you still have to pay for it. The scanner allows you to make an exact copy in plastic, fit it and see that it's correct. Even when you take plans to a machinist, it can be tricky. Say the part must be 3 mm thick here and 5 mm there. You get it back and then, "Oh no, it doesn't fit; it's too thick," or "It's too thin." My setup lets you create the perfect part. And you could press the button again and again--and keep making the part--twice the size, half-size, whatever you need. If you have a part that's worn away, or has lost a big chunk of metal, you can fill in that missing link on the computer. Then you make the part in plastic and have a machinist make a copy based on that example. Or you can do what we do--input that program into a Fadal CNC machine; it reads the dimensions and replicates an exact metal copy.

Some guys are so used to working in the traditional ways. They're old-school. So they've never seen this new technology in use--in fact, they're not even aware it exists. When you work on old cars, you tend to work with old machinery like lathes, milling machines or English wheels. When someone tells you that you can take a crescent wrench, for example, scan it, then press a button, copy it, and make a new wrench, these guys say, "Well, that's not possible. You can't make the little wheel that moves the claw in and out. You'd have to make it in two sections."

But they're wrong. You can duplicate the whole tool.

They stand in front of the machine and watch a wrench being made, and they still don't believe it. It's like The Jetsons. George Jetson would say, "I want a steak dinner." He'd press a button and the meal would come out of the machine, with the roasted potatoes and everything, all on one plate. We may not have the instant steak dinner yet--but my 3D Scanner system is like the car-guy equivalent.

If you had a one-off Ferrari engine, you could scan each part and then re-create the entire motor. Right now, we're scanning a Duesenberg body. It's a classic example of high tech melding with old tech. There are cars sitting in garages around the country, and they haven't moved in years for lack of some unobtainable part. Now they can hit the road once more, thanks to this technology.

My 1907 White engine would never have run again because its slide valve (or D-valve) was shot. We built that part, and now the car is back on the street.

Let's say you have an older Cadillac or a Packard, and you can't get one of those beautifully ornate door handles. You could go to the big swap meet in Hershey, Pa., every day for the rest of your life and never find it. Or you could take the one on the left side of your car, copy it, use the computer to reverse it, and put that new part on the other side.


It's an amazingly versatile technology. My EcoJet supercar needed air-conditioning ducts. We used plastic parts we designed, right out of the 3D copier. We didn't have to make these scoops out of aluminum--plastic is what they use in a real car. And the finished ones look like factory production pieces.

When I was in high school, a friend's father bought the new Pulsar LED watch. He paid $2200 for it. It had a red face; you pressed a button, it lit up and gave you the time. The next year I bought a similar watch from Texas Instruments for $19.99. I went over and showed it to my friend's dad, and he was sooo angry.

These 3D Printing machines are not suited for mass production, but they work well for rapid prototyping. Just as eBay has made many swap meets go away, this machine could eliminate the need to go to eBay for parts. Think about it: What old part do you want to make?

Learn the benefits of 3D Printing for the classic car industry. Come visit Objective3D at stand 107 at the Motor Classica and you stand a chance to win $300 worth of 3D Printed Parts




Source: www.popularmechanics.com

Tuesday, 13 October 2015

3D Printed Parts Help Launch a New Era of Recreational Aviation

ICON Aircraft is betting on a future where private recreational planes are as popular as powerboats and motorcycles. Its ICON A5 is a giant step toward that goal: A plane that “will handle like a sports car with the top down,” according to the Discovery Channel. To speed this beauty onto the runway for a major air show, they came to Stratasys Direct Manufacturing. We not only saved ICON time and money, our approach enabled complex features that other manufacturing methods could not.



ICON Aircraft recently took flight with the unveiling of its ICON A5, a small, recreational plane that its founder, Kirk Hawkins, hopes will revolutionize a market already enamored with powerboats and motorbikes. He calls the two-seat ICON A5 “the ultimate recreational vehicle,” able to reach speeds up to 120 miles per hour.

Speed was important when it came to creating some of the aircraft’s parts, too. The unveiling of the plane at the Experimental Aircraft Association Air Venture in Oshkosh, Wis., drove the decision to use Stratasys Direct Manufacturing’s rapid prototyping services to create the plane’s eight air ducting parts, according to Matthew Gionta, Chief Technology Officer and Vice President of Engineering, ICON Aircraft.

“Using Stratasys Direct Manufacturing eliminated the tooling process for us,” Gionta said. “We put the parts in place on the airplane and then laminated structural composites over them. They became a tool for the structural part. Otherwise, we would have machined the molds and then laminated composite parts into them.” Gionta estimated that ICON Aircraft gained two to three weeks on the schedule, as well as saved $2,000 and two person-days per part for tooling. “That’s a pretty significant amount,” he added.

Creating parts for a special aircraft required some special considerations. “Minimum part thickness was a big driver for us. We wanted to keep the weight as light as possible,” said Gionta. Stratasys Direct Manufacturing representatives recommended a 0.06 inch thickness to maximize handling and still keep the weight down. Some of the parts were seven feet long.



Gionta chose ABS material, which can withstand the projected heat deflection above 180 degrees Fahrenheit. He also used Stratasys Direct Manufacturing’s Ready Part process to provide a smooth finish. “Some parts are on the outer surface of the plane and visible,” he said. “It saved us some extra body work time.”

Parts created at Stratasys Direct Manufacturing included two 3D air intake units underneath the wings to bring in outside air to cool the engine. Because he was familiar with rapid prototyping, Gionta designed the parts to be more intricate. “I took advantage of the process and included intricate turning vanes inside the ducts that we couldn’t have manufactured by hand,” he said. “I put in extra features that we would not have been able to accommodate without very complex tooling. The result made for a higher performing duct.”

From start to finish, Gionta was impressed with the Stratasys Direct Manufacturing service. “I liked the process of uploading the file and receiving a quote back automatically,” he said. “When I had additional questions, I worked with a Stratasys Direct Manufacturing rep to optimize the design of the part to be more cost-efficient.” Gionta was even impressed with the way the parts arrived. “I was impressed with the packaging when the parts came to us,” he added. “The expediency of the service was fantastic.”


Although initially driven by a tight schedule, ICON Aircraft saved time, money and labor by using Stratasys Direct Manufacturing. Gionta’s advice to others? “Take the leap of faith,” he said. “Once you have, you’re going to get hooked.”

Sounds a lot like flying…!

Direct 3D Printing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Objective3D will also be hosting a Breakfast Seminar which looks at Additive Manufacturing for the Aerospace and Defence Industry on 16th Oct from 8am onwards. There are still places available if interest. For more details click here



Monday, 5 October 2015

Printing Hearts

Doctors at the Texas Cardiac Arrhythmia Institute utilize 3D printing technology from Stratasys Direct Manufacturing to recreate accurate models of their patients’ hearts before performing surgery.


As the physicians at the Texas Cardiac Arrhythmia Institute (TCAI) can attest, the heart is an enormously complex organ; no two human hearts are exactly the same. In fact, because of the organ’s complexity, it is virtually impossible for even the most brilliant physician to diagnose a heart condition without extensive imaging of the patient’s heart. While CT scans, echocardiograms, and ultrasounds, among other technological advances, have made incredible progress for doctors in the field of cardiology, the study of heart conditions, there’s no comparison to being able to see an actual model of the human heart in question—one the physician can hold in his or her hands.

Dr. Vikram Devaraj, director of solid materials research for the Texas Cardiac Arrhythmia Research Foundation had the idea to improve upon the preparation for open-heart surgery by using 3D printing technology to give the physicians at TCAI access to anatomically-accurate representations of their patients’ hearts.

“Dr. Horton and I, and Dr. Beaman, came together on this project to figure out a way to make additive manufactured models of the heart, from direct CT scans.” Dr. Devaraj explains.

However, without the budget, capacity or expertise needed to own and operate an additive manufacturing system, Dr. Devaraj and TCAI turned to Stratasys Direct Manufacturing to print models of patients’ hearts on demand, with extreme precision and rapid turnaround. They also knew that with Stratasys Direct Manufacturing the files would be handled safely and securely.

As Dr. Devaraj explains, the CAD files used to create the models are taken directly from the patient’s CT scans, so the printed heart model is an extremely accurate representation of the patient’s own anatomy. Stratasys Direct Manufacturing then optimizes the CAD file for 3D printing and uses Stereolithography (SL) technology to build the models. SL uses UV lasers to cure liquid resins layer by layer and is among the most precise 3D printing technologies. The clear resins available in SL also make it an ideal process for the project, with the transparent material giving doctors and patients a chance to see intricate internal valve structures and better prepare for the procedure.

“It was suddenly a way to look at the internal organs without having to open someone up. And frankly, even if you open someone up, it’s not the same; it doesn’t look the same. […] Having this type of 3-dimensional mapping and printing of an actual heart  of that particular patient is invaluable in speeding up and improving safety and efficacy of the procedure,” explains Dr. Rodney Horton, M.D., F.A.C.C., cardiac arrhythmia specialist, who worked alongside Dr. Devaraj to bring his idea to life.

Stratasys Direct Manufacturing works directly with TCAI on an ongoing basis in order to produce the printed hearts from CT scans. The hearts can be printed and delivered to the physicians in a matter of hours, enabling the physicians to study the models before performing open-heart surgery on a patient.

As Dr. Horton puts it, “If a surgeon needs to repair something, they have this in their hand before they open up the chest. So it’s enormously valuable from that standpoint.”

The ability to produce unique patient models is just one way additive manufacturing has shifted the health care industry away from a one-size-fits-all approach to more customized solutions for improving outcomes. Freed from the design and capital constraints of traditional manufacturing—and with further advancements in additive materials and processes—doctors and medical institutions will continue finding new ways to provide better care for all of us.

Direct 3D Printing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Tuesday, 29 September 2015

Toyota to 3D Print Lightweight Car Seat

When the automobile moguls at Toyota Motor Corporation decided that they wanted to produce a prototype for a car seat that was as lightweight as possible, they found themselves face to face with a complex project that was meant to be handled by 3D printing technology. How would the Toyota team possibly design, build, and manufacture such a complex and sizable 3D printed car seat? That’s where Belgium-based 3D printing service bureau and software developer Materialise and their enthusiastic engineering team came in.


Using a specialized method of topology optimization, Toyota and Materialise were able to assign various levels of density to the car seat design before transforming it into a 3D model. The lower density areas were then populated in Materialise’s 3-maticSTL software, which allowed for design modification, repair, and simplification of the car seat’s 3D files. The 3-maticSTL method was also utilized to remove unnecessary print material and add comfort to the seat through the placement of a pattern of elastic beams to the surface of the prototype.

The design itself is filled with so many complex patterns and unit cells that Materialise had to use their slice-based operations technology, which allows designers to apply texture and structure to gigantic, unmanageable STL files. Materialise’s procedure works by skipping over the general STL file stage of design and directly builds the geometric patterns onto the 3D slices, creating a large-scale model that would have been impossible to design without their innovative slice-based operations process.

Elastic beam pattern created with the 3-maticSTL process

The efforts of Toyota would have also been fruitless without the use of Materialise’s Build Processor, which works to simplify the 3D printing process by reestablishing large files into a much more manageable size. In the instance of the lightweight car seat prototype, the Build Processor cut the file size down from 250GB to just 36MB of metadata. Finally, the stage of rapid prototyping was performed by Materialise’s laser sintering technique, a manufacturing process geared towards producing a large amount of components in one shot, which is exactly what Toyota needed to create the large-scale prototype of their lightweight car seat.


Despite it’s size, the 3D printed prototype weighed just a staggering 7kg, and also reduced the heat capacity of the car seat from the standard 35.4 J/K (joule per kelvin) to just 14.5 J/K. With a big helping hand from Materialise’s engineers, Toyota was able to manufacture a car seat with a low volume that would have been unfathomable without the 3D printing process advancements implemented by Materialise. Their software and technology, combined with Toyota’s ambition to create the lightweight car seat prototype, is pointing the automobile industry in the direction of additive manufacturing, which as we can now see, can allow companies like Toyota to create complex prototypes that would have been impossible to design or manufacture without 3D printing innovators such as the Materialise team.

3D Printing Bureau services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

3D printed windpipe improves girl's operation

A 3D-printed windpipe has been used to practise delicate surgery before an operation on a six-year-old girl at London's Great Ormond Street Hospital.



It meant doctors could pick the correct tools needed to wash her lungs.

And as a result, Katie Parke, from Northern Ireland, needed to spend less time under anaesthetic and being ventilated.

Doctors at the hospital say the technology could also be used to train other doctors.

Katie has pulmonary alveolar proteinosis, which means grainy deposits build up in the microscopic air sacs in her lungs making it hard to breathe.

Regularly washing the lungs with saltwater is the only way to remove the deposits.

During Katie's operation one of her lungs needed to be ventilated while the other was cleaned.

Normally, surgeons waste time on the operating table trying multiple combinations of different-sized tubes in order to perform the delicate surgery.

The team at Great Ormond Street Hospital used a CT scan of Katie to print out a 3D rubber model of Katie's trachea. They could then select the tools they needed ahead of the operation.

Katie's mum, Sharon Parke, said: "It's amazing to see what a tiny bit of kit can do. Katie's had brilliant treatment at Great Ormond Street and now she can even go horseriding, which was unthinkable before."

Owen Arthurs, a consultant radiologist who organised the study said: "We can look at a 3D reconstruction on a computer, but this takes it into a whole new dimension.

"Being able to hold it in your hand makes the procedure much easier and safer."

Doctors at Boston Children's Hospital, in the US, have also tried printing models of part of the brain ahead of surgery.

Dr Arthurs added: "It could also be used to make training better, being able to print a part of the anatomy is quite powerful. It's really important to train the next generation of doctors and make them better."

Stratasys 3D Printers are available in Australia and New Zealand from Objective3D, a complete 3D Printing Solutions provider. From 3D Printers, 3D Parts, 3D Scanners including Printer Maintenance services and consumables for Stratasys 3D printers, Objective3D is the largest distributor of Stratasys 3D Printers across Australia and New Zealand, and were recently awarded the Stratasys Customer Satisfaction and Support Award for 2013 for the Asia Pacific region. 

Objective3D is also a total solutions provider of 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

For more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Source: http://www.bbc.com/news/health-34280641

Why 3D printing is the future of manufacturing, not just a cool gimmick

The next phase for 3D printing: Coming out of rapid prototyping and moving into the assembly line for end-use production.

Airbus has produced more than 1000 flight parts on 
Stratasys 3D printers for use in its A350 XWB aircraft.

New 3D printing processes have reduced the time it takes for designers and engineers to conceptualize, create, and test prototypes. But for 3D printing to catch on the rapidly changing manufacturing industry, it will have to be seen by companies less as a fascinating technological upgrade and more as an everyday business decision.

That’s the conclusion from a report published in August by Stratasys Direct Manufacturing, the service arm of the global 3D-printer manufacturing company Stratasys. SDM provides advanced manufacturing and prototyping services to manufacturing companies who might need a 3D-printed prototype or part, but lack the in-house equipment or staff expertise.

“Today 3D printing is still perceived as a technology solution, but the future of 3D printing is as a business solution,” wrote Joe Allison, CEO of SDM, in 3D Printing’s Imminent Impact on Manufacturing.


The report, pulled together survey responses given by 700 designers, engineers, and business executives, nearly half of whom work for manufacturing companies that pull in more than $50 million in revenue a year. Respondents came from the aerospace, medical, automotive, and energy industries, and all of them work for companies that are already using advanced manufacturing processes or plan to introduce things like 3D printing or direct metal laser sintering within three years. 

So what, exactly, does SDM mean in saying that additive manufacturing’s future is as a business solution? As Allison writes in the report, the growth in 3D printing over the next three years will come in “end-use” production.

“What we’re seeing now, and what our customers are doing … is using this technology all the way through the product lifecycle process,” said Jim Bartel, senior vice president of strategy, marketing, and business development for SDM. In a call with Fortune, Bartel said that participants in the survey are looking for the return on investment after purchasing 3D printing equipment and training the staff to use it. “Engineers are creating cool parts off their printers, but what it comes to is: What’s the business value?” he said.

In other words, the next phase of 3D printing development within manufacturing companies will involve bringing 3D printing out of the realm of rapid prototyping and into the assembly line, where additive processes are used to make parts that end up on the final product. This is already happening in some industries, and Stratasys has a direction connection to some of this work. In November 2014, NASA’s Jet Propulsion Laboratory installed parts 3D printed by Stratasys onto one of its satellites bound for outer space. Airbus is using Stratasys’ production-grade printers to print flight parts for its new A350 XWB airplane; the first one of these planes delivered in December 2014 had more than 1,000 3D-printed parts installed in it.

“Within 10 years, every commercial airplane will have 3D printed parts on it,” wrote Allison in the introduction to SDM’s new report.

To prepare for this shift in 3D printing, one that will see more companies using additive manufacturing, especially with metals, to manufacture end-use parts, companies are staffing up, training new workers, and buying more 3D printing machines, SDM’s report shows that 73% of the 700 respondents to SDM’s survey said their companies plan to increase their in-house production of additively manufactured parts, a trend more pronounced in the aerospace and medical industries. But Bartel said that, as companies increasingly turn to additive processes to manufacture end-use products, more outsourcing will be done by companies without the financial resources to purchase the equipment and train the staff. SDM’s report shows that more companies are planning to outsource additive metal production over the near-term.

And printing in metals is key. According to Bartel, SDM’s customers, especially those in the aerospace and medical fields, are asking for and using aluminum and titanium, lightweight metals with considerable material strength. SDM’s report bears this out: At 84%, respondents ranked metals as the leader when it comes to which materials they’d like to see developed further for additive manufacturing in the future. SDM predicts additive metal use overall to double in the next three years.

“If you wanted to print a full airplane wing, you could theoretically do it,” Bartel said.

SDM’s findings fit with some of the conclusions from this year’s Wohlers Report, the definitive, industry report on what’s happening with 3D printing and additive manufacturing worldwide. According to an analysis of the 2015 Wohlers Report by Engineering.com, ”the use of industrial metal additive manufacturing systems for demanding production applications in the aerospace and medical markets also grew strongly.” Worldwide, the market for additive manufacturing services and products grew to $4.1 billion in 2014, according to the Wohlers Report. And more growth is expected in coming years.

“People really have been looking at this [additive] technology historically more as a technology solution,” said Bartel, “but it’s now meeting business needs for customers.”

Stratasys Direct Manufacturing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)

Source: http://fortune.com/2015/09/17/3d-printing-future-of-manufacturing/

Wednesday, 16 September 2015

3D Printing Gives Flight to Humanitarian Efforts


Stratasys Direct Manufacturing teamed with Structural Integrity Engineering to further efforts on the latest Flying Eye Hospital for Orbis. Orbis, an organization dedicated to providing ophthalmic training to communities around the world, utilizes airborne training facilities called Flying Eye Hospitals. Orbis’s goal is to eliminate unnecessary blindness, of which 39 million people around the global suffer from needlessly. In order to heal blindness, the Orbis team performs eye surgeries and educates doctors in the proper execution of eye surgeries through two-way audio-visual links. To aid and instruct as many people as possible, Orbis’ entire hospital and training facility is housed on a converted MD-10 aircraft. To further their efforts, Orbis began the process of building a new airborne hospital by reaching out to Structural Integrity Engineering, who then sought out Stratasys Direct Manufacturing for help manufacturing an air duct.

Structural Integrity Engineering (SIE) is an aerospace company that re-designs, re-builds and re-claims old and unused aircraft. One of the more complex components needed for new Flying Eye Hospital project was an air duct required to conform to certain curvatures as well as meet all FAA requirements for airflow. Its purpose is to filter air between the cockpit and the operating rooms. SIE chose to use a 3D Printing process to produce the air duct.

Mark Curran, Senior Engineer at SIE, has been working with additive manufacturing (3D Printing) processes for years, but always as a way to prototype and test out new parts using Stereolithography (SL). During design and form and fit testing, Curran and his team realized that traditional methods of manufacturing ducts would not be ideal for the geometry of the air duct needed on the Orbis plane.



“We had done work with Stratasys Direct Manufacturing in the past because 3D printing processes are very viable for complex fitting and design, which would normally cost quite a bit if machined,” says Curran. “In discussing our needs with Stratasys Direct Manufacturing Engineer Jesse, he informed me that Stratasys Direct Manufacturing has material that is FAA compliant for smoke and burn regulations. We received samples of the material, ULTEM, and did secondary burn tests. To pass, the samples have to extinguish by themselves within a certain amount of time. The ULTEM pieces passed the test.”

ULTEM is a thermoplastic material that has been engineered to meet very harsh environments, which is why the material has become widely used in the production of large vehicles such as automotives, industrial equipment and aircraft. “We took what we normally would’ve done in fiberglass and shifted our approach,” says Curran. Instead of fiberglass, Curran and his team chose to use 3D Printing process Fused Deposition Modeling (FDM)coupled with the tan ULTEM material that worked so well for the team during testing. “We were able to design mounting feature attachment fittings into the actual part. The mounting features are usually separate. By designing them into the FDM ULTEM component, we were able to reduce our overall part count, which is always a good thing.” The success of the 3D Printed material and the ability of the process to consolidate parts was met with a lot of enthusiasm from Curran’s team.



FDM is an additive manufacturing process and works similar to a hot glue gun, extruding thermoplastics varying in degrees of durability, layer by layer, until a final product is achieved. The process, as Curran explained, allows for multiple features to be built into the actual completed product, opening up possibilities for designers to program-in virtually any feature they require. Had Curran and his team manufactured the duct using fiberglass, the machined mold and lay-up process would have taken weeks; with FDM, the team was able to receive their part in a matter of days, and should they need a replacement or an extra part, the team could receive multiple parts in just a few days.

Stratasys Direct Manufacturing proudly took on responsibility for ensuring the duct met FAA airworthiness certifications. Building a part that would be required to function on an actual aircraft (versus a prototype or non-critical part) required vigorous inspection by the FAA. The FAA sent two representatives to Stratasys Direct Manufacturing to test and certify the design and build of the air duct. First, a Designated Engineering Representative (DER), who is commissioned by the FAA and carries a legal license for engineering, visited Stratasys Direct Manufacturing to verify the design of the duct would meet airworthiness requirements. A Designated Airworthiness Representative (DAR), who inspects the part to ensure everything was built correctly and that the process used meets all airworthiness requirements, visited once the duct had been built. “Being responsible for FAA certifications opened our eyes to what additive manufacturing can accomplish,” stated Stratasys Direct Manufacturing’s Project Engineer Jesse Marin. “We’ve always been dedicated to internal research, and improving manufacturing processes, and I think it really paid off in this project.” Stratasys Direct Manufacturing successfully received an 8130 certification for their additive manufactured duct.


The Orbis team has never before used a 3D Printed unit on one of their Flying Eye Hospitals. The completed duct is 30” x 12.08” by 17.65” with a volume of 139.21.

An earlier prototype of the air duct has been awarded a place in the National Additive Manufacturing Innovation Institute (NAMII) in Washington, D.C., to display the capabilities of 3D Printing and transfer those visionary and realistic ideas to the mainstream U.S. manufacturing sector.

Jack Mc Hal, MD 10 Program Director of Orbis International, commented that their objective “is to build the most sophisticated, technologically advanced, state of the art, gold standard hospital platform”; Stratasys Direct Manufacturing’s additive manufacturing was able to meet those standards.

Direct 3D Printing services is available in Australia and New Zealand from Objective3D Service Bureau. Objective3D Service Bureau provides 3D printing and custom manufacturing through the the largest additive manufacturing centre in the southern hemisphere - Objective3D Advanced Manufacturing Centre, powered by Stratasys Direct Manufacturing with 16 commercial grade machines provides the widest range of 3D printing technologies and materials to enable a broad range of specialist solutions.

Try out our INSTANT ONLINE QUOTE or for more details, visit www.objective3d.com.au or call 03-9785 2333 (AUS)  09-801 0380 (NZ)