Blog Menu

3D Veterans Bootcamp

September 12, 2016

Filed under: 3D printing,Additive Manufacturing,CAD/CAM/CAE,Education,Life — Terry Wohlers @ 08:43

An interesting program for U.S. veterans concluded on Friday of last week in San Antonio, Texas. A start-up organization, named 3D Veterans, was formed to train veterans in CAD and 3D printing for high-tech American jobs. The first six-week “bootcamp” involved 13 enthusiastic veterans out of 70 applicants. I was lucky enough to witness them in action on Wednesday as they were wrapping up several intriguing final class projects—the culmination of expert instruction and hands-on learning. The projects were aimed at designing and 3D printing devices that would help less fortunate fellow veterans. I was moved by this giving of time, creativity, and energy to other veterans.

The 3D Veterans organization was founded by Michael Moncada and David Schnepp, with subsequent involvement from Andy Miller, Wayne Dudding, and others. I first met Moncada, a veteran himself, at Inside 3D Printing in New York City in April, and what he told me about the program got my attention. Among the current partners and sponsors are America Makes, Autodesk, and the Department of Veterans Affairs. Google.org, Google’s chartable arm, is the primary sponsor. The veterans completed the program with new skills in using Autodesk’s Fusion 360 CAD software, which was used for most of the design work.

3dveterans

I was with the staff and student veterans for about 2.5 hours. I especially wanted to meet the veterans and see their work, and I was lucky enough to get fairly in-depth explanations from six of them. Len, 59, designed a knee brace that he hopes will be more effective and fit more comfortably under a pair of slacks. The available 3D printers and materials did not allow him to complete and test his design, but I like the path he has taken, coupled with his passion. One of his comments to me said it all. “This is the most exciting time of my life,” referring to the class, the knowledge and skills he has gained, and where all of it could take him in the future. Wow!

Another student veteran, Deborah, designed a brace for those with carpal tunnel syndrome. She said the ones on the market work with mixed results. She went on to say, “The course has been challenging and exciting and something I needed.” Other projects involved 1) the use of a transcutaneous electric nerve stimulation device to treat pain, 2) an exoskeleton device for therapy of finger and hand movement, 3) a device to hold a straw in place in a drinking cup or glass, and 4) a versatile cup holder that can be mounted just about anywhere, including onto wheel chairs.

I like this program a lot. Credit goes to Moncada, his colleagues, and the program’s supporters. Gratitude also goes to the participating veterans for enrolling in the program and giving back to fellow veterans. It was a privilege to see, up close, the veterans at work. Plans are underway to expand it into other locations across the U.S. in coming months. If you are interested in supporting this outstanding program or hiring one of the 13 veterans, contact Michael Moncada at michael@3dveterans.com.

Big AM Investments Continue

August 27, 2016

Filed under: 3D printing,Additive Manufacturing,Future,Money — Terry Wohlers @ 06:44

The additive manufacturing and 3D printing industry is not short on money. Since early June, we’ve stumbled across five new investments that total more than $260 million. For example, French investment bank Bpifrance announced that it is investing €45+ million over the next five years in an initiative to develop advanced processes in the country’s AM industry. The government of the Netherlands said that it will invest €134 million into research projects focused on AM.

dutch-flag

In late June, it was announced that Norway’s Norsk Titanium secured $25 million in a round of funding to help expand operations. The investment follows the inclusion of $125 million in the 2016 New York State budget to support the development of Norsk Titanium’s Plattsburgh, New York factory. In early July, Desktop Metal stated that it had received commitments for investments from GE Ventures and Saudi Aramco Energy Ventures. Little is known publicly about the company’s technology, but the company has secured a total of $52 million from investors thus far. About a month later, Formlabs said that it had raised $35 million, with Autodesk being one of the investors.

Much of the $260+ million spans multiple years and represents a significant amount of money in just two months of announcements from five organizations. It is possible, even likely, that many additional large investments have occurred recently, but have been kept private. This activity is stimulating, especially given that we did not see anything like it many years ago. What’s more, I have every reason to believe that it will continue, especially given the insight we are receiving from our client companies, many representing some of the largest brands in the world. It is an exciting time to be a part of this industry.

RØDE Microphones

August 15, 2016

Two of our consultants and I have had the privilege of visiting RØDE Microphones of Sydney, Australia. RØDE is a manufacturer of world-class microphone products for studio recording, performances, video broadcasts, and live interviews. It also manufactures microphones for presenters (lavalier and button mics) and smart phones. Over the past nearly two years, we have worked with RØDE and learned a great deal about the company and its products. Peter Freedman, managing director and chief executive, has given permission to disclose and discuss our relationship publicly.

RØDE hires some of the best people in Australia and other parts of the world. The company has offices in Seattle, Los Angeles, New York, and Hong Kong. Most of the Australian employees we’ve met are young, bright, and energetic. Freedman is the driver of new products, is constantly pushing the limits, and is the heart and soul of the company. RØDE is running $30 million in precision equipment, including a considerable number of new machines that were installed since we’ve started working together. Freedman seeks to be among the best of the best in the design and manufacturing of microphones. And, it shows by the company’s strong growth in recent years.

rode

I feel lucky to be able to work with great companies such as RØDE and people like Freedman and his team. He always has a can-do attitude and is constantly looking for new and better ways for product development and manufacturing. Over our 29 years in business, I have worked with a few people and organizations that find reasons why you cannot do something and serve as obstacles to progress. Fortunately, most of the people that we’ve encountered have the right spirit and outlook. Engineering consultant, futurist, and friend Joel Orr once said, “Success breeds success.” I could not agree more, and RØDE is a company that is producing a lot of it.

GE’s New AM Center

August 1, 2016

Filed under: 3D printing,Additive Manufacturing,Manufacturing,Review — Terry Wohlers @ 09:45

In April 2016, GE opened its new Center for Additive Technology Advancement (CATA), located near Pittsburgh, Pennsylvania. The 11,613-sq meter (125,000-sq ft) facility was designed to drive innovation and adoption of additive manufacturing across the company’s major businesses. They include Aviation, Energy Connections, Healthcare, Oil & Gas, Power, Renewable Energy, Transportation, and Current, powered by GE. CATA houses multiple AM machines from EOS, SLM Solutions, Stratasys, and ExOne. They are complimented by many CNC machining centers, EDM, heat treatment chambers, and other equipment. Space is available that would essentially double the number of machines and processes at the facility.

I toured CATA last Thursday and found it to be jaw-dropping impressive. It will almost guarantee an acceleration of knowledge and understanding of AM for production applications within the company. Having spent time with GE employees from several businesses over the years, I can say without reservation that many have solid AM experience. Even so, company management would be first to admit that the opportunity to grow and expand expertise across the 305,000-employee corporation is vast. CATA will help the company get there more quickly. Work at the facility is focused on mid technology readiness levels (i.e., TRL 4-7).

cata

GE advanced its position in AM when it acquired Morris Technologies, and its sister company, Rapid Quality Manufacturing, in November 2012. Greg Morris, then CEO and owner of the company, is the leader of Additive Technologies at GE Aviation. In 2013, GE Aviation announced that it had developed a 3D-printed fuel nozzle for its new LEAP engine. The attention received by the nozzle, which is now in production, has been an inspiration to countless organizations worldwide. Airbus was the first to receive LEAP engines, each with 19 nozzles, in April 2016 for the A320neo aircraft.

GE is making a big investment in additive manufacturing. However, it has shown few new designs since the public announcement of the fuel nozzle program. In my view, it is time for the company to show another advanced and exciting design for AM to serve as further inspiration inside and outside the company. It would make a bold statement and show the company’s leadership in the adoption and advancement of AM technology.

CATA is located about an hour from America Makes, which is the National Additive Manufacturing Innovation Institute in Youngstown, Ohio. Other key organizations close to CATA are Alcoa, ATI, Carpenter Technology, ExOne, Lincoln Electric, and the National Center for Defense Manufacturing and Machining. Universities include Carnegie Mellon, Case Western Reserve, Pennsylvania State, University of Pittsburgh, and Youngstown State. These organizations were a factor in choosing the location for CATA, a $40-million facility that signals how important AM has become at GE. The world-class facility will likely serve as a model for other large corporations globally.

Lundeen Sculpture

June 5, 2016

Filed under: 3D printing,Additive Manufacturing,Review — Terry Wohlers @ 15:20

I had the pleasure of visiting Lundeen Sculpture in Loveland, Colorado, last week. The company produces world-class sculptures of about everything imaginable. The “sweet spot” at the company is the recreation of people and animals with spectacular precision and realism. The sculpting is done mostly by the Lundeen family, including Bets, George, Mark, their cousin Ann LaRose, and Joey Bainer, an unrelated sculptor. I first met Nelse Lundeen a few years ago. He handles accounting and other business issues at the company.

George Lundeen founded the company in the mid 1970s and was our host, along with Nelse. (My wife and two friends joined me on the tour.) George showed us many beautifully-crafted bronze versions of famous people, such as astronaut Jack Swigert, which is on display at Denver International Airport, and Dan Marino, a former Miami Dolphins quarterback that was inducted into the Pro Football Hall of Fame in 2005. The Marino sculpture is on display at the Dolphins stadium in Miami.

George told an amusing story of his daughter, a big Marino fan. George asked her to visit the company after school, but did not tell her that Marino was present. When she arrived, Marino walked around the corner to her astonishment and addressed her by name. I can’t imagine how big of a surprise it was to her.

lundeen

The company is working on a two-year project involving the creation of the Stations of the Cross, which depicts Jesus Christ and others on the day of his crucifixion. Each station involves incredibly detailed clay sculptures that end up being larger-than-life bronze works of art. The effort is being sponsored by billionaire Joe Ricketts, founder and former chairman and CEO of TD Ameritrade, a large discount brokerage located in Omaha, Nebraska. He is building a Christian retreat center named The Cloisters on the Platte on 930 acres near Omaha. (The Platte is a major river running through the state.) The retreat will include the bronze Stations of the Cross.

George showed us the many clay sculptures that are underway for the Stations of the Cross project. Each are being 3D scanned, scaled up, and 3D-printed using a machine from Voxeljet. He explained that the process of scanning and printing is saving a dramatic amount of time. The 3D-printed patterns are shipped to the Lundeen team for inspection and light work and then delivered to a Loveland foundry for investment casting. The bronze castings are then  assembled, welded, and finished into their final form. George allowed me to take many pictures, but asked that I not put them on the Internet. A good video, co-produced by Analise Lundeen, shows much of the work and is found here.

SME’s RAPID 2016

May 21, 2016

I attended this week’s RAPID 2016 in Orlando, Florida. As usual, the conference and exposition were excellent. An estimated 5,190 attended the event, compared to 4,512 last year. Exhibit space increased to 4,153 sq meters (44,700 sq ft), up from 2,903 sq meters (31,250 sq ft) last year. The following are a few highlights of the event:

● HP introduced and showed its Jet Fusion 3200 and 4200 3D printers for the first time publicly. The machines are capable of addressing 340 million voxels per second in thermoplastic materials, such as PA12. They are 10 times faster and operate at half the cost of competitive systems, according to HP. The systems are mostly open, which means they support third-party materials at competitive prices.

heart

● Renishaw showed its new RenAM 500M machine that produces metal parts. The engineering is impressive. Meanwhile, 3D Systems displayed its new ProX DMP 320 machine for producing metal parts. It is based on technology developed by Belgium-based LayerWise, which was acquired by 3D Systems in 2014.

● Xjet of Israel introduced its NanoParticle Jetting technology. It uses inkjet printing to produce parts in stainless steel and silver. The parts are small, but the feature detail is good.

● Event organizer SME hosted a fashion show that featured entirely new 3D-printed designs. Many were impressive. I have now attended five fashion shows that highlight 3D-printed products and it’s remarkable how far the designs have advanced in a few years.

fashion-show

Congrats to SME for another great event, which continues to improve year after year. With increasing applications of additive manufacturing and 3D printing for final part production, the event has the opportunity to grow much larger in the future.

RAPID 2017 will be held May 8-11 in Pittsburgh, Pennsylvania. Add it to your calendar and plan to attend.

Premium AEROTEC

May 6, 2016

Filed under: 3D printing,Additive Manufacturing,Event — Terry Wohlers @ 09:30

Last week, I visited Premium AEROTEC, a 10,000-employee company that is 100% owned by Airbus. The company has several locations in Germany, including Varel, the site that I visited. This is where Premium AEROTEC has installed its first four metal additive manufacturing machines, including the large X line 1000R system from Concept Laser. It served as the backdrop for the stage, as shown in the following picture. The machine was running, along with two M2 machines from Concept Laser during the one-day event. The large machine is being swapped for the newer X line 2000R later this month.

premium-aerotec

Premium AEROTEC is serving a key role in the series production of AM parts for cabin, fuselage, and other systems for Airbus. The approval by the authorities for air worthiness, a major milestone, was achieved in March 2016. Thus far, Premium AEROTEC has secured suppliers with total capacity of about 40 metal AM machines. Companies, such as Materialise, have set up manufacturing facilities nearby and are buying metal AM equipment with the hope of serving as a supplier. I had the chance to visit the new Materialise AM production facility in Bremen and was impressed by what’s already in place, coupled with its near-future growth plans. Many more machines will need to be added to the Airbus supply chain for it to meet its goal of producing 30 tons of metal AM parts monthly by December 2018.

More than 100 people attended the special Premium AEROTEC event. I was asked to speak on the state of the additive manufacturing industry and provide highlights and details from the recently published Wohlers Report 2016. I spoke 70 minutes to an enthusiastic crowd, followed by questions from many people in the room. Click here if you are interested in reading a recent article on Premium AEROTEC and the April 26 event.

Peter Sander, Head of Emerging Technologies & Concepts at Airbus, was my host during my stay in Bremen and Hamburg. The day after visiting Premium AEROTEC, Peter arranged to have me speak to a group of about 150 Airbus employees in Hamburg. The one-hour presentation was also broadcast live to an additional 150 people at Airbus sites in Bremen (Germany), Toulouse (France), Getafe (Spain), and Filton (UK). I was surprised but happy to see so many young people in the audience, several of which introduced themselves to me after the presentation. I could tell that they are clearly very excited about the potential of AM. The presentation was held in the new and impressive ZAL Center of Applied Aeronautical Research at Airbus, which is pictured below.

zal

My time in Germany could not have gone better, thanks to Peter Sander and his team. Thanks also to Dr. Thomas Ehm, Chairman of Premium AEROTEC, and Gerd Weber, Site Manager for the Varel location, for their warm welcome and kind words. They rolled out the red carpet for my visit and I appreciate it very much.

Wohlers Report Published

April 9, 2016

Filed under: 3D printing,Additive Manufacturing,Future — Terry Wohlers @ 17:13

I’m happy to announce that Wohlers Report 2016 was published this week. It is the 21st annual edition of our state of the industry report on additive manufacturing and 3D printing. We received tremendous support from many people and organizations, including 80 co-authors and experts in 33 countries. They contributed very important sections and provided great insight from their regions of the world.

Senior consultant and principal author Tim Caffrey was vital to this year’s report (once again). He has a special ability to efficiently find “nuggets of gold” from an avalanche of “news” that is often questionable. Associate consultant and new principal author Ian Campbell played an important role for the second consecutive year. I sincerely thank both of them for helping to produce a report that offers depth, breadth, and detail unmatched by others.

WohlersHorizontal.indd

I am also grateful to the 98 service providers, 51 system manufacturers, and 15 third-party material producers for responding to our requests for detailed information. Year after year, companies provide quantitative, and sometimes sensitive, data that we compile and use to produce industry-wide totals and trend lines that benefit the entire industry. Without their support, we could not produce many of the more than 100 charts, graphs, and tables that are spread across the report’s 335 pages. We did our very best again this year to be short on words but long on information.

The report has served as the undisputed industry-leading report on the subject for two decades. We are flattered when people refer to it as the “bible” of 3D printing. I am grateful to them, our customers, and the many people that supported the development of this edition. We are very lucky to have what we believe is the largest group of friends and contacts in the 3D printing industry—a network that spans 28 years.

Mattel’s New ThingMaker

February 27, 2016

Filed under: 3D printing,Additive Manufacturing,CAD/CAM/CAE,Entertainment,Future — Terry Wohlers @ 06:36

I’m old enough to remember the Creepy Crawler ThingMaker of the 1960s. I did not own one, but a neighbor friend did, and we made many plastic worms and bugs with it. We had fun with the simple product, even though we were limited to the shapes available from the small molds that came with it.

Fast forward a half century to two weeks ago. At the New York Toy Fair, Mattel announced that it is introducing a new ThingMaker that takes advantage of 3D printing. Price: $299. For me, this is an exciting announcement, given that I have put considerable thought into the idea over the past two decades. I even ran it by film producer James Cameron back in 2010 and he liked it.

thingmaker

Sure wish I could take credit for the idea, but I cannot. In the 1990s, Charles (Chuck) Johnson, then with the Naval Air Weapons Station China Lake, shared with me a future vision of 3D printing. He imagined a child waking up on a weekend morning and going to the kitchen for breakfast. The child switches on a device and then pours dry cereal, such as Cheerios, into it. She then pours milk into a reservoir inside the device. Viewing a small display, she selects a number of digital action figures that’s available and then readies the small machine.

The 3D printer grinds the cereal into fine powder and spreads it, as a print head jets milk for binder, layer by layer. If you’ve ever spilled milk, you know that it becomes sticky as it dries. After minutes of printing, she removes the action figures from the bed of powder, brushes them off, and then eats them.

Mattel’s new ThingMaker does not work like this, but it has a chance of becoming as popular as what Johnson had envisioned so many years ago. Over the past, I’ve shared his story with many groups and most found it interesting. Perhaps the new ThingMaker, slated to become available in October, will be a stepping stone toward Johnson’s cereal printer.

Autodesk has partnered with Mattel to provide software and an easy way to create 3D content—a key to success, in my opinion. So, stay tuned. It could be the beginning of something big.

Nano Dimension

February 2, 2016

Filed under: 3D printing,Additive Manufacturing,Future — Terry Wohlers @ 07:07

Nano Dimension is an Israeli company that is producing a 3D printer for making printed circuit boards. The machine and sample PCBs are on display at SolidWorks World 2016 here in Dallas, Texas. The dual printhead machine uses material jetting technology to deposit photopolymer as the base material and a silver nanoparticle ink for the conductive traces.

The printhead deposits the silver in layers that are 2 microns in thickness. It took about 75 minutes to print the circuit board pictured in the following. Light is used to fully cure the photopolymer and sinter the silver.

nano-dimension

The build volume of the machine is 20 x 20 x 0.3 cm (7.9 x 7.9 x 0.12 inches). In the future, the company hopes to increase the Z dimension to permit the printing of circuits that are fully integrated into a design.

Nano Dimension’s software accepts standard PCB Gerber design files, as well as STEP, JPG, and TIFF files. The company is hoping that SolidWorks Corp. and other companies will develop software that takes advantage of the machine’s capabilities.

The company expects to commercialize and ship machines later this year.

Next Page »