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DfAM at Materialise

June 4, 2017

Filed under: 3D printing,additive manufacturing,CAD/CAM/CAE,education,event — Terry Wohlers @ 13:27

What does a major German car manufacturer, surgeon from Brazil, producer of food-making equipment, and large toy maker have in common? All are interested in methods of design for additive manufacturing (DfAM). Twenty-five people from five continents came together last week to explore, discuss, and learn how to design products for AM. Also represented were manufacturers of pumps, audio systems for cars, data projection systems, packaging equipment, heavy industrial products, and large vacuum systems. Key service providers from South Africa and China also participated.

The advanced, three-day course from Wohlers Associates took a deep dive into methods of DfAM, including the consolidation of many parts into one to reduce tooling, manufacturing, and inventory costs. The training, held in Leuven, Belgium, provided guidance on design optimization for reducing the use of material and making parts as light as possible. The participants used their own CAD software, along with Inspire from solidThinking for topology optimization and Magics Structures from Materialise for lattices and meshes.

Materialise hosted the event and provided five DfAM experts in a 75-minute panel session. The company also gave an outstanding 90-minute tour of its impressive facilities. It was helpful to those in attendance to see the wide range of machines, parts, and new businesses at Materialise. One example is the production of Yuniku 3D scanning systems for custom eyewear. The prescription eyeglasses are designed so that the optics are located in the optimal location relative to the eyes. They come with beautifully-designed frames that are produced by AM at Materialise.

We are thrilled with the participant feedback and glad the training went so well. Even so, we plan to make a number of adjustments prior to offering it again. A big thank you goes to those who attended from around the world and to the fine people at Materialise for contributing to its success. We could not have partnered with a better company.

25 Years of RAPID

May 6, 2017

Next week is RAPID+TCT 2017, North America’s largest conference and exposition on additive manufacturing (AM) and 3D printing. It also includes CAD, 3D scanning, and other design and manufacturing products and services. The event marks the 25th year for me to attend the event. Although I don’t have hard proof, I’m reasonably certain I stand alone in that category, for what it’s worth. SME, the organization that launched the event in May 1993, has generously invited me to speak at RAPID for 25 consecutive years.

RAPID has been the go-to event in this region of the world for all things 3D printing. The multi-day, multi-track conference has always been the strength of the event and a big reason why people attend. With more than 330 exhibitors from around the world, the exposition is now a very serious part of it. UK-based Rapid News Communications Group, with its strong TCT brand, has partnered with SME for the first time. RAPID+TCT has the potential to grow significantly as organizations around the world expand their use of AM.

As usual, I’m looking forward to next week. I like to attend the conference sessions and see new products and services in the exposition. Meeting people, however, is a major reason why many choose to attend. Business is conducted, ideas are explored, and new friendships are forged. The people in attendance have been a big part of why I like to participate year after year. If you’re going to be in Pittsburgh next week to attend RAPID+TCT, I look forward to seeing you there!

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.

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.

Beginner’s Guide to 3D Printing

February 27, 2015

Filed under: 3D printing,additive manufacturing,education — Terry Wohlers @ 13:48

Note: The following was authored by Tyler Hudson, an intern at Wohlers Associates.

With the declining prices for consumer-grade material extrusion (FDM-like) 3D printers, more people are purchasing them. This has created a need for a basic understanding of how to get started with the technology.

The orientation of the part you are building is key to success. Orientation that produces the fewest number of overhangs tend to result in better builds because it requires less support material that later must be manually removed.

Few designs can be oriented in a way that eliminates overhangs and the need for some support material. When this happens, it is best to orient the part in a way that results in external overhangs instead of internal. The orientation at the left in the following is usually preferred over the one at the right.

orient

The orientation on the left results in external overhangs, which means that the support material will be easier to remove. The orientation at the right results in internal overhangs, so removing the support material becomes much for difficult. Some designs may not be as easy to orient as this one, but with experience, you will be able to decide which orientation works the best.

Click here to read the entire Beginner’s Guide to 3D Printing.

More Inside 3D Printing

December 22, 2014

Filed under: 3D printing,additive manufacturing,education,event — Terry Wohlers @ 08:30

I was fortunate to participate in nine Inside 3D Printing events in 2013-2014. The first one was in New York City in April 2013. The most recent one was in Shanghai, China in November 2014. It drew 4,000+ people, and the one in Seoul, Korea in June 2014 attracted about 5,000. Attendance, such as this, for a first-time 3D printing event, is unprecedented.

In the 25+ history of additive manufacturing (AM) and 3D printing—terms that are used interchangeably—we have not seen such an impressive level of commitment and investment in a worldwide series of events. Inside 3D Printing is the brainchild of Alan Meckler, PhD, head of MecklerMedia (previously of Mediabistro). I first wrote about Meckler and Inside 3D Printing in a blog commentary in April 2013.

nyc2014
Inside 3D Printing in New York City in April 2014

Running large conferences and exhibitions is big business, but it’s also an opportunity to introduce important subjects to many people, as well as update those who have been in an industry for some time. It’s impossible to estimate the educational and economic value that this series of events is having on our industry, but I believe it is significant. For many, Inside 3D Printing is the first event on AM that they’ve attended. The information they collect and contacts they make are invaluable.

A high percentage of the people attending are mature, practicing professionals from major corporations. It’s my belief that the series is leading to many new collaborations and partnerships, start-up companies and new businesses, equipment purchases, and other types of investment in AM. The number of meetings and interactions that I have witnessed is exciting.

For 2015, Inside 3D Printing conferences and exhibitions are scheduled for Singapore, Berlin, São Paulo, London, New York, Melbourne, Seoul, and Santa Clara. Meanwhile, other locations are being considered. I recommend that you attend one or more of them, and if you do, I look forward to meeting you there in person.

Best wishes to you for a safe and relaxing holiday season!

Inside 3D Printing

April 27, 2013

Filed under: 3D printing,additive manufacturing,education,event,review — Terry Wohlers @ 11:22

This is the name of an event that was launched this week at the Javits Convention Center in New York. I attended and was very impressed on a number of levels. First, I was surprised to learn that about 3,000 attended the two-day conference and exposition. I cannot remember attending a first-time event that has attracted more a few hundred people. Some events have been around for 10, even 20 years, and still draw fewer than 2,000 people.

Second, I was pleased at how well it was organized. Mediabistro, a company led by Alan Meckler, PhD, is the group behind it. The company clearly knows what it takes to organize and run events. Every detail, down to the refreshments, was handled expertly. Some might consider Meckler a trade show genius. In 1990, he created a newsletter called Internet World, the first of its kind. It led to the launch of the Internet World trade shows, which were the fastest growing in trade show history. His company, Mecklermedia Corp., was subsequently acquired by Penton Media in 1998 for $274 million in cash.

Seeing an audience of 1,000+ is a speaker’s dream come true. That’s what I saw when walking onto the stage early Tuesday morning. The attendees were a mix of NY investors, analysts, startup companies, and corporations of all types. Most were more interested in business opportunities in 3D printing than in the technology itself. What struck me most about the audience was their amazing appetite for information on the subject. They behaved like people that hadn’t eaten in days.

Mediabistro has scheduled Inside 3D Printing events for July 10-11 in Chicago, Illinois, September 17-18 in San Jose, California, October 1-2 in Singapore, and February 2014 in Munich or Berlin, Germany. The event returns to the Javits Convention Center in New York April 3-4, 2014. It’s clear that Meckler sees a window of opportunity, similar to the Internet shows of the early 1990s. If these additional events follow the formula used for this first event, they stand a good chance of success.

Idea 2 Product Labs

September 2, 2012

Filed under: 3D printing,additive manufacturing,education,future,life,manufacturing — Terry Wohlers @ 09:30

The Idea 2 Product (I2P) series of labs is an initiative that was launched in South Africa last year. The labs consist of CAD workstations and 3D printers for hands-on learning, experimentation, invention, and new product development. The primary goal of the labs is to offer opportunities for professional and economic development, especially in underdeveloped regions of South Africa and other parts of Africa.

The I2P initiative is the brainchild of professor Deon de Beer of Vaal University of Technology (Vanderbijlpark, South Africa). I have known Deon for 17 years and he has a track record of success with about everything he touches. If there’s a single individual responsible for helping to launch and grow additive manufacturing and 3D printing in South Africa, it is Deon. He has gained the respect of countless people from industry, academia, and government in South African and around the world.

Deon launched the first I2P lab at VUT in mid 2011 with the installation of 20 personal 3D printers—a historic first worldwide. (A personal 3D printer is one that sells for less than $5,000, but more typically $1,000 to $2,000.) He also created a smaller I2P lab with two 3D printers in a rural area of South Africa. He has ordered 70 additional 3D printers (20 have been received thus far) for four new I2P labs at educational institutions that are similar to community colleges here in the U.S. In parallel, he is creating I2P labs at three VUT satellite campuses and two more at science centers.

Deon has big future plans for I2P labs. Based on his past and current support from the South African government, I have no doubt that he will succeed. Deon envisions I2P labs across the African continent and already has tentative plans for labs in Zambia, Mozambique, and Botswana. In the meantime, he sees the potential for labs at up to 22 universities, 50 community colleges, 25 private institutions, 20 science centers, and many secondary and primary schools in South Africa. He is also gaining support for the first I2P 2Go mobile unit that would take 3D printers on the road to remote areas.

The impact that the I2P labs could have is almost beyond calculation. Each lab could introduce hundreds of people of all ages to CAD, design, product development, and manufacturing. This could lead to a dramatic increase in new ideas, new products, and new mini economies that would lead to improving economic conditions in underdeveloped regions. Rural areas living in poverty conditions could develop products that they could sell on “main street” within their community, as well as to neighboring communities. I applaud Deon’s efforts and fully expect that he and his I2P labs will make a dramatic and unprecedented difference.

Dean Kamen

May 27, 2012

Filed under: 3D printing,additive manufacturing,education,event — Terry Wohlers @ 09:06

Dean Kamen’s name has come up repeatedly for many years and I have always wanted to meet and hear him speak. Kamen is best known as the inventor of the Segway, an electric, self-balancing vehicle. He has 440 patents to his name and is the head of Deka Research and Development Corp., a company with 400 employees. I got the chance to hear Kamen and later meet him briefly last week in Atlanta, Georgia. He was invited to speak at the EOS North American User Day, which coincided with the RAPID 2012 Conference and Exposition.

Kamen is an inventor and entrepreneur, but he is mostly a relentless advocate of science and technology. He is the founder of the incredibly successful FIRST (For Inspiration and Recognition of Science and Technology), launched in 1989. FIRST competitions involve hundreds of thousands of elementary and secondary students in 21 countries, as well as 100,000+ volunteers that come together to make it possible. Former Presidents George W. Bush and Bill Clinton, Morgan Freeman, will.i.am from The Black Eyed Peas, and many other celebrities have supported FIRST. The CEOs from Time Warner Cable, Xerox, Avon, and Baxter serve on the FIRST board of directors.

The presentation that Kamen gave on Tuesday is difficult to describe. You really needed to be there. He has an incredible passion for ensuring that young people view science and technology with as much or more enthusiasm as professional sports, music, and Hollywood entertainment. His stories and words of inspiration brought tears to many in the room.

My sincere thanks to EOS for bringing Kamen to Atlanta. Kamen’s company is a regular user of EOS laser sintering technology and he showed many interesting examples, which made his presentation even more relevant and meaningful to those in the room.

A 3D Printer for Kids

October 15, 2011

Filed under: 3D printing,additive manufacturing,education,entertainment,future — Terry Wohlers @ 08:20

Finally, a 3D printer for children. Well, it’s not yet available, but it’s in the works. Origo, a small startup in Belgium, is in the conceptual phase of product development. The goal: to offer a product that’s attractive to 10-year olds, and to make it as easy to use as an Xbox or Wii. The estimated price of $800 may be a little steep for kids and their parents, but it’s a starting point.

For more than a decade, I’ve sensed that a large market could develop for a very low-cost 3D printer targeted at children. Young people use their imagination to create objects of all types. With so much digital content now available, and a lot more in the works, a 3D printer would be the ultimate device for creative play and entertainment. A recent article published by Singularity Hub said it could be the last toy you’ll need to buy for your child.

In February 2010, I had a short meeting with James Cameron, the producer of Avatar, Titanic, The Abyss, and many other blockbuster films. Knowing that he is a user of 3D printing, I asked him about the idea of an inexpensive 3D printer targeted at children for entertainment. He responded by saying, “Absolutely,” with interest. This is a verbal endorsement that carries some weight.

Indeed a business opportunity is out there for Origo and others to develop and commercialize a safe and simple 21st century ThingMaker for children. A price range of $100-200 has been in my mind, but maybe people would pay more for an elaborate toy that could produce almost any shape.

As the saying goes, the devil is in the details and Origo is faced with many. To reach a level of volume that drives cost and price to a minimum, the effort would require significant investment in engineering, manufacturing, market development, distribution, and support. It’s a giant mountain to climb, but I hope company founders Joris Peels and Autur Tchoukanov, both young men, are able to raise the capital needed to succeed. Peels is a former employee of Shapeways and i.materialise and a contributor to Wohlers Report 2011.

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