3D Print industry solutions

Problem

The design of household appliances requires not only accurate 3D models to communicate design concepts to internal and external customers, but a series of functional test parts to assess critical performance attributes early in the design cycle. Exposure to elevated temperature, moisture, airflow and vibration all combine to present demanding environmental conditions that many early stage concept models fail to withstand.

3D Printers Improve:

Internal Communication 3D printers enable design teams to efficiently iterate on product concepts early in the design process, enabling multiple renditions to be visualized and critiqued by a variety of functional teams within an organization.

Presentation Models 3D parts can be finished in a variety of ways to yield high quality surfaces. Exact replicas of production models can be used to solicit focus group feedback on proposed new features. Half-scale models of products can be built and transported to customer sites for evaluation, frequently eliminating the need to ship actual production units.

Functional Testing Utilizing our 3D Printers range of infiltration resins, manufacturers achieve application-specific functionality to gauge performance criteria. Infiltrated parts can be machined, drilled, and tapped. Additionally, infiltrants can be used to significantly improve the durability, humidity resistance and high temperature properties of parts during airflow, vibration and other rigorous environmental tests.

FEA Analysis The ability to print parts in full color enables engineers to quickly understand the material stresses on their designs. Our 3D parts can be printed in over 2 million colors, highlighting potential weak points well before parts reach tooling development.

Black & Decker
Pelican Products
Robert Bosch
Seoul National University HospitalHarvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare

Problem

From the very first concept development meeting, Companies visualizes, learns, and communicates in 3D. Whenever possible, they use physical models to explore concepts and communicate their vision to clients. Many companies has found hand-made model-making techniques to be constraining for two reasons: the time required to make the model is too lengthy, and the process required to extract the necessary data from the computer file for the model makers takes valuable time away from the design team.

The ability to create multiple models at reasonable cost For certain projects it is an advantage to be able to print multiple copies of the model to share with different client and end user constituencies. 3D printing allows the production of multiple parts with minimal effort.

The ability to create reproducible models In the case where several elements of a specific area of the design change, any one particular section can be reprinted in a matter of hours.

Morphosis
Escondido Reprographics
Bena Corporation
Fifth Dimension Architectural Design
Seoul National University Hospital
Harvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare

Problem

The automotive industry has historically used rapid prototyping as an integral tool in the design process. However, outsourcing high-end prototypes is expensive, and can cause a strain on design lead times. The fast-paced design cycles in the automotive industry require a rapid prototyping solution that can produce almost any geometry with a variety of material properties, quickly and inexpensively.

3D Printers Improve:

Internal Communication 3D Printers enable design teams to efficiently iterate on product concepts early in the design process, enabling multiple renditions to be visualized and critiqued by a variety of functional teams within an organization.

Functional Testing Utilizing 3D Printers range of infiltration resins, automotive design engineers are able to conduct functional testing on parts printed on a 3D Printer. Infiltrated parts can be machined, drilled and tapped. Additionally, infiltrants can be used to significantly improve the durability, humidity resistance and high temperature properties of 3D parts during airflow, vibration and other rigorous testing.

Casting Direct Metal Casting process allows engineers to pour metal directly into a mold printed on a 3D Printer, eliminating the need for a pattern. Additionally, the 3D parts can be used as patterns in the traditional investment casting and sand casting processes for the production of metal prototype parts.

Production Planning Automotive companies use 3D. parts to walk the product line and ensure that they have the right tools at each station to complete production in the most efficient way possible.

Finished Presentation Models 3D parts can be sanded and painted to create a "class A" finished look. Exact replicas of production models can be used to solicit focus group feedback on proposed new features.

Ford
Benteler
F1 Racing
Porsche
Seoul National University Hospital
Harvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare

Problem

It is critical for students to have access to physical models of their designs early in the design process in order to fully understand and experience the product design cycle. Key criteria for evaluating 3D Printers for classroom use are:
1. Speed: A high throughput 3D printer is necessary to support several classes of 20 to 30 students each semester.
2. Low Cost: A low cost per printed part is critical both to support students and keep within budgetary constraints.
3. Reliability: A safe and reliable 3D printer is important, since it operates continuously in a classroom environment.

The 3D Printers in use throughout education:

Mechanical Engineering 3D Printers are capable of creating appearance prototypes directly from digital data, allowing students to evaluate their designs in 3D.

Architecture Quick, inexpensive models make it possible to print multiple pieces during the course of a project and use the models not only to present, but also as part of the creative process.

Industrial Design 3D Printers can produce models of any complexity. The models can be sanded and painted to replicate production models.

Fine Arts Students are able to create physical output of their projects and gain valuable feedback on their projects.

Bio-Medical Research The unique capability of Color 3D Printers to create full color parts allows researchers to accurately represent molecular models in three-dimensions.

Harvard University
University of Hong Kong
Springfield High School, OR
MIT
University of Kentucky
Seoul National University Hospital
Harvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare

Problem

Clear communication between designers and manufacturers is crucial during the design process, because consensus on a design is critical before investment in expensive tooling. In addition, reducing design cycle time is critical to getting new concepts to market ahead of the competition. The traditional method of modeling designs out of clay or milling wood is often expensive, time-consuming and inaccurate.

The3D Printer Provides the Solution to:

Communicate with Customers 3D Printers are capable of creating appearance prototypes of any complexity directly from digital data, quickly and inexpensively.

Communicate with Vendors The 3D Printer allows footwear companies to print out complex designs for proofing and communicating with vendors. The Printers are also used to communicate across continents by sending files electronically and printing at different plant locations.

Produce Functional Prototypes 3D parts can be used to create RTV molds quickly and inexpensively. The molds can then be used to create prototypes with the look and feel of the finished product.

Create Elastomeric Parts 3D parts ability to create parts with the qualities of rubber allows shoe designers to create flexible soles for customer review and manufacturing feasibility evaluation.

Print Full Color Parts The unique capability of color 3D Printer to create full color parts quickly and inexpensively results in more complete communication of design intent and more constructive feedback.

Nike
New Balance
Wolverine

Problem

HDR was working on a full redesign of a hospital and its surrounding buildings in San Diego. Accurate 3D models of the design concepts were necessary in order to communicate the plans for the project and win the business. Traditionally, HDR created models using large format printed 2D images pasted onto cut and raised foam board to communicate the topographical surface. The models were extremely time consuming to produce. In this case, the schedule was too tight to allow for the traditional modeling process.

The Solution:

Roundstone Digital uses a Z Corp. 3D Printer, capable of creating full color models directly from digital data. The Printer accepts data from CAD, representing the buildings, and GIS data, representing topographical images. HDR contracted with Roundstone Digital to have several models of the proposed plans produced.

Roundstone Digital was able to combine the CAD and GIS data, and produce several color 3D models of the project in 48 hours. HDR was thrilled with the quality of the models and the fast turnaround time.

The Result:

HDR was able to present complex build proposals to the client, and provide a 3D model of each design. These models were used as a tool to better explain the scope and concept of the project as well as a being a great “leave behind” marketing tool for HDR. The models played an integral role in HDR receiving a significant amount of work on the project.

“Roundstone Digital’s turnkey 3D modeling services and 3D Printing technology allowed us to present multiple full-color models to our client at the proposal stage - without any internal resources, significant delays, or large costs. It capitalized on our internal 2D drawing, 3D modeling, GIS, and animation content to create a very accurate and fully colored model in days not weeks.”

-Richard Grogan, HDR

Lockheed Martin
Mitre
Seoul National University Hospital
Harvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare

Problem

Two critical factors in successful orthopaedic and maxillo-facial procedures are clear communication between physicians and patients, and precise implant pre-contouring. Clear communication allows patients to make informed decisions about their medical care, and precise implant fitting is crucial for the well-being of the patient. 3D physical models are an invaluable tool in improving the experience for both doctors and patients.

The 3D Print Solution Provides Models for:

Pre-surgical planning: The ability to use models for pre-surgical planning reduces operating room time, lowers cost, and enhances patient outcomes by minimizing incision sizes, reducing recovery time and allowing for procedure rehearsals. Examples of pre-surgical planning:

• Implant pre-contouring
• Screw trajectory
• Screw selection/location
• Instrument selection
• Technique rehearsal

Custom implant manufacture: 3D models permit the world’s leading implant manufacturers to fabricate custom implants rapidly and cost effectively for the ultimate in performance

Physician to physician communication: 3D models permit excellent communication between physicians and surgical teams; particularly useful in multi-disciplinary cases

Powerful patient presentation tool: 3D models enhance the physician’s ability to communicate with patients; raising confidence in the surgeon and the likelihood of a successful outcome

Medical student/resident education: 3D models prove very useful in communicating with students and residents. Complex 2D images can be converted into easy to understand 3D models that can be held and easily manipulated for a more complete understanding of the anatomy

3D Surface Scanning/Custom Prosthesis Design: Utilizing 3D surface imaging technology; custom prosthesis can be fabricated and used as patterns for the development of molds

University of New Mexico Medical Center
Seoul National University
EBI
Synthes
Medical Modeling

Problem

Visualization and understanding of the geometry of and interaction between complex molecules is extremely difficult using 3D visualization or renderings. According to Art Olsen at the Scripps Institute, “Chemistry is about shape and geometry. To physically interact in real space with molecules provides complete information and new insights. Leading researchers that have been working with a protein or molecule for ten years will immediately learn something new when they hold the molecule in their hand.”

The 3D Print solution provides:

Full Color Models The 3D Printer can create full color models from digital data, representing electrical charge or atomic composition in full color.

Rubberized Parts The system can create parts that can be infiltrated with resin to simulate the qualities of rubber. This makes it possible to produce molecular models that can wrap around each other and accurately represent the interaction in physical space.

Real Space Interaction The 3D Printer quickly and inexpensively produces dozens of iterations of molecules that can then be physically manipulated to help understand their interaction. The high speed and cost-effectiveness of the System makes it possible to have 3D physical space be a routine working medium.

Hybridized Models for Process Visualization and Training The 3D parts can be combined with other elements and inserts to provide a complete picture of the behavior of the molecule being studied. For example, a DNA strand can be printed with magnets inserted to demonstrate the unzipping and replication sequence in very clear physical detail. This hands-on understanding is critical to a fast and complete learning process.

Scripps Institute
Yale University
UCSD
Milwaukee School of Engineering
Seoul National University Hospital
Harvard University
ETH Zürich
TU Chemnitz
FH Wilhelmshaven
UniKlinikum Freiburg
DaimlerChrysler
BMW
Volkswagen
Robert Bosch
SonyEricsson
Pininfarina
Baxter Healthcare