What Can SFF Be Used For?

Use of 3D Hardcopy (+ Finishing) What is 3D Hardcopy good for? (cont.) u Consumer Electronics Design Prototypes ==> touch and feel ! u Mathematical & Topoplogical Models ==> visualization and understanding u Artistics Parts & Abstract Sculptures ==> all-round visual inspection, including light and shadows. My goal is to inspire you to put these SFF technologies to new and intriguing uses. Comments on post-processing:  application dependent !

Consumer Electronics Prototypes Role of 3D Hardcopy – (Part 1): Modeling and Prototyping u Packaging of various electronics components. u Custom designed housing for other utility products. u Prototype demonstrations of novel mechanical gears or linkages.

Prototyping Consumer Products “Solarcator” and “Contact-Compact” Two student-designed “products” in ME221

More ME 221 Student Projects This device combines the functions of a GPS with an altimeter, and also tracks water use. “Dionysense”: a device to track fermentation by monitoring the PH value and acidity in a barrel of wine.

“Gameboy” Form-Factor Studies u Initial Shape Studies: 3D Print  quick turn-around u Final Prototype Shape: FDM  robustness

Watt-Meter: Concept Study (3D Print)

Watt-Meter: Rugged Prototype (FDM)

Button “Mote” and Casing (FDM)

Pico Radio Casing (FDM;  Mold) Custom-made Casing for Modular Research Kit

Injection Mold for Pico Radio u Very sophisticated and very expensive ! Slot done with Electro Discharge Machining

Model  Prototype  Mold Injection Molded Housing for ST TouchChip

Scientific / Engineering Applications SLA

Geometrical / Topoplogical Models Role of 3D Hardcopy – (Part 2): Visualization of objects, when 2D is not quite enough. u Self-intersecting surfaces. u Projections of 4-D polytopes. u Prototyping modular parts, before an injection mold is made.

Single-thread Figure-8 Klein Bottle Modeling with SLIDE

Triply-Twisted Figure-8 Klein Bottle FDM, 9” diam.6 days

The Projective Plane C PROJECTIVE PLANE -- Walk off to infinity -- and beyond … come back upside-down from opposite direction. Projective Plane is single-sided; has no edges.

Model of Boy Surface Computer graphics by John Sullivan

Boy Surface A model of the single-sided projective plane (with no rims and no singularities). FDM 6” diam. 6 days

Morin Surface This is the half-way point of a sphere eversion (without causing creases or tears). 3D-P 6” diam 5 hrs.

Small 4D Polytopes u 24-cell (hyper-octahedron) u 4D simplex (five-cell) u 4D cross polytope

Two Ways to Make a Hypercube 3D Color Print Assembly of flat FDM parts ==>

Hypercube, Perspective Projections

Parallel Projection of the 4D 120-Cell u Zcorp, u 6” diam., u 6hrs.

120 Cell -- Close-up

120 Cell -- Perspective View u Zcorp, u 6” diam., u 6hrs.

Parallel Projection of the 4D 600-Cell u Zcorp, u 5” diam., u 5hrs.

Post-Processing for 3D-Printing Surface is porous, dusty.  seal and strengthen the part: u Dip in wax: l Nice smooth finish l Needs separate waxing station u Infiltrate with “superglue”: l Tedious, dirty manual labor u Spray-paint with a sealant: l Polyurethane (yellowish, smelly) l Krylon (invisible)

Post-Processing for 3D-Printing u Spray-paint surface with Krylon

6D Zonohedron u Sweep symmetrically in 6 directions (in 3D)

4D Hypercube (= Zonohedron) u Tiles are based on Polymorf TM edge connectors. Prototypes made by Kiha Lee on FDM.

Modular Zonohedron Construction Kiha Lee, CS 285, Spring 2002 Injection-Molded Tiles:

u 30 tiles in triacontra- hedral shell u 45 tiles for internal subdivisions 6-Dimensional Zonohedron

Tiles to Assemble Smooth Surfaces u Debugging of geometry using FDM Snap modular tiles together to form smooth surfaces.

Evolution of T-Connector Tiles FDM

Injection-Mold for T-Connectors u Injection-mold geometry after four versions of FDM prototypes. u Still not totally satisfactory: (materials properties!).

Boy Surface from T-Connectors KIHA LEE

Boy Surface

Artistics Parts, Abstract Sculptures Role of 3D Hardcopy – (Part 3): Maquettes for Visualization u All-round inspection, including light and shadows. u Parts to give tactile feedback. u Parts that could not be made in any other way …

Collin’s Conceptual Design SWEEP CURVE (FOR DOUBLE CYLINDER) IS COMPOSED OF 4 IDENTICAL SEGMENTS, FOLLOWS THE SURFACE OF A SPHERE.

Reconstruction / Analysis (v1) AWKWARD ALIGNMENT FROM THE FDM MACHINE

Sculpture Design / Optimization u “Galapagos 2” and “Galapagos 3” ( collaboration with Brent Collins )

Fine-tuned Final(?) Version (v5)

Exploring Minimal Surfaces … “Volution” elements, embedded in a circuit of 12 quarter circles in a cube.

More Minimal Surfaces Stack these modular elements.

Bronze Investment Casting u FDM original can be burnt to cinders in the plaster- of-Paris shell.

How to Get Multi-Colored Parts u Zcorporation: 3D color printer. u FDM: Make ABS pieces in different colors and assemble them; (use ABS solvent as glue). u Paint with different colors. Enamel works very well; (may have to use 2 coats of paint because of porosity of material).

Escher Spheres 1 Assemblies of individual FDM tiles (2.5” diam.)

Escher Spheres 2 Multi-colored Zcorp parts: no assembly needed!

Escher Spheres 3 Multi-colored Zcorp parts: No support removal needed!

“Viae Globi” Sculptures FDM maquettes of possible bronze sculptures

Family of Scherk-Collins Trefoils

Maquettes for a Snow-Sculpture 3D-Print For initial submission FDM For use on site

“Whirled White Web” Int. Snow-Sculpting Championship, Breckenridge C0, 2/1/2003

Which Process Should You Pick? Do you need a prototype (not just a model)? l SLS, FDM (for robustness, strength). Do you need a mold for a small batch? l SLA (for smooth, hard surface). Does part need multiple colors? l 3D Color-Printing. Does part have convoluted internal spaces? l 3D-P, SLS, SLA, FDM* (easy support removal). * Stratasys FDM3000 with WaterWorks

The Most Challenging SFF Part 3 rd -order 3D Hilbert Curve: u much weight u much length u no supports u only two tube- connections between the two halves.

Informal Process Ratings Matrix