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What Can SFF Be Used For?
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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 !
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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.
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Prototyping Consumer Products “Solarcator” and “Contact-Compact” Two student-designed “products” in ME221 http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/
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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.
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“Gameboy” Form-Factor Studies u Initial Shape Studies: 3D Print quick turn-around u Final Prototype Shape: FDM robustness
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Watt-Meter: Concept Study (3D Print)
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Watt-Meter: Rugged Prototype (FDM)
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Button “Mote” and Casing (FDM)
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Pico Radio Casing (FDM; Mold) Custom-made Casing for Modular Research Kit
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Injection Mold for Pico Radio u Very sophisticated and very expensive ! Slot done with Electro Discharge Machining
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Model Prototype Mold Injection Molded Housing for ST TouchChip
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Scientific / Engineering Applications SLA
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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.
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Single-thread Figure-8 Klein Bottle Modeling with SLIDE
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Triply-Twisted Figure-8 Klein Bottle FDM, 9” diam.6 days
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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.
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Model of Boy Surface Computer graphics by John Sullivan
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Boy Surface A model of the single-sided projective plane (with no rims and no singularities). FDM 6” diam. 6 days
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Morin Surface This is the half-way point of a sphere eversion (without causing creases or tears). 3D-P 6” diam 5 hrs.
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Small 4D Polytopes u 24-cell (hyper-octahedron) u 4D simplex (five-cell) u 4D cross polytope
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Two Ways to Make a Hypercube 3D Color Print Assembly of flat FDM parts ==>
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Hypercube, Perspective Projections
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Parallel Projection of the 4D 120-Cell u Zcorp, u 6” diam., u 6hrs.
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120 Cell -- Close-up
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120 Cell -- Perspective View u Zcorp, u 6” diam., u 6hrs.
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Parallel Projection of the 4D 600-Cell u Zcorp, u 5” diam., u 5hrs.
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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)
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Post-Processing for 3D-Printing u Spray-paint surface with Krylon
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6D Zonohedron u Sweep symmetrically in 6 directions (in 3D)
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4D Hypercube (= Zonohedron) u Tiles are based on Polymorf TM edge connectors. Prototypes made by Kiha Lee on FDM.
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Modular Zonohedron Construction Kiha Lee, CS 285, Spring 2002 Injection-Molded Tiles:
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u 30 tiles in triacontra- hedral shell u 45 tiles for internal subdivisions 6-Dimensional Zonohedron
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Tiles to Assemble Smooth Surfaces u Debugging of geometry using FDM Snap modular tiles together to form smooth surfaces.
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Evolution of T-Connector Tiles FDM
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Injection-Mold for T-Connectors u Injection-mold geometry after four versions of FDM prototypes. u Still not totally satisfactory: (materials properties!).
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Boy Surface from T-Connectors KIHA LEE
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Boy Surface
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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 …
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Collin’s Conceptual Design SWEEP CURVE (FOR DOUBLE CYLINDER) IS COMPOSED OF 4 IDENTICAL SEGMENTS, FOLLOWS THE SURFACE OF A SPHERE.
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Reconstruction / Analysis (v1) AWKWARD ALIGNMENT FROM THE FDM MACHINE
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Sculpture Design / Optimization u “Galapagos 2” and “Galapagos 3” ( collaboration with Brent Collins )
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Fine-tuned Final(?) Version (v5)
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Exploring Minimal Surfaces … “Volution” elements, embedded in a circuit of 12 quarter circles in a cube.
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More Minimal Surfaces Stack these modular elements.
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Bronze Investment Casting u FDM original can be burnt to cinders in the plaster- of-Paris shell.
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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).
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Escher Spheres 1 Assemblies of individual FDM tiles (2.5” diam.)
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Escher Spheres 2 Multi-colored Zcorp parts: no assembly needed!
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Escher Spheres 3 Multi-colored Zcorp parts: No support removal needed!
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“Viae Globi” Sculptures FDM maquettes of possible bronze sculptures
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Family of Scherk-Collins Trefoils
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Maquettes for a Snow-Sculpture 3D-Print For initial submission FDM For use on site
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“Whirled White Web” Int. Snow-Sculpting Championship, Breckenridge C0, 2/1/2003
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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
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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.
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Informal Process Ratings Matrix
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