3D Printed Pin3D Printed Pinhole Camera From The Fronthole Camera Front View

Pinhole Camera Designed By Primary School Student

You wouldn’t believe that a primary school student with NO experience in CAD software manage to design a pinhole camera, check out how it looks like below.

Outcome:

3D Printed Pin3D Printed Pinhole Camera From The Fronthole Camera Front View

3D Printed Pinhole Camera From The Front

We started this project few months back to teach student on how to design using SolidWorks and also printing out their designed models. This model in particular was printed with Polyjet.

So… this is what we get after weeks of nurturing.¬†We have to say we were really surprised, at the same time honored¬†to see such an astounding result. Kudos to the student who designed this!

Symphoy 3D Printed Gift_Side

Embedding Application in 3D Printing

3D Printing has been flexible in many ways and of course – even in embedding IT chips. It is widely known that this technology is capable of integrating electronics into the prototype, just by pausing and inserting the chip. During our preparation for SolidWorks Innovation Day, we toyed around this similar concept, but instead of chips, we wanted to embed words within the gift.

Here Is What We Did:

File Source: Own design
Technology: Polyjet
Printer:  Objet500 Connex3
Materials: Digital Materials (Cyan, Yellow & Transparent)
Build Time:  2 hours 49 minutes

Screenshots in CAD file:

Symphony 3D Cad File

Symphony 3D Printed Gift

Noticed how it was designed to embed words inside inside the printed transparent frame?

Outcome:

Symphoy 3D Printed Gift_Side

Symphony 3D Printed Gift

Looks pretty cool eh? While we spin off the application onto printing a premium item, this is widely used in both engineering & medical field as for prototyping purposes as well as teaching aid. Check out this medical application by The Engineering here.

From a business perspective, the capability to do multi-material and multi-color printing cut shorts a significant amount of time and error.

  1. Reduced manufacturing layer – no need to go through multiple processes for a single part.
  2. Manufacturing a prototype will go through many manual process and by eliminating these processes, human error will be significantly reduced as well.

There is more to what Polyjet can do, check out our relevant posts below to find out more!

3D Printed iPhone Amplifier_CAD_Top

How We Turn iPhone 4 Into Loud Speaker.

The Story Behind The Idea

With the recent hype on iPhone 6 and iPhone 6 plus, we decided to shower some love for its predecessors, and no, we are not doing any bend test.

Just in case you didn’t know, we just ended our nationwide SolidWorks Innovation Day¬†few weeks ago. However during the planning of the event, we were stuck with few things:

  • What innovative lucky draw gift¬†can be given out? It needs to be unique to the receiver (none in the market) yet innovative.
  • It needs to be relevant to the mass participant profile (we wouldn’t want you to receive something that you have no use of).

While we were having casual discussion (still struggling with the lucky draw gift), we realised that most of our customers are using iPhone 4 during our sales visit & past events attendance. That is how we started off with doing something for iPhone 4.

Our Issue With iPhone 4

Most often than not, we “the iPhone” users over here find that the audio speaker seems to be lacking, it is definitely better than majority of the phones where speaker is placed behind, however, placing it bottom doesn’t provide the best experience either. We need an iPhone speaker amplifier.

We did our research and realise¬†that there were many amplifier being sold online. but surprisingly, we didn’t find a 3D printed one. There you go, that’s how we came up with 3D printing an iPhone 4 amplifier.

Here is what we did:

File Source: Own design
Technology:  FDM
Printer:  Idea Series РuPrint SE
Materials: ABS Plus Orange
Build Time:  7 hours 16 minutes

Screenshots in CAD file:

3D Printed iPhone Amplifier_CAD_Top

#IME #SWID2015 3D Printed iPhone Amplifier

It was designed in a way to conveniently stand on its own, you can just simply slot in your iPhone into it vertically and play the music. Hence the printed model needs to be able to support iPhone’s weight (specific endurance).

Outcome:

3D Printed iPhone Amplifier Functional Test

#IME #SWID2015 3D Printed iPhone Amplifier Functional Test

Here you go! While we hope the lucky draw winner is happy with this, more importantly this proves the concept of direct digital manufacturing – where you can simply design & print on demand.

3D Printed Fixture for Consumer Electronic

What is a fixture?

A fixture is mainly used in manufacturing industry to hold manufactured part and act as a support device to secure position in a specific location or orientation. The use of fixture is widely adopted by manufacturers as it improves the productivity by streamlining operation and quick transition from part to part.

How jig & fixture is done traditionally?

In contrast with mass production concept, a manufacturer will only need a few jigs & fixtures typically 5 – 100 pieces depending on their assembly line. These are normally manufactured via subtractive manufacturing method in metal / aluminium, and easily take 3 – 6 months time along with the master mould production.

Imagine a manufacturer with different projects Рthey would require a different fixture as the product differs. This translates into high overhead / inventory cost for keeping a short term use fixture.

Assembly Line Example

Assembly Line Example

 This is where 3D printing comes in.

3D printing leverage on few points to tackle the current manufacturing problem:

  • Print on demand. This not only allow you to significantly cut short on production time, it also allows you to streamline your operation at a quicker pace.
  • Lesser cost. Optimize your fixture cost by printing it in a tough material but at a cheaper cost.
  • Custom design. Some fixtures require custom novel design which traditional manufacturing has limitations, this is where 3D printing shines.
Assembly Line With Fixture

Assembly Line With Fixture

 

Here is what we did for our customer recently:

File Source: Client
Technology:  FDM
Printer:  Idea Series РuPrint SE
Materials: ABS Black & ABS White
Build Time:  3 hours 30 minutes

Screenshots prior printing:

Outcome:

Implications:

  • This was printed in mere 3 hours and 30 minutes – shortened the production time by a significant gap.
  • This allows manufacturers to better streamline their current operations without fuss.
  • More importantly, this flexibility provides a significant competitive advantage to manufacturers as they have shorter turn around time!

 

3D Printed Aeroplane - Assembled 3

Wind Tunnel Testing with 3D Printed Aeroplane

Wind tunnel test is an integral part of the design process in many industries, especially for aerospace. This is used to verify and study the aerodynamic properties of solid objects such as air velocity and pressure.

Traditionally, concept model made for wind tunnel testing relied heavily on CNC machining. Common materials are metal, plastics and compisites. These operations require programming, machine setup, operator supervision which adds to lead time and cost.

This is where 3D printing comes in. The printed concept model is durable, yet faster, less expensive and more efficient. This is especially useful when it comes to doing hollow printing to simulate internal passages where this would complicate the CNC milling process. Embedding testing equipment into the model is also accessible with 3D printing.

Here is the file source & technology we used:

File Source: Client
Technology:  Polyjet
Printer:  Design Series РObjet30 Pro
Materials: Vero White
Build Time:  4 hours

Screenshots prior printing:

Outcome:

3D Printed Aeroplane

3D Printed Aeroplane for Wind Tunnel Testing.

Implications:

  • In comparison with traditional manufacturing method, 3D printing this concept model will only take a fraction of the original cost in terms of lead time and money.
  • Having more time allows more refinement/improvement ¬†to happen. The potential for improvements is bigger as we take shorter time to produce concept model for testing purposes.
  • Another important factor is¬†the availability of model material. Aerospace and automotive industry in particular study about how weight reduction can assist in overall efficiency. Light weight material from Polyjet machine is able to simulate such environment for a better study result.
3D Printed Mobile Kiosk Assembled - Diagonal View

Concept Model for Mobile Kiosk Cart

When was the last time you¬†“tapau” food from a mobile kiosk? These mobile kiosks are getting immensely popular especially in colleges and universities.

This time, we 3D printed a novel mobile food kiosk for concept modelling. It was designed by an architecture student in Taylor’s University and wanted to see how it will look like – physically.

Here is the file source & technology we used:

File Source: Client
Technology:  FDM
Printer:  Idea Series РuPrint SE Plus
Materials: ABSPlus-P430 Black, ABSPlus-P430 Grey
Build Time:  32 hours (we printed this in 3 batches for assembly purposes)

Screenshots prior printing:

Outcome:

3D Printed Mobile Kiosk Cart

3D Printed Mobile Kiosk Cart, looks pretty cool eh?

Implications:

  • For concept modelling and upon request, this was printed in pieces for assembly to study the design & precision printing. Of course if needed, this can be built in a single print.
  • As this will be detached and reassembled for quite a number of times, we printed this in FDM¬†so it will be more durable.

We’re excited to see new mobile kiosks design coming up and hope that this will breathe a new life into architecture design!

How We 3D Print A Tower’s Dome

When was the last time you went for a property search, especially new property launches?

Architecture Model

We often scout around the models, checking if the facilities are built as per promised. Checking the traffic around the vicinity, direction and coordinates for the best Feng Shui. These property models are typically handmade from card boards to wood, or even acrylic as these are precise manufacturing methods, however, they are taking at least 1 – 2 months for the production and may cost up to hundred thousands for a simple model with LED lightning etc.

 

With the understanding that models need to be explicit, one client approached and requested for us to test print the highest part of a tower Рa Dome:

File Source: Client
Technology: Polyjet
Printer:  Objet Design Series
Materials: VeroWhite Plus, VeroClear, Fullcure 835
Build Time: 7 hours and 7 minutes

Screenshots prior printing:

Outcome:

Implications:

  • We printed this model with Polyjet technology at 30 microns or 0.03mm for the precision. Noticed that it has some windows in between the dome itself?
  • It was in glossy finish (hence you would notice the surface is shiny). While the image quality may not be good or it appears to be, rough finishing (blame our phones), it actually has a pretty smooth surface and can be enhanced if needed.
  • Traditional model making methods may require assembly and take major time on refining the minor details on the dome. This was printed in mere 7 hours with no touch-up.
  • The best part is the material cost is way cheaper than traditional method, contact us to understand more about the costs and ROI.

Seeing AM as a different way to tackle traditional model making not only allows a better ROI, it also allows a better flexibility in terms of man-power. Best part is, you get better quality product as well!

3D Printed Heart Model - Full 2

We Printed An Actual Human Heart

It’s real. We 3D printed a heart.

Hold your horses on questions and listen to us for now.

The ultimate goal in medical field  is to 3D print a fully functional heart however, with many technical considerations such as tissue condition, implantation, sustainability and etc, 3D printing technology is still lacking in these areas albeit advancing at a steady pace.

This 3D printed heart in particular belongs to a patient. Our client intended to study his/her heart to understand how the surgery can be done, as well as using the heart model for explanation. As we’ve mentioned on our¬†Facebook¬†and¬†LinkedIn, this is one of the best study materials you can have prior a surgery.

Here is the file source & technology we used:

File Source: Rapid Model Development Sdn Bhd
Technology: Polyjet
Printer:¬†¬†Objet Design Series –¬†Connex 3
Materials: VeroWhite, VeroCyan, VeroMagenta
Build Time: 11 hours and 52 minutes

Screenshots prior printing:

Outcome:

Implications:

  • We used Polyjet (or Connex 3 in particular) in this case as it offers multi-material and multi-color capabilities. This heart model in particular, requires a lot of precision to print out blood arteries as well as rubber-like texture.
  • Some may ask, why not print this in a go? Yes we can, not an issue at all. However to allow doctors and patient to understand the heart structure in a detailed manner, we made the model in assembly format.

We hope that this model will aid surgeons in their surgery understanding, as well as helping patient to understand better of their own heart condition.

3D Printed Motorcross Helmet - Front

Motorcross Helmet in Action

This week we printed something different, something that racer boy would yearn for – Motorcross Helmet. The best part is right after the model was printed, we had the opportunity to showcase this during Innovating Malaysia Conference 2014.

Here is how we did the printing, and some underlying reasons of material & technology selection:

File Source: Rapid Model Development Sdn Bhd
Technology: FDM
Printer:  Fortus 380mc, uPrintSE
Materials: PC-ABS (Black), ABS (Red)
Production Time:

Fortus 400mcuPrintSE
Build Time86 hours 24 minutes 7 hours 44 minutes
Assembly Time30 minutes
Support Removal Time16 hours6 hours

Screenshots prior printing:

Outcome:

Implications:

  • Traditionally, the production material for helmet is polycarbonate (PC) for best endurance and heat resistance. However, as we wanted the helmet in black and red which is not in the range of our PC material, we opted for PC-ABS instead.
  • PC-ABS combines the best of both materials (PC & ABS) – the superior strength¬†and heat resistance of PC and the flexibility of ABS.
  • For drop testing and pressure testing etc, this prototype will serve as a good gauge for improvements as compared with existing product.
  • Noticed how the black helmet base was printed in a go but we had to print the decor separately? This is due to FDM does not support multi-material modelling as that is under Polyjet’s feature.

We Printed A Spectacle For Colleague

Lots of people have been asking – do you have transparent material? So this round we decided to print something unique – spectacles.

Below is some information on file source & technology we used:
File Source: Rapid Model Development Sdn Bhd
Technology: Polyjet
Printer:  Objet Design Series
Materials: Tango Black+, VeroWhite, VeroCyan, VeroClear (lens)
Build Time: 5 hours and 35 minutes

Screenshots prior printing:

Outcome:

Ezrul wearing 3D Printed Spectacle

Implications:

  • This is a concept modelling application which we need to find out if the design is feasible. Various factors such as ergonomics, functionality (joint of spectacle) and design were factored in for this project.
  • Polyjet is selected as it offers a wider range of materials, which in this case a mixture of rubber-like, ABS & translucent material.¬†As this was part of our experiment with¬†Connex 3, it¬†is capable of injecting 3 materials at a go which consists of ABS and rubber-like materials in different colors (2 different blue & 1 black, with different shore level).
  • The frame itself was printed in a go, notice how the joint functions, no post assembly is needed. This is the representation of precision printing.
  • To ease the wearer’s uneasiness when frame is too tight etc, we printed some rubber-like material at the end of the frame (black rubber), this acts as a buffer to reduce the uneasiness.
  • The lens on the other hand, is printed separately and assembly later.

At the end of the day, the specs came quite quite comfy, look at how Ezrul is wearing it happily. So if you’re looking to do concept modelling and it requires multiple material printing as well as colors, go for Polyjet as it offers much more diversity compared with FDM.