3D-PRINT YOUR OWN WORLD CUP TROPHY

The widely-loved sports game – FIFA World Cup 2018 has come to a perfect end in July. With the 2018 FIFA World Cup taken place in Russia, fanatic sports fans around the world are getting faces painted and flags waving in support of their home country or favourite team. While sports fans celebrate the triumph of the winning team in all unique ways, now you can 3D-print your own FIFA World Cup Trophy to commemorate the glorious victory.

The model is based off of the event’s iconic trophy, called the “FIFA World Cup Trophy”, first introduced in 1974 and circulated until present which depicts two human figures holding up the Earth.

With a bit of post-handling, you can make this looks like a read World Cup trophy. If you want to keep the spirit of this international tournament alive with a 3D-printed trophy, keep reading to find out what you need and how to build it.

The printed concept is less expensive and has a very solid touch from the FDM technology using 3D Espresso. It does not require any support material in the process and as the printing bed is limited, the trophy is printed in three different STL files, which includes the globe, the body and the base.

  

Aside from 3D printer and the STL files, there are a few more things you’ll need to make this symbolic trophy. Here’s what you need to complete this project:

  • Hot glue gun
  • Metallic spray paint

With all materials ready, the process started with printing all three parts using PLA materials. At a printing speed of 30mm/s along with 0.2mm layer thickness, it took approximately 28 hours to complete printing all parts. The globe, body and base were then assembled using hot glue gun to see the trophy fully come into shape.

To enhance its aesthetic, the replica was painted in gold metallic paint followed by two signature green lines at its base to resemble the authentic FIFA World Cup Trophy. The trophy was placed into the Memmert oven of about 30°C to dry the paint out. The drying process took around 10 minutes and the trophy is ready to shine.

The FIFA World Cup Trophy replica was created by Rapid Model Team from IME.

Watch the video and get behind-the-scene with us.

Summary of the characteristics of the 3D-printed World Cup replica as follows:

File type : .STL
Printer : 3D Espresso
Technology : FDM
Material    : PLA
Height      : 240mm
Structure   : Assembled from 3 parts – the globe, the body, and the base.
Approximate

build time

: The globe; 10 hours

The body; 14 hours

The base; 3-4 hours

The entire replica was printed using 3D Espresso, a 3D-printer developed by IME.


Features
Printable size    220 X 220 X 220 H mm
Technology Fused Filament Modelling 3D Printer
Nozzle Auto Leveling Single Nozzle, Ø 0.4mm
Positioning Accuracy Z 0.002mm, XY 0.01mm
Printing Speed 20-150 mm/s
Layer Thickness                0.05-0.30mm
Material Supported PLA, ABS, PETG, Nylon, PC, FLEX/TPU & Composer
Filament Size Ø 1.75mm
Max. Extruder Temperature 260 °C
Max. Bed Temperature 120 °C
Specifications
Equipment Dimensions 390 X 390 X 390H mm, 12Kg
Connectivity USB / SD Card
Operation Systems Windows & Mac Compatible
File Format for printing STL, obj, amf, dae, Image & G-Code
System Software Cura & Others Slicer
Power requirements 110V/220V, 250V

Talk to our team if you wish to know more @ info@rapidmodel.com.my , 03-77818878.

Automotive Engineering

CASE STUDY: How TXMR Showcase Chassis Jig Solution Through 3D Printing

Automotive Plant

TXMR Sdn Bhd is a full fledge manufacturing solution provider that mainly focuses on automotive industry, in particular, precision die cut components and manufacturing support products. They provide a complete manufacturing engineering services ranging from ideas, research and development, prototyping to mass production for mechanical and electrical engineering.

As a manufacturing solution provider, TXMR has automated the process of assembling chassis for various automobiles.

As it involves a complex mechanism in automating the chassis, TXMR find it hard to explain this process in particular to their clients.

They tried creating concept models with wood or cupboard paper but it didn’t help much.

Until they decided to 3D print it.

In this post, we will be sharing on what are the challenges faced by TXMR and why they decided to go ahead with 3D printing the gantry rail and crane.

The Process of Chassis Assembly

For a small scale unique production like racing car, the small team would produce a chassis jig to assembly and weld the chassis together.

However when it comes to mass manufacturing things are different.

It is inefficient to rely on manual labour to carry chassis parts individually for welding.

While the simple chassis jig is still valid, but it doesn’t help in solving the challenges faced in assembling and welding process.

With its unique gantry crane and railway, TXMR is able to automate the process through structural engineering to transport the respective automotive parts. This not only helps in holding chassis parts together, but it also help in moving parts for assembly and welding.

With this unique advantage, the challenge for TXMR now is to communicate efficiently with their clients on how can this process adds value to them.

Using Concept Models to Communicate with Clients

Their intention was simple – creating a concept model that can showcase how it works.

Gantry Crane in STL Format

Gantry Crane in STL Format

Conventional method in producing concept models not only seep away their staff’s productivity but it proves to be disrupting their time and production schedule as the traditional concept models couldn’t clearly articulate how the process adds value to their clients.

And that is how they stumble upon 3D printing the concept models.

Gantry Railway

Gantry Railway

Laser Focus on Core Business Activities

The conventional method requires a minimum of 5 days to produce a concept model while the staff struggled to cope with their main tasks.

The concept model costs less than RM 250 and it was printed in ABS, a thermoplastic material. With 3D printer in place, it only took them 8 hours while staffs can focus on their existing fabrication and design engineering project.

While 3D printing concept model is not new, it allows TXMR to focus on tasks that mattered to the business.

To learn more about industrial application for 3D printing – check out our industrial guide which is tailored made for specific industries.

 

 

Petzl Sitta

CASE STUDY: Doing Quality Testing on Petzl Sitta with Customized Jig

Petzl Sitta

Petzl Manufacturing Malaysia uses their jigs and fixtures measure of quality assurance for their product – Petzl Sitta.

While making jig and fixture is nothing new, what’s interesting is the way Petzl Manufacturing Malaysia integrate 3D printing into their existing processes.

If you own a manufacturing floor you would be very familiar with the usefulness of jig and fixture. They serve as a guide to provide repeatability and consistency.

Be it increasing productivity, or guiding assembly for the product, at the end of the day, jig and fixture helps in ensuring the quality of your product through a standardized dimension and process.

So what does that have to do with 3D printing?

Actually it does.

In this post, we will be sharing on why Petzl Manufacturing Malaysia decided to go ahead with 3D printing jig & fixture and a demonstration on how it works.

#1 Increasing Cost of Jig and Fixture

You won’t have economies of scale while doing jig and fixture.

Jig and fixture was tailored made for specific job across the assembly line. If you have 3 assembly lines with 3 different functions, that means you may potentially need 9 jigs and fixtures.

Assembly Line Example

Assembly line example, imagine CNC that many jig and fixtures.

Do note that manufacturing industry in Malaysia is typically a high-mix industries, which involves a series of different projects with fundamentally different items – this means you need to develop even more jigs and fixtures.

Moreover, considering that the cost of jigs and fixtures made in aluminium – it does not come cheap. With the ever-growing amount of jig & fixture, you would hit a point where you spend more time managing inventory instead of manufacturing them, and this leads to the next point.

#2 Productivity Long Lead Time on Jig & Fixture

To increase productivity whilst maintaining high level of consistency and tolerance is not an easy feat.

What most manufacturers do is to create guides and templates i.e. jig and fixture to maintain quality.

However, spending extra machine capacity on making jig and fixture is  tying up machine tools for production works – which is not money making activity.

On the other hand, outsourcing to other may have issues with lead time that take weeks.

Regardless of your choice, the ultimate issue here is spending time in getting the jig & fixture design right.

The design tolerance and function may not be optimal for the product – simply because machining tools in Malaysia are labor intensive.

With 3D printing, Petzl Manufacturing would just print them out at ease.

Watch How Petzl Uses It For Quality Assurance

This video was recorded during poka-yoke check. Poka-yoke is mistake proofing process that helps Petzl Manufacturing Malaysia to avoid (yokeru) mistakes (poka). This fool proofing process is meant to eliminate product defects by reducing human errors as they occur.

Here is a closer look on the digital file:

As a harness for mountain climbers, the gold ring needs to be sturdy enough to not buckle when it meets with a light tap. Conforming to it’s light weight design, the gold ring must be within a specified weight to ensure it doesn’t restrict the movement of mountain climbers.

This is why Petzl Manufacturing Malaysia came up with the 3 labels on the right of the jig – “no”, “OK” and “no good” as a testing measurement. As demonstrated in the video, the buckle on jig must not pass through the gold ring on Petzl Sitta to ensure it falls at the OK range.

Integrating 3D Printing as Part of The Core Process

The whole production of the jig only costs 2 hours and 23 minutes to print, with the cost of less than RM 140. This jig in particular was printed in ABS-M30, a thermoplastic material, this application however, is applicable in both technologies, be it FDM or Polyjet.

This not only gives more flexibility and empowering the design team to develop a functional jig, it would also be time saving as well for the company. Issues such as design validation or design iteration can be done without dwindling down on productivity as the whole process is automated.

Simply put, you can allow the machine to run overnight to produce the jig while everyone is resting while not compromising on productivity.

To learn more about industrial application for 3D printing – check out our industrial guide which is tailored made for specific industries.

 

 

Cutting Costs With Traditional Injection Molding

Factory

Plastic injection molding is one of the most widely used manufacturing processes in the world today. Look around you and you’ll probably see dozens of injection molded parts in your wallet, kitchen, car and office. Here is a quick explanation on plastic injection molding process by MATRADE:

Injection molding is a process of injecting molten plastic into the mode made by custom moldmaker or toolmaker to produce the shape in the way it needs to be designed. This process is known as injection molding process or plastic manufacturing process.

The finished products are normally electrical & electronics parts or components, automotive parts, engineering parts and household products.

If you’re a custom moldmaker or toolmaker that owns your own molding machine, you’ll understand how plastic injection molding can be crucial yet deadly to your business. So in this post, we’ll be discussing on the advantages and disadvantages of injection molding, and how can we further mitigate the disadvantages.

Advantages of Injection Molding

With injection molding, moldmakers can typically enjoy:

  • Faster Production
  • Flexibility in Material & Colour
  • Low Labour Cost
  • Design Flexibility
  • Low Waste

Injection molding is capable of producing an incredible amount of parts per hour. Depending on how many impressions (or known as part molds) are in your tool, you can be expecting 15-30 seconds for each cycle time. Once you have your tool made ready, you can simply inject the material and color of the part that you’re producing at ease.

Most importantly, these are self-gating, automated tools that run on it’s own with little to no labour.

Disadvantages of Injection Molding

There are also some huge restrictions on injection molding:

  • High Initial Tooling Cost
  • Part Design Restrictions

Not only you need to own an injecting molding machine, you will need to be equipped with the technical know-how on designing the mold which can be very expensive. You will need to have some capital to start the project and here is why it is a make or break deal: sales must be guaranteed or at least assured before you start this.

It is also crucial to understand that mold tool is made from two halves that need to pull apart, and the injected part needs to be able to be released from the tool. The process of designing plastic injection mold will require a few key elements such as:

  • Good flow design
  • Good in cooling distributions (or conformal cooling application)
  • Good in air venting

You can also view this infographic guide for better understanding.

So How Do We Achieve Cost Savings With Injection Molding?

While there has always been a debate over whether mold design or molding machine is much more important.

Mold Design in Cooling Channel

If you look at it from the perspective of time spent to correct a problem, typically if there is a faulty molding machine you can simply move the plastic mold to a more capable machine or fix it within a day or two.

However, if the problem exists within the tool it may require a significant tool redesign that could take weeks or even months depending on the complexity of the tool. Tool design inclusive to steel type and construction details is critical for getting the mold initially qualified and also vital for long term quality parts coming from the tool.

If you’re a practitioner of lean manufacturing, it is always about getting it done the right way the first time. In this case, if you’ve gotten a good functional mold design at early stage, you’re gaining a significant amount of cost savings already, due to:

  • Manufacturers normally proceed with injection molding as the deal is confirmed. This manufacturing process allows you to reap the most productivity and savings.
  • If you cut down on time spent on design iterations and prototype productions, you’re earning on machine occupancy & productivity. That means more efficient process to get more business in.

Key-takeaway: It is extremely crucial to have a good functional mold designs. Don’t ever compromise on mold design. Period.

So How Do We Validate The Mold Design?

Here is a steps we used to validate mold design which greatly helped our clients:

  • Traditional Injection Molding Process
  • Part Design
  • Tool Design
  • Tool Machining
  • Molding Machine Setup
  • Sample (first article) run
  • 3D Printing & Injection Molding Process
  • Part Design
  • Tool Design
  • 3D Print Tool
  • Molding Machine Setup
  • Sample (first article) run

Yes, we merely swapped the tool making process by 3D printing it for production testing purposes. 3D printing an injection mold is best fit when:

  • Thermoplastics with reasonable molding temperatures (< 300 °C )
  • Good flowability
  • Candidates such as PE, PP, PS, ABS, TPE, PA, POM, PC-ABS or glass filled resins.

Number of Molded Parts by Resin class

The major savings that you can get from this refined process is:

  • A 50% – 90% on both time and cost savings.
  • The specification of output, spec resins or even production process can be simulated. You can do true functional evaluation.
  • Multiple design iterations won’t hurt your bottomline. You can now detect flaws in part & tool design much more earlier prior commit in mass producing.

Does this mean that I don’t need an aluminium mold anymore?

Injection Molding Sample

Not true. 3D printing injection molds are not meant to replace conventional mass manufacturing process. Alternatively, if you’re looking to do short runs without custom making tool template, 3D printed molds are best fit if:

  • Low quantities (5 – 100)
  • Mid-sized parts (<165cc[10 cu. in.])
    • 5 – 200 ton press.
  • Tolerances>0.1mm(0.004in) *tighter tolerances can be attained depending on post processing.

Conclusion

What we realize is that, if you’re a custom molders, OEMs or even tool and die services shops that requires:

  • Early, rapid product confirmation (design, function, standards (e.g. UL, CE)
  • Early rapid assessment of design for manufacturability.
  • And you’re in the following industries:
    • Consumer Electronics
    • Consumer Products
    • Medical Device

You’ll be able to benefit greatly simply by tweaking this process. Feel free to share with us on your thoughts and how you do cost savings for injection molding.

Why Aesthetic Design Is Important For Footwear

Give a girl the right shoes, and she can conquer the world.

Marilyn Monroe is right, but only half right, because this statement applies to all of us. When it comes to footwear, majority of us would be attracted by the aesthetic design first, then followed by trial to check whether we’re feeling comfortable after wearing the shoe.

Some might have different considerations such as brand, trendiness, or even some other factors, but the trigger point to all this is always the shoe design. When was the last time you bought shoes without looking at the design?

With status, identity and images come into place, no one would want to wear something that doesn’t represent themselves. This is a typical consumer purchasing process.

 

Why Aesthetic Design Is Important?

Imagine this, you’re walking into a footwear retail store with your girlfriend, and she is looking for a pair of sneakers, which she doesn’t have an idea how exactly that look like, yet.

You both walk through dozens of stores, took a break at ChaTime, and continued shopping.

After a whopping 5 hours, you caught a glimpse of shimmering light from her eyes, she said “Hey that sneaker looks good!”

You were happy, grateful and excited, not before long another shocking news hit you – “It doesn’t feel too comfortable. Let’s move, there is nothing more to see here.”

This is my real life experience and I know many of us might face the same scenario. So how does this impact shoemakers?

If the shoe is not designed aesthetically enough, it won’t pique interest of people. What’s more, if it is too aesthetically designed but human ergonomics is ignored, you can’t sell either. 

 

How Nike used 3D Printing To Face This Challenge.

nike-vapor-leash-talon-17-640x426-c

Nike Innovation Director – Shane Kohatsu told Financial Times this:

Within six months we were able to go through 12 rounds of prototype iterations that we fully tested, and ultimately we were able to make super dramatic improvements to our products.

This is how Nike & Adidas uses 3D printing to conduct design experiments, to fully understand how to integrate between design elements, ergonomics and functionality. Take, for example, Nike Vapor Leash Talon was designed to help the nation’s top football athletes maintain their drive stance longer as they train for and compete in the 40-yard dash. Adidas was reported at bringing down the typical prototyping duration from four to six weeks down to two days.

The best thing about 3D printing is it allows you to print and test on demand, this speeds up the traditional design and manufacturing process by leaps and bounds.

 

Our Own 3D Printed Shoe.

We actually designed and printed a “leather” shoe on our own, it was printed via Polyjet with a combination of rubber and rigid materials to control the shore value (a.k.a rubber hardness).

Look at the fine surface texture. It was printed in a go, no assembly, no gluing.

As of now, we’re not there yet in terms of directly 3D printing the shoe for daily use, yet. But if we’re talking about design iterations and form, fit study, then yes, 3D printing is a very good fit for R&D companies.

 

 

 

 

3D Printed Optics Inspired by Disney Research

 

Inspired by Disney’s Research & Development team for their 3D printed optics, we’ve designed a 3D printed light pipe block to experiment on light travelling across by using VeroClear from Objet500 Connex3. This light pipe block uses the light travelling theory such as the deflection theory, theory of light intensity and the optics theory. Here is what we did:

#1 Developing A Technical Drawing

Upon reviewing the optical test made by Disney’s Research & Development team, we made several adjustments to our design. The block was designed to have an approximation base of 7.4cm, 7.3cm for its width and 1.9cm for its height(actual finish part). This gives us a clearer view of the light intensity and the travelling limits that light can pass thru.

Block Dimension

  • Height : 20mm
  • Base   : 80 mm
  • Width : 80 mm
Ring Dimension

  • Outer ring: 2.5R
  • Inner ring: 2.45R
  • Tolerance: 0.025R

Once the favorable dimensions has been determined, curved tubes were drawn which were designed to embed within the block. We tested 8 curved tubes which were designed from one face and swept to the other rectangular face of the block, leaving a few centimeter gap from the tail of the tube, whilst the head touches the first rectangular face of the block.

3D Printed Light Pipe - Technical Drawing

The trick that allows the light travel through the ring in the block actually is the tolerance between the outer & the inner ring. When this was part printed by the Polyjet technology machine, the tolerance between that two ring will printed with full of support materials that allow light to travel.

#2 Sanding & Polishing Techniques

Upon completion of printing, we used a high speed water jet machine to remove the support material. Once it is cleaned, the block is sanded using several types of abrasive sandpapers. Once the surface of the block has been smoothed, the block is then polished using a polishing liquid. The final product would be a clear block with embedded tubes.

3D Printed Light Pipe Block - Before After

The light effects were tested using laser pointers and built-in torch smartphones. The resulted light effects were visible at the tail of the curved tubes.

3D Printed Light Pipe - Light Illumination

Noticed how the light dots are appearing at the 3rd pipe?

Key Takeaways

Results were not as perfect as what was shown on Disney’s light path block video but from this experiment, we can conclude that the Stratasys Polyjet printers are able to develop a clear object that can match the reflective capabilities of a mirror.

3D Printed Impossible Triangle

The Impossible Triangle

I suppose most of us are pretty familiar with this – impossible triangle optical illusion.

Impossible Triangle Sketch

Impossible Triangle Sketch

 

What about a 3D printed one?

3D Printed Impossible Triangle

3D Printed Impossible Triangle

3D Printed Impossible Triangle - Bottom View

It’s actually curved.

3D Printed Impossible Triangle - Side View

Check out the side view.

Don’t mind the triangle, we were too excited to check out the optical illusion instead of cleaning it properly (it was printed in rubber-like material from Polyjet). Do you have any optical illusion stuff to share with us?

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 – uPrint 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.