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أخواني في الله أحضرت لكم كتاب 3D Printing for Product Designers Innovative Strategies Using Additive Manufacturing Jennifer Loy, James Novak, and Olaf Diegel
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Contents List of figures viii List of tables xv Acknowledgements xvi Author biographies xvii Introduction 1 1 Demystifying 3D printing processes and workflow 12 2 Working with a design for additive manufacturing (DfAM) consultancy 52 3 Strategy 1: Working with existing production 67 4 Strategy 2: Product redesign and new product design 96 5 Strategy 3: Digital business innovation 122 6 Case studies: 3D printing from the product designers’ perspective 145 7 DfAM: Design guidelines for product designers 207 8 3D printing sustainability and digital ecosystems 244 9 Making the future/remaking product design 266 Glossary of terms and acronyms 275 Notes on organisations, companies, and designers 278 Index 281viii u List of figures 1.1 A new framework for additive manufacturing technologies for product designers. Solid boxes/circles indicate overlap with the ISO/ASTM 52900 standard categories of additive technologies 17 1.2 Close-up detail of the layers on a dual-material 3D print produced on a desktop FFF machine using 0.2 mm layer thickness and a PLA material (grey) and TPU (white) 22 1.3 Stereolithography (SLA) – laser cured resin with internal resin support structure (Loy) 23 1.4 Multiple material, full-colour material jetting technology used for medical models as communication and planning tools, such as on the Mimaki printer (a) and on a Connex (b) 25 1.5 HP Multi Jet Fusion (MJF) colour sample that is cut open to show interior grey colour 25 1.6 The three main processes required to go from CAD to 3D print 26 1.7 A solid model of a tube in CAD software (a) compared to a low-resolution STL (b) and high-resolution STL (c) 28 1.8 The two core components of an OBJ file are the 3D mesh file (a) and PNG image file (b) that combines into a full-colour model (c) 29 1.9 The same STL file with error in two different slicing programs, with only one of them clearly indicating a problem through red colouring 31 1.10 Mesh repair software can be used to highlight and correct problems in 3D print files, in this case overlapping triangles 32 1.11 A mesh hole (a) which has been repaired to follow surrounding geometry compared with a more organic addition (b) that does not suit the designers’ intent 33 1.12 Typical file conversion stages from CAD to 3D printer 34 1.13 Imported STL (a), sliced model (b), and detail of some of the slices showing the pathway of the print nozzle (c) 35 1.14 Setting up different supports for a Selective Laser Melting (SLM) process 35ix u List of figures j 1.15 Process of removing the “cake” from the SLS printer and then removing parts by hand on a table with a built-in vacuum to collect powder 41 1.16 Blast cleaning the parts and detail of a part with fine details where blasting does not completely remove excess powder 41 1.17 Handle manufactured in stainless steel using selective laser melting (Loy) 46 1.18 Handle showing support material from the selective laser melting process 47 1.19 Multiple prints attached to the base plate (top); manual removal of support material (bottom) 48 1.20 Small test pieces for understanding support material strategies for metal printing 49 1.21 Creating an assembly with metal printing is possible and requires an understanding of support placement (a) and tolerances, informed by an understanding of post processing (support structures removed) (b, c) 50 2.1 Mapping the technology adoption journey 54 3.1 Overview of Strategy 1 approaches to 3D printing 67 3.2 68 3.3 Example of rapid prototyping – MagnaLatch Series 3 pool safety gate latch 72 3.4 Example of bridge manufacturing: drug delivery storage container 74 3.5 Example of fixtures for welding 77 3.6 Example of a jig – angled drilling jig to achieve a precise 31.6° angle 82 3.7 Example of enhanced tooling – conformal cooling channels shown through both cross-section (left) and transparent print (right) 86 3.8 Example of agile manufacturing – a one-off mould for vacuum forming utilising a 3D scan of someone’s face, to be used for some chocolate moulds 88 3.9 Example of a positioning jig 94 4.1 Overview of Strategy 2 approaches to 3D printing 96 4.2 97 4.3 Example of part consolidation – guitar holder and guitar stand 104 4.4 Example of light-weighting – Atlas Copco Hydraulic Manifold 106 4.5 Example of customisation – topology-optimised walking frame lugs 111 4.6 Example of form determined by function – Canal House wall construction 114 4.7 DUS Architects 3D printed formwork creates voids that can then be filled with different materials, such as concrete or pulp 115 4.8 Example of product innovation – Tuber9 light series 117x u j List of figures 4.9 Fox Coral Solutions can now supply their traditional aftermarket motorcycle parts like foot pegs (green), while also providing customised 3D printed inserts (orange) that can be sold as part of the package, or individually curated by riders online 119 5.1 Overview of Strategy 3 approaches to 3D printing 122 5.2 123 5.3 Example of a digital inventory project – parts digitised, redesigned, and validated in Australia for 3D printing, then 3D printed in Nairobi, for the Oxfam G.B. WASH project 125 5.4 Example of a distributed manufacturing context – low-cost, open-source 3D printed face shield called the RC3, designed by Prusa Research (Novak) 128 5.5 Example of personalisation – Child’s Play prosthetic made to fit an arm scan 131 5.6 3D scanning interfaces are becoming easier to work with, and a wider range of equipment is now available 132 5.7 Example of the creation of an adaptable system – Nodal Design 134 5.8 Example of an automatically generated race car spaceframe from a solid CAD model 136 5.9 Example of digital business innovation – Prosfit, led by Alan and Christopher Hutchison 138 6.1 A selection of Rehook prototypes 3D printed using desktop FFF to allow quick and cost-effective iteration (a) SLS production of Rehook in progress 146 6.2 Evolution of Rehook from prototype to final product 147 6.3 Process of topology optimisation of the seat post bracket with a final image of the bracket in its printed orientation, amongst other frame pieces on a build plate 148 6.4 Complete 3D printed titanium bicycle frame from Empire Cycles and Renishaw 149 6.5 Compression testing of early lattice sample (left), comparison of aerodynamic properties of a standard tube and lattice geometry using simulation (right) 150 6.6 FIX3D bicycle frame 151 6.7 Wind tunnel testing of Dynaero at 44 km/h 153 6.8 Dynaero 3D printed bike helmet and accompanying mobile app 153 6.9 The Atom 155 6.10 FEA analysis showing deflection of original ODD Guitar body (a), 2nd iteration (b), and 3rd (c) 156 6.11 A production run of Americana and Atom guitars. Each guitar has features specific to each musician (Diegel) 158 6.12 The Scarab ST full-colour 3D printed guitar (Diegel) 159xi u List of figures j 6.13 Aluminium guitar still welded to the build-plate, and close-up showing the support material below the barbed wires (a). Finished Heavy Metal aluminium 3D printed guitar (b) 160 6.14 The GreenAxe 3D printed wood guitar. Printed in sawdust and lignin-based bio epoxy using a proprietary binder-jetting 3D printing process 161 6.15 Close-up of Adrian McCormack’s SLS guitar 162 6.16 Marbled finish achieved using hydro-dipping for the SLS printed guitar (McCormack) 162 6.17 Multiple piece guitar, filament printed 163 6.18 Berto Pandolfo designed the “MND” furniture series exploring the relationship between the handmade and machine-made, in timber with 3D printed legs 164 6.19 Fingerprint Stool 165 6.20 Failed print after being dislodged from the build plate without raft (a) and completed stool in the BigRep ONE printer (b). 166 6.21 Ghost Chair 168 6.22 Pneumatic, flexible water-creatures by Ross Stevens (a) and rigid 3D printed prop glove by Tor Robinson and Ross Stevens of Victoria University, New Zealand (b) 170 6.23 Material jetting, 3D printed, multi-material eyes 171 6.24 3D printed faces based on 3D scan, with 3D printed eye inserts – see Figure 6.23 171 6.25 Large format 3D printing by Studio Kite: Chariot for the movie Thor: Love and Thunder; statue and column for Thor: Love and Thunder prior to finishing 175 6.26 Textile assembly printed as a single part (a), 3D printing directly on fabric (b) 175 6.27 Examples of SCAN2CAST 3D printed custom splints 178 6.28 Setting up the trim and split lines to automatically generate a ready-to-print splint 179 6.29 Custom-made, 3D printed decorative splint 180 6.30 Stigma-to-Silver-Linings 181 6.31 Super-abled 182 6.32 Angel Leg 183 6.33 3D printed artery model with stent 184 6.34 Detailed view of a prototype implant housing which was printed using FFF (a); a collection of different prototypes can be printed with FFF in <30 minutes at this scale (b); testing the fit of different sized magnet housing on different 3D printed skull anatomy (c); a collection of SLS printed housings to be embedded in the silicone prosthesis (d); fitting of a prosthetic ear using the magnet systemxii u j List of figures over a skin-like silicone sheet (e); detailed view of early experiments directly gluing magnets into a prosthesis to match the 3D printed implant design (f) 185 6.35 Experimenting with materials and simple prototypes from a Stratasys J750 Digital Anatomy Printer to gain feedback from neurosurgeons about haptic and other qualities compared with real anatomy 187 6.36 Cartridge system models designed by Liam Georgeson 187 6.37 A final prototype of the EVD training model, along with some material samples, and a StealthStation navigation device set up in the background 188 6.38 Topology-optimised mask produced using FFF being fit tested to a phantom (a, designed by Amirhossein Asfia), full-colour MJF printed mask featuring light-weight lattice structure and markers for tracking (b, designed by Faizan Badar) 189 6.39 Intubation simulation with the mask fitted with square filter housings (left), fit testing with the Halyard qualitative fit testing kit (right) 190 6.40 Creating samples as a catalogue of digital printing to inform practice and for communication with clients 191 6.41 Exploring the ability to create form with 3D printing using SLM, SLS (right), and MJF (left), designs modelled in Solidworks 192 6.42 Exploration of organic form, designed, 3D modelled, and 3D printed by David Haggerty 193 6.43 Fractilus range of jewellery designed by David Haggerty, using 3D printing in different ways during the process (a) direct metal printing, and (b) lost wax casting 193 6.44 Material jetting vases, showing prior to postprocessing through finishing, and a large example of a print (approx. height 600 mm and a close-up showing internal detail) 194 6.45 Ball within a ball trophy design and Bling3D earrings/cufflinks 195 6.46 Smallest versions of the earrings (a) and larger size showing the level of detail that can be achieved (b) 195 6.47 Underside of failed experimental print (a); series of postprocessing steps (b); finished bracelet designs (c) 196 6.48 Comparison of a conventional mass-produced kitesurfing fin and 3D printed ABS version (left), 3D printed kitesurfing fin during early tests on the water (right) 198 6.49 Example range of surf fin shapes that can be generated algorithmically using Grasshopper and Rhino, with users interacting with a simple control interface that hides the complex model processes (a), 3D printed carbon fibre-filled nylon surf fin, generated algorithmically (b) 199xiii u List of figures j 6.50 Cross-section through 3D printed heat exchanger 200 6.51 Illustrative example of a single gyroid cell (two versions on the left) and network of connected gyroid cells (two versions on the right). The red (hot) zone is kept separate from the blue (cold) zone 201 6.52 Basic CAD body for a radiator showing 10 separate bodies that form the radiator sub-components (left) and a diagram of a heat exchanger (right) 202 6.53 Creation of a gyroid with a cell size and wall thickness to meet specified heat transfer characteristics (a) with a cross section of the TPMS (b) 202 6.54 Section view of completed heat exchanger, including hot and cold fluid zones (a), the printed part showing minimal support material requirements (b), printed heat exchanger section (c), and assembly for testing (d) 203 6.55 Using a related workflow to go from a heat exchanger to a radiator (a). Printed radiator made using same heat exchanger workflow (b) and cross-sectional view (c) 204 7.1 Cut sample off an HP Jet Fusion 580 machine showing the difference between the internal fusing agent (dark grey) and external detailing agent with colour 211 7.2 3D FFF printed lattice structures 221 7.3 Colour test pieces printed on a HP Jet Fusion 580 machine prior to surface treatment: (a) font and colour testing on curved geometry, (b) CMYK swatches which can be sampled through spectrophotometry and compared to digital colours 224 7.4 From left to right: Original CAD model; High resolution STL mesh; Low resolution STL mesh; Detail showing the variable spacing between assembled parts and faceted curves 225 7.5 ‘THEY’ principles of support and orientation 228 7.6 Example of packing for the HP Jet Fusion 580 3D printer 229 7.7 Different infill geometries commonly available for FFF 3D printing. All of these were specified within slicing software 232 7.8 Alternative surface finishes for metal prints – a part that has been polished (a), and the same part bead blasted with a more matte surface finish (b) 236 7.9 From left to right: Raw aluminium ring from SLM process with some support material removed; ring after support removal, filing, and bead blasting; ring after polishing for five minutes with a polishing wheel 237 7.10 Test pieces: Support structure for FFF can be difficult to remove (a); designing to eliminate support structure (b); complex structures avoiding supports (c) 240xiv u j List of figures 8.1 Hexa-Phone Amplifier won the iMaterialise 3D Printed Wood Challenge. It is 3D printed using selective laser sintering, with the bulk of the powder made up of waste wood product 245 8.2 Australian start-up Polylab developed a screw-based extruder system which can utilise shredded plastic from discarded prints, or other waste products, through a hopper system. In this example, HDPE material is being turned into a new product 246 8.3 Examples of 3D printing used to repair common household products: Replacement drawer roller (a), corner joint for aluminium window screen (b), bracket to retain control buttons inside a kitchen rangehood (c) 248 8.4 3D printed versions of “inflatables” artwork by Gregor Kregar, showing support structure on metal 3D print 250 8.5 At-home, desktop 3D printer fridge vent repair 261xv u List of tables 1.1 Data for tube STL files 28 7.1 Commonly available materials for SLS and MJF 211 7.2 Opportunities and challenges of PBF in relation to the three strategies of this book 212 7.3 Commonly available materials for FFF and metal extrusion 213 7.4 Opportunities and challenges of FFF in relation to the three strategies of this book 214 7.5 Commonly available materials for DMLS/SLM and EBM 216 7.6 Opportunities and challenges of metal PBF in relation to the three strategies of this book 217 7.7 Overview of build volumes for key additive technologies 218 7.8 Minimum distance between moving parts 222 Index 3D scanning 83–84, 131–132, 152–153, 170–171, 176, 188–189 3MF/AMF files 29–30, 223; see also file Accuracy 28, 79 Aerodynamics 150, 152–153 Agile manufacturing 88–92 Algorithmic design 113, 116, 108–109, 167–168, 198–199 Anatomical model 183–184, 186–188 Animation 116, 141; stop motion 172–174 Anisotropy 80–81, 225 Anodising 232–233 Architecture/buildings 113–115, 134–135 Art 191–195, 250 Assembly printed as one see part consolidation Automation 133, 135, 139, 179, 227–228, 235 Batch production 146; see also bridge manufacturing Bead blasting 40–41, 235–236 Bicycles 145–153 Binder Jetting (BJ) 18, 23, 160–161, 209 Bound metal deposition 213 Bridge manufacturing 74–76, 146–147 Build farm 129–130; see also distributed manufacturing Build envelope/volume 37–39, 218–219 Business: education 241–242, 268; future practice 260–269; innovation 103, 116–119, 137–142, 173 Carbon fibre 79, 198–199 Circular economy 246–247, 258–259, 264 Climate change 256 Co-design 181–182 Collaboration 4, 119, 268–269 Colour printing 22–26, 28–29, 222–224; full-colour 24–25, 110–111, 159, 169–171, 189, 211, 223–224; multi-colour 24, 222 Computational design see algorithmic design, computer-aided design, parametric modelling Computer-aided design (CAD) 26–34, 110, 132, 192 Computer numerically controlled (CNC) machining 13–14, 53, 237–238; see also machining Conformal cooling 86–88, 236 Connectors (e.g., tube and lug) 110–111, 133–137 Consumer/consumerism 140–141, 250–251, 256–262 Continuous liquid interface production (CLIP) 208 COVID-19 4, 89, 127–128, 189–190, 261 Customisation 82, 110–119, 135, 140–141, 150, 177–180, 197–199 Design for additive manufacturing (DfAM) 12–14, 34, 97–99, 108, 207–242 Design thinking 268 Digital inventory 125–127, 272; see also distributed manufacturing Digital Light Processing (DLP) 90, 208 Digital thread 248 Dip coating 235 Directed Energy Deposition (DED) 210 Distributed manufacturing 127–130, 137, 150, 253, 263, 272; see also build farm; supply chain Dual extrusion/filament 209 Durability 80 Dyeing 211, 234 Education 14, 16–19 Electron beam melting (EBM) 215–216 Index282 u j Index Electroplating see metal plating End-use parts 74–76 Entrepreneur see start-up Epoxy coating 234–235 Ergonomics 82–83 Extended producer responsibility 247 Fablab 263 Fashion 171, 191; costumes 174–175; see also jewellery; prosthetics Filament see Fused Filament Fabrication File: conversion 26–30; export 26–30, 32, 224–225; repair 32–33; size 28; types 26–30, 223 Film and special effects 169–176 Finite element analysis (FEA) 111, 156; see also topology optimisation Fixtures 77–81 Form follows function 113–116 Furniture 45–50, 163–169 Fused Filament Fabrication (FFF, also called Fused Deposition Modelling, FDM) 19, 72–73, 163, 165–167, 174–175, 184–186, 198–199, 209–210, 213–215; see also infill Future: technology 2–5, 269–270 Generative design 108–109, 112–113, 116–117, 167–168, 250–251 Guitars 154–163; stand 103–104 Gyroid 199–204 Health see medical devices, prosthetics Heat exchangers 199–204 Heat treatment 238–239 Helmets 150–153 Hybrid manufacturing 237–238 Hydrographics (aka. Hydro dipping) 162, 232–233 Implant 184–186 Implicit modelling 178–180, 199–201 Industry 4.0 254–258 Industry 5.0 258 Infill 231–232; see also gyroid Intellectual property (IP) 127 Inventory see digital inventory Jewellery 180–181, 192–197 Jigs 81–86 Joining details 220 Lattice structure 109–110, 150–151, 178–180, 189, 191–192, 199–204, 220–221 Layer thickness 219, 230–231 Legislation (e.g., extended producer responsibility) Lifecycle assessment 247–248 Lighting 116–117 Light-weighting 106–109, 178, 249; see also lattice structure; topology optimisation Logistical postponement 125, 136 Machining 237–238 Market testing 74–76 Material extrusion 209–210, 213–215, 219–220; see also fused filament fabrication; infill Materials (e.g., handling, storing) 100–101, 213 Material jetting (MJ) 22–25, 159, 169–171, 193–194, 209 Mechanical properties/tests: compression 150; cyclic 149; grip 81; rigidity 79; shear 80–81; tensile 80; wear 81; see also anisotropy; finite element analysis; orientation Medical devices 176, 178–180, 183–190; see also prosthetics Meshes: mesh modelling 26–29; mesh repair 30–33; see also STL file Metal 3D printing 35, 44–51, 215–216; see also bound metal deposition; electron beam melting; selective laser melting Metal plating 168, 236–237 Mobile application 153 Moulds (aka. tooling) 86–92; casting 90, 192–193; hybrid 89–90; injection 12–13; polymer 89; vacuum forming 86, 90 Multi jet fusion (MJF) 24–25, 137–138, 189, 210–211; see also dyeing Multi-material printing 186–188 Non-fungible tokens (NFT) 252 OBJ file 28–29, 223; see also file One-off design 154–163; see also agile manufacturing; personalisation Open source 128, 197–199, 252 Optimisation see topology optimisation Orientation 80–81, 129, 225–228; see also support material Packing density 228–230; see also build volume Painting 232–233 Parametric modelling 78–79, 150, 198–199 Part consolidation 50, 103–105, 194–197, 221–222 Personalisation 82–84, 131–133, 152, 165–167, 177–180283 u Index j Personal Protective Equipment (PPE) 127–128, 189–190 Polishing 196, 237–238 Post-processing 232–239; SLM 45–50, 196–197; SLS 40–42; see also surface finish Powders: polymer 39, 211; metal Powder Bed Fusion 208–212, 215–216, 219, 228–230; see also selective laser sintering; multi jet fusion; selective laser melting Powder coating 232–233 Pre-processing 38–40, 224–232 Process parameters 33–35, 218–222, 225–232 Product innovation 116–119 Prosthetics 131, 137–138, 176–183; see also medical devices Prosumer 130, 261 Prototype see rapid prototyping Quality control 127, 129, 255 Rapid prototyping 71–73, 146–147, 184–186, 189–190 Rapid tooling 91 Recycling 101, 246–248 Repair 246–247 Resin 22–23, 100–101; see also material jetting; vat photopolymerisation Role of the designer 267–273 Safety 81–85, 216 Scalable systems of supply 133–137 Scenarios 55–66, 67–69, 93–94, 96–97, 119–120, 122–123, 142 Segmentation 131, 184 Selective Laser Sintering (SLS) 18–20, 36–43, 154–157, 161–162, 178–180, 210–212 Selective Laser Melting (SLM) / Direct Metal Laser Sintering (DMLS) 44–51, 147–149, 160, 194–197, 215–216 Service bureau 20, 44–45, 139, 226 Sheet lamination 209 Slicing 33–36, 40, 231–232; see also process parameters Society 5.0 253–254; responsibility 257–260 Spare parts see digital inventory Splints 178–180 Sporting products see bicycles, helmets, surf fins Standards (e.g., ISO/ASTM) 15–18, 30 Start-up 98, 122, 130, 146–147, 184–186 Stereolithography (SLA) 208 STL file 26–28, 224-225; see also file Supply chain 89, 125, 139–140; see also digital inventory; distributed manufacturing Support material 80, 221–222, 226–227; metal 46–49, 200–203, 215–216; polymer 21, 213–214, 240; see also orientation Surface finish 21–22, 232–238; see also bead blasting; hydrographics; painting; polishing; vapour smoothing Surface quality 226; see also layer thickness; orientation; surface finish Surf fins 197–199 Surgical training 186–188 Sustainability 244–265; future 258–260; invested objects 249–252; product service system 245–246; temporary products 246–248 Technology adoption 52–66, 69–71, 92–93 Test pieces 49–50, 230 Tolerances 221–222, 225; SLS 41, 43 Topology optimisation 107–108, 111, 147–149, 188–189 Tumbling 235–236 User-centred design 152, 178, 180–183, 264, 271–273 Vapour smoothing 234–235 Vat Photopolymerisation 23, 208; see also digital light processing; stereolithography Voxel 24 VRML file 29, 223; see also file Wall thickness 219–220 Waste 101, 249, 261–262, 264; see also support material Wood 3D printing 160–161, 245 Workflow 26–43, 199–204 Workforce development / upskilling 69–71, 92–93 X3D file see VRML ,#3D,#Printing,#3D_Printing,#3D-Printing,#3DPrinting,#الطباعة_ثلاثية_الأبعاد,
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