Transcript SFF What Can SFF Be Used For? SFF Use of 3D Hardcopy (+ Finishing) What is 3D Hardcopy good for? (cont.)  Consumer Electronics Design.

SFF
What Can SFF Be Used For?
SFF
Use of 3D Hardcopy (+ Finishing)
What is 3D Hardcopy good for? (cont.)

Consumer Electronics Design Prototypes
==> touch and feel !

Mathematical & Topoplogical Models
==> visualization and understanding

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 !
SFF
Consumer Electronics Prototypes
Role of 3D Hardcopy – (Part 1):
Modeling and Prototyping
 Packaging
of various
electronics components.
 Custom
designed housing
for other utility products.
 Prototype
demonstrations of novel
mechanical gears or linkages.
SFF
Prototyping Consumer Products
“Solarcator” and “Contact-Compact”
Two student-designed “products” in ME221
http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/
SFF
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.
SFF
“Gameboy” Form-Factor Studies

Initial Shape Studies:
3D Print
 quick turn-around

Final Prototype Shape:
FDM  robustness
SFF
Watt-Meter: Concept Study (3D Print)
SFF
Watt-Meter: Rugged Prototype (FDM)
SFF
Button “Mote” and Casing (FDM)
SFF
Pico Radio Casing (FDM;  Mold)
Custom-made Casing for Modular Research Kit
SFF
Injection Mold for Pico Radio
 Very
sophisticated
and very expensive !
Slot done with
Electro Discharge Machining
SFF
Model  Prototype  Mold
Injection Molded Housing for ST TouchChip
SFF
Scientific / Engineering Applications
SLA
SFF
Geometrical / Topoplogical Models
Role of 3D Hardcopy – (Part 2):
Visualization of objects,
when 2D is not quite enough.
 Self-intersecting
 Projections
 Prototyping
surfaces.
of 4-D polytopes.
modular parts,
before an injection mold is made.
SFF
Single-thread Figure-8 Klein Bottle
Modeling
with SLIDE
SFF
Triply-Twisted Figure-8 Klein Bottle
FDM, 9” diam.
6 days
SFF
The Projective Plane
PROJECTIVE PLANE
C
-- Walk off to infinity -- and beyond …
come back upside-down from opposite direction.
Projective Plane is single-sided; has no edges.
SFF
Model of Boy Surface
Computer graphics by John Sullivan
SFF
Boy Surface
FDM
6” diam.
6 days
A model of the single-sided projective plane
(with no rims and no singularities).
SFF
Morin Surface
3D-P
6” diam
5 hrs.
This is the half-way point of a sphere eversion
(without causing creases or tears).
SFF
Small 4D Polytopes

24-cell (hyper-octahedron)

4D simplex (five-cell)

4D cross polytope
SFF
Two Ways to Make a Hypercube
3D Color Print
Assembly of
flat FDM parts ==>
SFF
Hypercube, Perspective Projections
SFF
Parallel Projection of the 4D 120-Cell
 Zcorp,
 6”
diam.,
 6hrs.
SFF
120 Cell -- Close-up
SFF
120 Cell -- Perspective View
 Zcorp,
 6”
diam.,
 6hrs.
SFF
Parallel Projection of the 4D 600-Cell
 Zcorp,
 5”
diam.,
 5hrs.
SFF
Post-Processing for 3D-Printing
Surface is porous, dusty.
 seal and strengthen the part:
 Dip
in wax:

Nice smooth finish

Needs separate waxing station
 Infiltrate

with “superglue”:
Tedious, dirty manual labor
 Spray-paint
with a sealant:

Polyurethane (yellowish, smelly)

Krylon (invisible)
SFF
Post-Processing for 3D-Printing
 Spray-paint
surface with Krylon
SFF
6D Zonohedron
 Sweep
symmetrically in 6 directions (in 3D)
SFF
4D Hypercube (= Zonohedron)
 Tiles
are
based on
PolymorfTM
edge
connectors.
Prototypes
made by
Kiha Lee
on FDM.
SFF
Modular Zonohedron Construction
Injection-Molded Tiles:
Kiha Lee,
CS 285, Spring 2002
SFF
6-Dimensional Zonohedron
 30
tiles
in triacontrahedral shell
 45
tiles
for internal
subdivisions
SFF
Tiles to Assemble Smooth Surfaces
Snap modular tiles together
to form smooth surfaces.
 Debugging
of geometry
using FDM
SFF
FDM
Evolution of T-Connector Tiles
SFF
Injection-Mold for T-Connectors

Injection-mold geometry
after four versions of FDM prototypes.

Still not totally satisfactory:
(materials properties!).
SFF
Boy Surface from T-Connectors
KIHA LEE
SFF
Boy Surface
SFF
Artistics Parts, Abstract Sculptures
Role of 3D Hardcopy – (Part 3):
Maquettes for Visualization
 All-round
inspection,
including light and shadows.
 Parts
 Parts
to give tactile feedback.
that could not be made
in any other way …
SFF
Collin’s Conceptual Design
SWEEP CURVE (FOR DOUBLE CYLINDER)
IS COMPOSED OF 4 IDENTICAL SEGMENTS,
FOLLOWS THE SURFACE OF A SPHERE.
SFF
Reconstruction / Analysis (v1)
FROM THE FDM MACHINE
AWKWARD ALIGNMENT
SFF
Sculpture Design / Optimization

“Galapagos 2” and “Galapagos 3”
( collaboration with Brent Collins )
SFF
Fine-tuned Final(?) Version (v5)
SFF
Exploring Minimal Surfaces …
“Volution”
elements,
embedded
in a circuit
of 12 quarter
circles in a
cube.
SFF
More Minimal Surfaces
Stack
these
modular
elements.
SFF
Bronze Investment Casting
 FDM
original
can be
burnt to
cinders
in the
plasterof-Paris
shell.
SFF
How to Get Multi-Colored Parts
 Zcorporation:
3D color printer.
 FDM:
Make ABS pieces in different colors
and assemble them;
(use ABS solvent as glue).
 Paint
with different colors.
Enamel works very well;
(may have to use 2 coats of paint
because of porosity of material).
SFF
Escher Spheres 1
Assemblies of individual FDM tiles (2.5” diam.)
SFF
Escher Spheres 2
Multi-colored Zcorp parts:
no assembly needed!
SFF
Escher Spheres 3
Multi-colored Zcorp parts:
No support removal needed!
SFF
“Viae Globi” Sculptures
FDM maquettes of possible bronze sculptures
SFF
Family of Scherk-Collins Trefoils
SFF
Maquettes for a Snow-Sculpture
3D-Print
FDM
For initial submission
For use on site
SFF
“Whirled White Web”
Int. Snow-Sculpting Championship, Breckenridge C0, 2/1/2003
SFF
Which Process Should You Pick?
Do you need a prototype (not just a model)?

SLS, FDM (for robustness, strength).
Do you need a mold for a small batch?

SLA (for smooth, hard surface).
Does part need multiple colors?

3D Color-Printing.
Does part have convoluted internal spaces?

3D-P, SLS, SLA, FDM* (easy support removal).
* Stratasys FDM3000 with WaterWorks
SFF
The Most Challenging SFF Part
3rd-order 3D Hilbert Curve:
 much
weight
 much
length
 no
supports
 only
two tubeconnections
between the
two halves.
SFF
Informal Process Ratings Matrix
Hollow
Hollow
2 Nested,
Sphere Sphere with Perforated
Drain/Vent Spheres
3D
Hilbert
Pipe
Preassembled
Gear
Mechanism
LOM
(F)
F
F
D
F
SLA
(F)
D
C
B
D
FDM
3D-P
(F)
(F)
F
A
C
A
C
C
D
B
SLS
(F)
A
A
B
B