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