CHS UCB CS 294-12 -- October 2002 Rapid Prototyping and its Role in Design Realization Carlo H.
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CHS UCB CS 294-12 -- October 2002 Rapid Prototyping and its Role in Design Realization Carlo H. Séquin EECS Computer Science Division University of California, Berkeley CHS UCB Focus of Talk How can we use the visualization power offered by computer graphics and by computer-controlled rapid prototyping in design and in design realization? CHS UCB DESIGN The following questions should be raised and be answerable: What is the purpose of the artifact ? What are the designer’s goals for it ? How will the artifact be evaluated ? What How are the associated costs ? can we maximize the benefit/cost ratio ? CHS UCB Example Task “Design an Instrument as an Interface to an Existing Data Base. Purpose: Enhance access to data base. Goals: Provide: novel insights, deeper understanding, better user interface. Evaluation: Let several users use the device and observe what emerges. Costs: Fabrication, as well as operation. Optimization: Heavily dependent on approach taken. CHS UCB Design is an Iterative Process Formal Specifications Detailed Description Clear Concept Experiments, get feedback Vague idea Revision of artifact 1st `hack' Demo Prototype Usable Evaluation Series Marketable Systems Product CHS UCB A Specific Challenge Create as soon as possible a 3D "free-form" part (not a box-like thing that can be built from flat plates) for evaluation in its application context. This includes: visualization tactile feedback function verification simulation of final use. CHS UCB Conceptual Prototyping The Traditional Options: Model from clay Carve from wood Bend wire meshing from styrofoam – perhaps with surface reinforcement Carve Mill from a block of plastic or aluminum (3- or 4-axes machines) CHS UCB “Hyperbolic Hexagon II” (wood) Brent Collins CHS UCB Brent Collins’ Prototyping Process Armature for the "Hyperbolic Heptagon" Mockup for the "Saddle Trefoil" Time-consuming ! (1-3 weeks) CHS UCB New Ways of Rapid Prototyping Based on Layered Manufacturing: Build the part in a layered fashion -- typically from bottom up. Conceptually, like stacking many tailored pieces of cardboard on top of one another. Part geometry needs to be sliced, and the geometry of each slice determined. Computer controlled, fully automated. CHS UCB Slices through “Minimal Trefoil” 50% 30% 23% 10% 45% 27% 20% 5% 35% 25% 15% 2% CHS UCB “Heptoroid” ( from Sculpture Generator I ) Cross-eye stereo pair CHS UCB Profiled Slice through the Sculpture One thick slice thru “Heptoroid” from which Brent can cut boards and assemble a rough shape. Traces represent: top and bottom, as well as cuts at 1/4, 1/2, 3/4 of one board. CHS UCB Emergence of the “Heptoroid” (1) Assembly of the precut boards CHS UCB Emergence of the “Heptoroid” (2) Forming a continuous smooth edge CHS UCB Emergence of the “Heptoroid” (3) Thinning the structure and smoothing the surface “Heptoroid” CHS UCB Collaboration by Brent Collins & Carlo Séquin (1997) CHS UCB Some Commercial Processes Additive Methods with Sacrificial Supports: Fused Deposition Modeling (Stratasys) Solidscape Solid (Sanders Prototype, Inc.) Printing / Imaging (3D Systems) Stereolithography Powder-Bed Based Approaches: 3D Printing (Z-Corporation) Selective Laser Sintering CHS UCB SFF: Fused Deposition Modeling Principle: of semi-liquid ABS* plastic get deposited by a head moving in x-y-plane. Beads Supports are built from a separate nozzle. Schematic view ==> Key player: Stratasys: http://www.stratasys.com/ * acrylonitrile-butadine-styrene CHS UCB Fused Deposition Modeling CHS UCB Looking into the FDM Machine CHS UCB Zooming into the FDM Machine CHS UCB Single-thread Figure-8 Klein Bottle As it comes out of the FDM machine CHS UCB Layered Fabrication of Klein Bottle Support material CHS UCB Klein Bottle Skeleton (FDM) CHS UCB Fused Deposition Modeling An Informal Evaluation Easy to use Rugged Could and robust have this in your office Good transparent software (Quickslice) with multiple entry points: STL, SSL, SML Inexpensive to operate Slow Think about support removal ! CHS UCB What Can Go Wrong ? Black blobs Toppled supports CHS UCB Solid Object Printing ModelMaker II (Solidscape) CHS UCB SFF: Solid Object Printing ModelMaker II (Solidscape) Alternate Deposition / Planarization Steps Build envelope: 12 x 6 x 8.5 in. Build layer: 0.0005 in. to 0.0030 in. Achievable accuracy: +/- 0.001 in. per inch Surface finish: 32-63 micro-inches (RMS) Minimum feature size: 0.010 in. Key Player: Solidscape*: http://www.solid-scape.com/ * formerly: Sanders CHS UCB SFF: Solid Object Printing (2” diam.) Projection of 4D 120-cell, made in “jewelers wax.” CHS UCB SFF: Solid Scape (Sanders) An Informal Evaluation The most precise SFF machine around Very slow Sensitive to ambient temperature Must be kept running most of the time Poor software Little access to operational parameters Based on comments by B. G.: http://www.bathsheba.com/ CHS UCB SFF: Solid Imaging Droplets of a thermoplastic material are sprayed from a moving print head onto a platform surface. Need to build a support structures where there are overhangs / bridges. These supports (of the same material) are given porous, fractal nature. They Key need to be removed (manually). player: 3D Systems: http://www.3dsystems.com/index_nav.asp CHS UCB SFF: Solid Imaging Supports made from same material, but with a fractal structure CHS UCB SFF: Solid Imaging Thermojet Printer (3D Systems) Technology: Multi-Jet Modeling (MJM) Resolution (x,y,z): 300 x 400 x 600 DPI Maximum Model Size: 10 x 7.5 x 8 in (13 lb) Material: neutral, gray, black thermoplastic: ThermoJet 88: smooth surfaces for casting ThermoJet 2000: more durable for handling CHS UCB SFF: Solid Imaging That’s how parts emerge from the Thermojet printer After partial removal of the supporting scaffolding CHS UCB 9-Story Intertwined Double Toroid Bronze investment casting from wax original made on 3D Systems’ “Thermojet” CHS UCB SFF: Solid Imaging An Informal Evaluation Fast Inexpensive Reliable, Good robust for investment casting Support removal takes some care (refrigerate model beforehand) Thermojet 88 parts are fragile CHS UCB Powder-based Approaches Key Properties: Needs no supports that must be removed! Uniform This bed of powder acts as support. powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part. CHS UCB SFF: 3D Printing -- Principle Selectively deposit binder droplets onto a bed of powder to form locally solid parts. Head Powder Spreading Printing Powder Feeder Build CHS UCB 3D Printing: Some Key Players Z Corporation: http://www.zcorp.com/ Plaster and starch powders for visualization models. Soligen: http://www.zcorp.com/ Metal and ceramic powders for operational prototypes. Therics Inc.: http://www.therics.com/ Biopharmaceutical products, tissue engineering. CHS UCB 3D Printing: Z Corporation The Z402 3D Printer Speed: 1-2 vertical inches per hour Build Volume: 8" x 10" x 8" Thickness: 3 to 10 mils, selectable CHS UCB 3D Printing: Z Corporation CHS UCB 3D Printing: Z Corporation Digging out CHS UCB Optional Curing: 30 min. @ 200ºF Keep some powder in place <-- Tray for transport CHS UCB 3D Printing: Z Corporation Cleaning up in the de-powdering station CHS UCB 3D Printing: Z Corporation The finished part Zcorp, 6” diam., 6hrs. CHS UCB 120 Cell -- Close-up CHS UCB 3D Color Printing: Z Corporation The Z402C 3D Color Printer Differences compared to mono-color printer: Color print head with: Cyan, Yellow, Magenta, Black, and Neutral. Smaller build area. Specs: Speed: 0.33 - 0.66 vertical inches per hour Build Volume: 6" x 6" x 6" Thickness: 3 to 10 mils, selectable Color depth: 80 mils CHS UCB 3D Color Printing: Z Corporation CHS UCB 3D Color Printing: Z Corporation Use compressed air to blow out central hollow space. CHS UCB 3D Color Printing: Z Corporation Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors. CHS UCB What Can Go Wrong ? Blocked glue lines Crumbling parts CHS UCB Broken Parts CHS UCB 3D Printing: Z Corporation An Informal Evaluation Fast ! Running expenses: moderate, (but overpriced powder) Color print head and tubes need some care in maintenance. Somewhat Lot’s messy cleanup ! of dust everywhere ... CHS UCB SFF: Stereolithography (SLA) UV laser beam solidifies the top layer of a photosensitive liquid. UV Laser Beam Photopolymer Build Stage CHS UCB SFF: Stereolithography (SLA) SLA Machine by 3D Systems Maximum build envelope: 350 x 350 x 400 mm in XYZ Vertical resolution: 0.00177 mm Position repeatability: ±0.005 mm Maximum part weight: 56.8 kg CHS UCB Stereolithography An Informal Evaluation Can do intricate shapes with small holes High precision Moderately Fast Photopolymer Laser is expensive ($700/gallon) is expensive ($10’000), lasts only about 2000 hrs. CHS UCB Séquin’s “Minimal Saddle Trefoil” Stereo- lithography master CHS UCB Séquin’s “Minimal Saddle Trefoil” bronze cast, gold plated CHS UCB Minimal Trefoils -- cast and finished by Steve Reinmuth CHS UCB What Can SFF Be Used For? CHS UCB Use of 3D Hardcopy 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. CHS UCB Consumer Electronics Prototypes Role of 3D Hardcopy -- Part 1: Modeling and Prototyping Packaging of various electronics components. Custom designed housing for other utility products. The physical frame for an “instrument” … CHS UCB Prototyping Consumer Products “Solarcator” and “Contact-Compact” Two student-designed “products” in ME221 http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/ CHS UCB Model Prototype Mold Part Injection-Molded Housing for ST TouchChip CHS UCB Geometrical / Topoplogical Models Role of 3D Hardcopy -- Part 2: Visualization of objects, when 2D is not quite enough. Self-intersecting Projections surfaces. of 4-D polytopes. CHS UCB Single-thread Figure-8 Klein Bottle Modeling with SLIDE CHS UCB Triply-Twisted Figure-8 Klein Bottle FDM, 9” diam. 6 days CHS UCB Projections of Reg. 4D Polytopes 4D Cross-Polytope CHS UCB Artistics Parts, Abstract Sculptures Role of 3D Hardcopy -- Part 3: Maquettes for Visualization All-round inspection, including light and shadows. Parts that could not be made in any other way … Prototyping modular parts, before an injection mold is made. CHS UCB Family of Scherk-Collins Trefoils CHS UCB “Viae Globi” Sculptures FDM maquettes of possible bronze sculptures CHS UCB Brent Collins at Bridges 2000 CHS UCB Photos by Brent Collins CHS UCB Collin’s Construction Description SWEEP CURVE (FOR DOUBLE CYLINDER) IS COMPOSED OF 4 IDENTICAL SEGMENTS, FOLLOWS THE SURFACE OF A SPHERE. CHS UCB Reconstruction / Analysis (v1) FROM THE FDM MACHINE AWKWARD ALIGNMENT CHS UCB Further Explorations (v2: add twist) CHS UCB A More Complex Design (v3) CHS UCB Verification with 3D Model (v4) GALAPAGOS-4 CHS UCB Fine-tuned Final(?) Version (v5) CHS UCB Galapagos-6 in the Making CHS UCB Galapagos-6 (v6) CHS UCB Sculpture Design: “Solar Arch” branches = 4 storeys = 11 height = 1.55 flange = 1.00 thickness = 0.06 rim_bulge = 1.00 warp = 330.00 twist = 247.50 azimuth = 56.25 mesh_tiles = 0 textr_tiles = 1 detail = 8 bounding box: xmax= 6.01, ymax= 1.14, zmax= 5.55, xmin= -7.93, ymin= -1.14, zmin= -8.41 CHS UCB Competition in Breckenridge, CO CHS UCB FDM Maquette of Solar Arch 2nd place CHS UCB We Can Try Again … in L.A. CHS UCB “Whirled White Web” Design for the 2003 International Snow Sculpture Championship Breckenridge, CO, Jan.28 – Feb.2 CHS UCB 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 (easy support removal). CHS UCB The Most Challenging SFF Part 3rd-order 3D Hilbert Curve: much weight much length no supports only two tubeconnections between the two halves. CHS UCB 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 CHS UCB How Can You Get Access to SFF ? We have under our control: A Fused Deposition Modeling Machine A Z-Corp Color/Mono 3D Printer You need to prepare: A “watertight” boundary representation with less than 100’000 triangles In .STL format.