SFFSFF What Can SFF Be Used For?What Can SFF Be Used For?

SFFSFF Use of 3D Hardcopy (+ Finishing)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 !

SFFSFF Consumer Electronics PrototypesConsumer 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.

SFFSFF Prototyping Consumer ProductsPrototyping Consumer Products

“Solarcator” and “Contact-Compact”

Two student-designed “products” in ME221 http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/

SFFSFF More ME 221 Student ProjectsMore 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 thePH value and acidity in a barrel of wine.

SFFSFF ““Gameboy” Form-Factor StudiesGameboy” Form-Factor Studies

Initial Shape Studies: 3D Print quick turn-around

Final Prototype Shape: FDM robustness

SFFSFF Watt-Meter: Concept Study (3D Print)Watt-Meter: Concept Study (3D Print)

SFFSFF Watt-Meter: Rugged Prototype (FDM)Watt-Meter: Rugged Prototype (FDM)

SFFSFF Button “Mote” and Casing (FDM) Button “Mote” and Casing (FDM)

SFFSFF Pico Radio Casing (FDM; Pico Radio Casing (FDM; Mold) Mold)

Custom-made Casing for Modular Research Kit

SFFSFF Injection Mold for Pico RadioInjection Mold for Pico Radio

Very sophisticated and very expensive !

Slot done with Electro Discharge Machining

SFFSFF Model Model Prototype Prototype Mold Mold

Injection Molded Housing for ST TouchChip

SFFSFF Scientific / Engineering ApplicationsScientific / Engineering Applications

SLA

SFFSFF Geometrical / Topoplogical ModelsGeometrical / Topoplogical Models

Role of 3D Hardcopy – (Part 2):

Visualization of objects, when 2D is not quite enough.

Self-intersecting surfaces.

Projections of 4-D polytopes.

Prototyping modular parts, before an injection mold is made.

SFFSFF Single-thread Figure-8 Klein BottleSingle-thread Figure-8 Klein Bottle

Modelingwith SLIDE

SFFSFF Triply-Twisted Figure-8 Klein BottleTriply-Twisted Figure-8 Klein Bottle

FDM, 9” diam. 6 days

SFFSFF The Projective PlaneThe Projective Plane

C

PROJECTIVE PLANE

-- Walk off to infinity -- and beyond … come back upside-down from opposite direction.

Projective Plane is single-sided; has no edges.

SFFSFF Model of Boy SurfaceModel of Boy Surface

Computer graphics by John Sullivan

SFFSFF Boy SurfaceBoy Surface

A model of the single-sided projective plane(with no rims and no singularities).

FDM6” diam.6 days

SFFSFF Morin SurfaceMorin Surface

This is the half-way point of a sphere eversion (without causing creases or tears).

3D-P6” diam5 hrs.

SFFSFF Small 4D PolytopesSmall 4D Polytopes

24-cell (hyper-octahedron)

4D simplex (five-cell)

4D cross polytope

SFFSFF Two Ways to Make a HypercubeTwo Ways to Make a Hypercube

3D Color Print

Assembly of flat FDM parts ==>

SFFSFF Hypercube, Perspective ProjectionsHypercube, Perspective Projections

SFFSFF Parallel Projection of the 4D 120-CellParallel Projection of the 4D 120-Cell

Zcorp,

6” diam.,

6hrs.

SFFSFF 120 Cell -- Close-up120 Cell -- Close-up

SFFSFF 120 Cell -- Perspective View120 Cell -- Perspective View

Zcorp,

6” diam.,

6hrs.

SFFSFF Parallel Projection of the 4D 600-CellParallel Projection of the 4D 600-Cell

Zcorp,

5” diam.,

5hrs.

SFFSFF Post-Processing for 3D-PrintingPost-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)

SFFSFF Post-Processing for 3D-PrintingPost-Processing for 3D-Printing

Spray-paint surface with Krylon

SFFSFF 6D Zonohedron6D Zonohedron

Sweep symmetrically in 6 directions (in 3D)

SFFSFF 4D Hypercube (= Zonohedron)4D Hypercube (= Zonohedron)

Tiles are based on PolymorfTM edge connectors.

Prototypesmade byKiha Leeon FDM.

SFFSFF Modular Zonohedron ConstructionModular Zonohedron Construction

Kiha Lee, CS 285, Spring 2002

Injection-Molded Tiles:

SFFSFF

30 tiles in triacontra-hedral shell

45 tiles for internal

subdivisions

6-Dimensional Zonohedron6-Dimensional Zonohedron

SFFSFF Tiles to Assemble Smooth SurfacesTiles to Assemble Smooth Surfaces

Debugging of geometry using FDM

Snap modular tiles together to form smooth surfaces.

SFFSFF Evolution of T-Connector TilesEvolution of T-Connector Tiles

FDM

SFFSFF Injection-Mold for T-ConnectorsInjection-Mold for T-Connectors

Injection-mold geometryafter four versions of FDM prototypes.

Still not totally satisfactory: (materials properties!).

SFFSFF Boy Surface from T-ConnectorsBoy Surface from T-Connectors

KIHA LEE

SFFSFF

Boy SurfaceBoy Surface

SFFSFF Artistics Parts, Abstract SculpturesArtistics Parts, Abstract Sculptures

Role of 3D Hardcopy – (Part 3):

Maquettes for Visualization

All-round inspection, including light and shadows.

Parts to give tactile feedback.

Parts that could not be made in any other way …

SFFSFF Collin’s Conceptual DesignCollin’s Conceptual Design

SWEEP CURVE (FOR DOUBLE CYLINDER)IS COMPOSED OF 4 IDENTICAL SEGMENTS,FOLLOWS THE SURFACE OF A SPHERE.

SFFSFF Reconstruction / Analysis (v1)Reconstruction / Analysis (v1)

AWKWARD ALIGNMENT

FROM THE FDM MACHINE

SFFSFF Sculpture Design / OptimizationSculpture Design / Optimization

“Galapagos 2” and “Galapagos 3” ( collaboration with Brent Collins )

SFFSFF Fine-tuned Final(?) Version (v5)Fine-tuned Final(?) Version (v5)

SFFSFF Exploring Minimal Surfaces …Exploring Minimal Surfaces …

“Volution” elements,embedded in a circuit of 12 quarter circles in a cube.

SFFSFF More Minimal SurfacesMore Minimal Surfaces

Stack these

modular elements.

SFFSFF Bronze Investment CastingBronze Investment Casting

FDM original can be burnt to cinders in the plaster-of-Paris shell.

SFFSFF How to Get Multi-Colored PartsHow 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).

SFFSFF Escher Spheres 1Escher Spheres 1

Assemblies of individual FDM tiles (2.5” diam.)

SFFSFF Escher Spheres 2Escher Spheres 2

Multi-colored Zcorp parts:no assembly needed!

SFFSFF Escher Spheres 3Escher Spheres 3

Multi-colored Zcorp parts:

No support removal needed!

SFFSFF ““Viae Globi” SculpturesViae Globi” Sculptures

FDM maquettes of possible bronze sculptures

SFFSFF Family of Scherk-Collins TrefoilsFamily of Scherk-Collins Trefoils

SFFSFF Maquettes for a Snow-SculptureMaquettes for a Snow-Sculpture

3D-PrintFor initial submission

FDMFor use on site

SFFSFF ““Whirled White Web”Whirled White Web”

Int. Snow-Sculpting Championship, Breckenridge C0, 2/1/2003

SFFSFF Which Process Should You Pick?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

SFFSFF The Most Challenging SFF PartThe Most Challenging SFF Part

3rd-order 3D Hilbert Curve:

much weight

much length

no supports

only two tube-connectionsbetween the two halves.

SFFSFF Informal Process Ratings MatrixInformal Process Ratings Matrix

Hollow Sphere

Hollow Sphere with Drain/Vent

2 Nested, Perforated Spheres

3D Hilbert

Pipe

Preassembled Gear

Mechanism

LOM (F) F F D F

SLA (F) D C B D

FDM (F) F C C D

3D-P (F) A A C B

SLS (F) A A B B