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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