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Supercar with 3D printed parts from OMNI3D

16.02.2017

Poland's first supercar, Arrinera Hussarya, contains 3D printed parts from OMNI3D

Feb 15, 2017 | By Tess

Polish sports car manufacturer Arrinera Technology has teamed up with local industrial 3D printer manufacturer OMNI3D to additively manufacture parts for the Arrinera Hussarya, Poland’s first supercar. OMNI3D, known for its industrial and large-format FFF 3D printing solutions, says it helped to manufacture functional prototypes for the supercar, as well as final parts.

The Arrinera Hussarya supercar, which was first unveiled as a concept back in 2012, has been put into production, and, to a degree, we have 3D printing to thank. Like in other industries, additive manufacturing technologies were leveraged by Arrinera to speed up the prototyping and production process without sacrificing or compromising on quality or optimal design.

As one can imagine, designing a car, especially a supercar, is a rigorous process that involves continuous changes and adjustments to designs, so having the ability to make changes to prototypes on the fly, test them, and tweak them some more, is invaluable. OMNI3D provided Arrinera Technology with this capacity, with the added bonus of manufacturing large-scale, complexly structured parts for the car. The companies have been working together for over a year.

3D printed parts for Arrinera Technology

“Detail production on a 3D printer significantly accelerates the work of our R&D team and reduces production time and costs,” commented Łukasz Tomkiewicz, president of Arrinera Technology S.A. “Frequent changes to a model’s shape–the diameter or length–are not as problematic as they used to be. A new model can be printed in just over twelve hours.”

OMNI3D, perhaps best known for its Factory Production System 2.0, a large-scale (500 x 500 x 500 mm) FFF 3D printer, has been offering on-demand 3D printing services for the past year through its Printroom. The service came about through a necessity to demonstrate OMNI3D’s manufacturing technology to potential clients, as well as to provide an option to companies that aren’t prepared to invest in their own 3D printer.

As Krzysztof Kardach, Chief Technologist at OMNI3D, explains, “We opened the Printroom as a result of observing market needs. Many of our customers before making a final purchase decision about Factory 2.0, ask us for test prints. Others, like Arrinera don’t want to invest in their own machine, but still need professional 3D prints. There are also companies that have big needs for 3D printing, but prefer to trust experienced 3D printing technologists from our company.”

OMNI3D Factory 2.0 3D printer

Not only does OMNI3D’s Printroom offer relatively large-scale 3D printing, its FFF technology can also accommodate high-quality and durable thermoplastics such as ABS-42, ASA-39, PC-ABS- 47, PET-G- 32, and HIPS-20. For the Arrinera Hussarya supercar, mirror caps, air vents, and other important components were 3D printed primarily using ABS-42.

Evidently very happy with the supercar’s 3D printed parts, Tomkiewicz added, “Parts printed in 3D on Factory 2.0 Production System meet all of our requirements...in terms of strength, dimensional accuracy, and turnaround time. Some elements, such as air vents, are even installed in the car as the final product.”

 

 

 

Posted in 3D Printing Application

ZMorph case study for product design

13.02.2017

Designer & biomedical engineer Eliza Wróbel has created a multifunctional walker using the company’s 2.0 SX multitool 3D printer. The walker prototype is made of over 100 parts and is realised in Silver ABS for the frame; durable yellow and black PLA support parts; and rubbery Flex filament for the wheels, brakes, and arm pads.

zmorph casestudy

Wróbel’s design also gives the walker an interchangeable basket and seat so it can be used for walking or to aid in shopping.

BT Invests in ProJet 2500 from CDG

01.02.2017

Telecommunications company BT has invested in a new 3D printer for its distribution center in Leicestershire, England. The 3D Systems MJP ProJet 2500 Plus 3D printer is being used for prototyping and creating spare parts. [Article By Benedict, reproduced from at www.3ders.org]

BT (British Telecommunications) is a British multinational company that provides telephone, internet, and television services in roughly 180 countries around the world. Last year it acquired cellphone network EE for £12.5 billion, and currently has assets worth more than £38 billion. As in many industries, telecommunications can benefit from new and advanced manufacturing techniques, whether for installing new phone lines, producing internet routers, or simply fixing up existing equipment. Because of this, BT has recently installed a 3D System 3D printer at its distribution center in Leicestershire, where it will use the additive manufacturing machine for a number of purposes.

Since purchasing its new 3D printer in December, BT has wasted no time in setting it up, with the ProJet MJP 2500 Plus reportedly fired up for the first time in mid-January. BT says it is using the printer for various purposes, including fabrication of spare and replacement parts that are no longer available from suppliers, fast production of urgently needed parts, and rapid prototyping of new items during the research and development stage of product development. The telecommunications company believes the 3D printer will help improve many aspects of life at the distribution center.

Speaking to V3, BT’s Andy Fielden, CIO Supply Chain and Cables, explained how the 3D printer has allowed BT to “provide the stock items at the point of use without having to order, store, and distribute the item—thus significantly reducing cost and time to market.” He added that the 3D Systems machine has enabled BT to “print low volume items for our internal engineers” and “easily prototype and test new ideas.”

The idea of investing big money into a high-quality 3D printer came about after one engineer suggesting that 3D printed plastic needles (below) could be used to thread fibers. The idea was eventually turned into actuality on a MarkerBot Replicator 2X, a much more affordable desktop 3D printer, and the 3D printed pieces helped save the research lab a small amount of money. Before this, an engineer at Openreach (the BT subsidiary that deals with the UK’s telephone cable network) had built her own 3D printer to show others how the technology could benefit BT.

BT staff have said that, as 3D printing technology improves, they will consider adding to their additive manufacturing equipment, with the main focus of the technology being small-batch production of various parts. BT Lead Consultant Iain Monteath told V3 that BT was particularly attracted to 3D printers “that let you print flexible and solid parts in one,” since they could enable the company to print entire objects in one go.

The 3D Systems ProJet MJP 2500 Plus has a build volume of 295 x 211 x 142 mm, a resolution of 800 x 900 x 790 DPI with 32 μ layers, and a typical accuracy of ±0.1016 mm per 25.4 mm.

CDG supply of 3D Systems professional and production printers in the UK.

Cambridge DT partners for reverse engineering

30.01.2017

Our friends at Cambridge Design Technology have published the following article on reverse engineering.

Link to orginal article:- Cambridge Design Technology

 

What is reverse engineering?

Reverse engineering is the process of analysing an existing product’s constituent components to allow a fully replicated design – or design knowledge – to be created from the information extracted.

Products and concepts as wide-ranging in structure and function as mechanical devices, electronic components, computer software, chemical formulas or organic matter are all suitable for analysis using RE techniques.

In practical terms, a typical reverse engineering project will involve working backwards from a chosen product to determine the design and technology used by the product’s creator. This accrued data then allows those applying RE to reproduce or refine the product – or simply to put the information to use in the concept development of a companion or related product.

Why would you need reverse engineering?

In today’s fast-paced business environment, existing mature life cycle products may require reverse engineering for:

2017-01-exploded-model-thumbnail

  • Compliance or revalidation processes
  • Converting design drawings into 3D digital data.
  • Recovering data and designs lost during company transition, data corruption or IT failures
  • Product Improvement

Whatever the need, reverse engineering can shine a light on the processes involved in the creation of the product in question – whether this is to establish details of an existing technologies or an unusual device, or simply to determine technical aspects of an established product that may not have been manufactured for some time.

Product Improvement

Product improvement can be a significant driver in wanting to RE a product.

  • Reducing manufacturing cost
  • Refining product performance
  • Replacement of a product

Designers and engineers are always looking for ways to improve both novel concepts and existing products. RE can provide the data and knowledge required to refine and improve a product’s assembly process and working capabilities.

By simplifying a product’s manufacture, its cost can potentially be reduced and its performance improved. The information provided by reverse engineering can even give designers and engineers the necessary spark to create an alternate version of a product.

How do you reverse engineer?

The basic goal of reverse engineering is to develop an understanding of a product and its parts by applying in de01pth analysis. Once these factors are understood, the engineer can begin to crystallise the original design intent of the working parts, their critical tolerances, materials used and key functions within the assembly.

Design intent capture

The design team will start by measuring components using digital, traditional and sometimes non-contact methods to define the parts. These parts are then modelled up using 3D CAD.

Once the parts have been made and the 3D assembly is created, the models may be proofed and tested. Although in some instances absolute accuracy in the RE process is crucial, some RE projects will require the design to be improved at the same time. Detailed understanding of a design can sometimes lead to the reducing of accuracy, in less critical areas, allowing potential cost savings in manufacture.

There is a technical risk to every design exercise. In RE, a seemingly minor measurement error involving as little as a fraction of a millimetre can potentially have a major and negative effect on the assembly process, so checking and proof reading of specifications and prototyping can be essential.

There are several tools within the CAD environment to achieve accurate design capture:

  • Interference checking to ensure the parts can operate with sufficient clearance or are purposely interfering (such as self-tapping screws etc)
  • Wall thickness analyses to ensure that (for example) a moulding has not been modelled with excess wall thickness which would potentially cause problems in moulding further down the line
  • Draft analyses, again with moulded components to ensure that all surfaces have been correctly drafted in the right direction. This also helps to validate the split lines of the product.
  • Surface analysis methods such as “Zebra Striping” can be employed to visualize curvature on smooth surfaces and evaluate the quality of surfaces created.
  • Other CAD tools that aid the process look at part volume, mass properties and undercut checking to help ensure the products parts are robust.

These various methods can all be employed to develop and streamline modern manufacturing techniques, processes and material usage. With design excellence being a for
emost principle of the exercise, the elimination of parts due to their redundancy or obsolescence are as important as the introduction of new parts and features that will enhance the product.

How do you reverse engineer a very complex shape?

CDT’s design team had their reverse engineering skills challenged when Hornby Hobbies asked us to reverse engineer various shapes of their classic Grand Prix racing cars. This involved detailed research and recreation of car body shapes using various measurement methods, photographs, artistic licence- as well as assessing design features by eye.

Reverse engineering projects like this can be costly and time-consuming – but the results can be spectacular. Even the smallest detail, such as the beautiful lines of a full-scale racing car are reduced to exquisite, 1/32nd scale replica slot cars. A stunning showcase of reverse engineering’s versatility and almost unlimited scope.

There is an alternative – 3D scanning

2017-01-3d-scanning-courtesy-of-cdg-and-shining-3d

Images supplied courtesy of CDG & Shining 3D

The accuracy of modern scanning is down to fractions of a millimetre even on large scale dimensions. And when large, organic shapes require ultimate accuracy to be taken from the original, then the extraordinary precision of 3D scanning can be harnessed to great effect.

By taking multiple scans of an object from all possible directions and viewpoints, the 3D scanner collects geometric data that is combined using a common reference system. From the extrapolated data, a digital 3D model can then be constructed.

3D scanning is a diverse technique, used broadly across many industries. Objects as large as ships, aeroplanes and even entire buildings have been successfully scanned. At the opposite end of the scale, minute, intricately-detailed objects such as dental devices, coins and skin textures have been succesfully captured.

It’s a technique that excels in scanning tangibles, yet can also be used to create intangible designs such as 3D animations and special effects.

3D Scanning applications include:

  • reverse engineering into CAD
  • data input for digital modelling or editing
  • measuring and inspecting parts
  • data achiving
  • virtual reality


3D Scanning partnership: working with Concurrent Design Group

We have been working with 3D scanning experts Concurrent Design Group (CDG) for many years now. In fact, we bought our first 3D printer from CDG. They have been at the cutting edge of 3D engineering design technology since 1993 and, given their vast experience and knowledge in this field, they are Cambridge Design Technology’s preferred supplier of 3D scanning.

Realise your vision

If your company has ideas that require cutting-edge design, technology and engineering input, Cambridge Design Technology have the knowledge, experience and creative energy to help you realise your vision – including a full Reverse Engineering and 3D Scanning service.

For more information about Cambridge Design Technology and how we can work with you on your next product design project, please call Jon Plumb now on 01787 377106 or email info@cambridge-dt.com

3D Systems Top 10 applications over the past year

30.12.2016

3D Innovation: The Top Ten Applications in 2016 (in reverse order):-

10. Craft

For nearly 50 years, Polich Tallix Fine Art Foundry has helped artists develop and produce their work. Using a complete digital workflow that combines 3D scanning with Geomagic software and wax 3D printing, Polich Tallix’s digital production department helps its clients deliver art exactly as envisioned. According to the foundry’s 3D Artist and Production specialist, these solutions have helped Polich Tallix extend its capabilities beyond what anyone thought possible.

 

9. Autonomy

After seven decades of relying on external suppliers, Hyde Park Partners decided to take product development applications into its own hands with in-house 3D printing on the ProJet® MJP 2500. Now able to implement new ideas and designs faster without the cost and delay of contracted work, Hyde Park is more nimble and effective in its day-to-day operations.

 

https://youtu.be/RFWoNwThq0o

 

8. Ingenuity

While there’s no denying the uniqueness of a live performance, Intel and Lady Gaga took things to the next level at this year’s 58th Grammy Awards. Facilitated by the on-demand manufacturing expertise and digital artistry of our Gentle Giant Studios entertainment specialists, Lady Gaga’s tribute to David Bowie was full of the inventiveness and creativity of the team that conceptualized it and the man it honored, with a supporting role by 3D scanning and 3D printing.

7. Inspiration

The members of the University of Connecticut’s Formula SAE team showed incredible initiative in the making of their most recent racecar. Realizing that they could dramatically impact the weight, lines and performance of their car by designing the body around the engine, rather than accommodating the engine after the fact, they turned to Bolton Works, a local reverse engineering specialist, to help them with their task. Using a suite of Geomagic scan-to-CAD software, the team devised a perfect on-screen replica of their engine to tailor their car like never before.

6. Efficiency

In collaboration with Oak Ridge National Laboratory, the University of Maryland’s Center for Environmental Energy Engineering (CEEE) is on a quest to develop next generation heat exchangers for HVAC and refrigeration applications. Using automated design algorithms for optimal thermal resistance at a reduced size and weight, CEEE produced a 1kW heat exchanger that was 20% more efficient, in addition to being lighter and smaller. CEEE was also able to reduce the manufacturing cycle from months to weeks with the help of our on demand manufacturing service and direct metal printing.

5. Healing

Following multiple spinal fusion surgeries after a fall from construction left him partially paralyzed, Mark Weimer began to experience consistent lower body pain alongside bowel and bladder issues. To help alleviate the compression of Weimer’s nerves and spinal cord, Dr. George Frey designed his surgical approach with digitization and manufacturing services provided by 3D Systems Healthcare and his patented FIREFLY® Technology for pedicle screw placement. Equipped with 3D printed anatomical models and surgical guides specific to Weimer’s anatomy, Dr. Frey performed a 15-hour surgery that returned Weimer’s attention to more important things like his grandsons’ budding passions for hockey.

 

4. The Little Guys

The ability to customize solutions means no problem is too big or too small to fix. In the case of Grecia the Toucan and Yellow-Purple (AKA “Purps”) the penguin, this was good news in 2016. Using an array of 3D design and manufacturing technologies, the team of veterinarians and communities of animal lovers behind these birds had ample reason to whistle a happy tune.

 

https://youtu.be/5XmD8PgXQIs

 

3. Productivity

Conformal cooling in mold design enables vast improvements in overall cycle time and cost, but remains relatively underutilized due to the design and manufacturing hurdles that accompany the technique. Bastech tackled these problems with a streamlined workflow of digital design and manufacturing solutions. Using Cimatron™ software for accelerated mold design, direct metal printing on the ProX® DMP 320 and inspection with Geomagic® Control™, Bastech reduced design time by 70%, cut costs by 16% and shrank cycle time by 14% to set a new standard in productivity.

 

https://youtu.be/TNeaAKPUx1k

 

2. Digital Molding

2016 saw the laying of considerable groundwork towards Digital Molding. Whereas traditional injection molding requires substantial time and material investment before a product can be realized, Digital Molding is changing the manufacturing equation. Powered by our Figure 4 technology, Digital Molding delivers tool-free plastic parts with exceptional efficiency, design flexibility and economics. This ultra-fast, automated stereolithography (SLA) system enables manufacturers to go straight from CAD to manufacturing to go to market faster.

 

 

1. Tomorrow

Grace Kablaenga was born with rare and severe facial cleft deformities, extreme distance between her eyes, and no bone separating her brain from her oral cavity.  Due to the physical difficulty of swallowing, she soon suffered from undernourishment and anemia, leading her childhood to be anything but carefree. Fortunately, Grace’s condition came to the attention of the World Craniofacial Foundation, and a team of doctors intervened to solve the anatomical puzzle of Grace’s condition with the help of VSP and 3D printed surgical guides.

Omni large format 3D printer case studies

14.12.2016

Two great case studies showing the capabilities of the Omni Factory 2.0 3D Printer.

Prototyping of car parts for Arrinera Automotive S.A.

Racing car producer – Arrinera Automotive S.A. – was looking for an optimum solution to produce car-part prototypes. The engineering process requires the continuous improvement of elements. Creating prototypes with previous production methods extended the time needed and involved high costs.

The company commissioned the printing of auto parts to OMNI3D Printroom. Parts are printed
on a 3D printer – Factory 2.0 Production System using ABS, ASA, PC-ABS, PET-G, HIPS filaments depending
on the requirements. List of all available filaments is available here.

Here is what our client says about the results:

“OMNI3D services significantly accelerate the work of our R&D team. 3D printed parts meet all of our requirements – both in terms of strength, dimensional accuracy and turnaround time.”

Łukasz Tomkiewicz, Managing Director, Arrinera Automotive S.A.

Thanks to the additive technology, we realized the Arrinera’s target – to shorten the process of obtaining the final part. Detail production on a 3D printer reduces production time and costs. Frequent changes of a model’s shape – the diameter or length – are not as problematic as they used to be. A new model can be printed in just over a dozen hours.

 

Chair seat design

One of our customers were looking for a low cost solution, which would enable to produce a chair seat prototype in the full scale. The most important thing, apart from the size, was the durability and the perfect shape of the model. The customer’s main objective was to specify the ergonomics of the furniture before mass production.

“The 3D printer – Factory 2.0 Production System allows large-format printing. Thanks to OMNI3D solution, we can analyse the ergonomics of models that were printed in a full scale. It’s very important in our sector.”

_mg_0989

What we did?

Printroom by OMNI3D printed out couple of chair seat prototypes. Our machine – Factory 2.0 meets two main requirements, which were essential for this project:

  • a working surface of 500 mm in each axis (the chair size is 450 mm x 430 mm x 465 mm),
  • the ability to print with support structures  (two extruders). Generated support structures were necessary to copy the geometry of the 3D model in the proper way. Two materials were used in this project – ABS-42 (main material) and HIPS-20 (supporting material).

List of OMNI3D filaments is available here.

What was the effect?

Thanks to printing the model in its full scale and retaining its durability, designers could test ergonomics of the chair and prepare the best possible design the final furniture. What’s more, using 3D technology to produce a prototype involves low costs.

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