Create a First-Rate 3D File

Quality designs lead to quality parts, but it’s not always an easy process. Some very important steps must occur before it is possible for a 3D model to make it into a 3D printer. A healthy dose of inspiration and motivation is required first—leading to the ideation phase—which must be accompanied by tools meant to streamline the process from modeling to manufacturing.

Shapeways works with customers every day who are dedicated to designing unique 3D models for a tremendous range of projects, varying in requirements that affect options in terms of settings, materials, and technology. This is why the ongoing design partnership with ZVerse has been so positive for simplifying the customer experience. ZVerse was a logical partner due to the massive scope of 3D printing going on at Shapeways—leading to the need for a professional design team with broad resources.

The ZVerse platform is uniquely AI-enabled, allowing for better automation in file creation workflow, along with helping Shapeways scale to customer needs better. Every customer has access to comprehensive design solutions offering the most streamlined path from concept to 3D model.

3D printing experts from the Shapeways User Application Team are also available for one-on-one consultations to discuss the best fit for materials and manufacturing methods, as well as finding ways to overcome typical issues with printability.

“We are here to help with any and all questions about design, materials, or the processes that make our customers’ models come to life,” says Zach Dillon, User Application Team Lead at Shapeways.

Get the most out of product development

While 3D printing allows for incredible creativity, innovation, and the ability to make products with complex geometries that simply were not possible previously, this technology lends itself to superior product development processes, beginning with rapid prototyping. Models can be designed and 3D printed, offering detailed visualization of products, along with the ability to test and validate parts according to project specifications. A good example would be checking for proper fit in new automotive parts or aerospace applications where there is absolutely no room for error. Rapid prototyping has played a major role for customers like Tilt Hydrometer, with CEO Noah Neibaron designing and 3D printing over a hundred iterations with Shapeways before settling on the final design for his free-floating monitoring device used in homebrewing.

Shapeways 3D prints products in over 90 materials and finishes, with over 11 technologies to choose from. Thermoplastics like Nylon 12 [Versatile Plastic] are extremely popular for a wide range of applications, from drone technology for customers like Quantum-Systems, to a luxury jewelry series of cuff bracelets for Dutch designers Groen & Boothman. All of these companies have used Nylon 12 [Versatile Plastic] for both extensive prototyping to ‘get it just right,’ along with making it the final choice for high-performance, functional products. That does not mean, however, that as longtime customers they haven’t delved into a variety of metals, to include other thermoplastics like MJF Plastic PA12 or precious metals like silver. Along with these materials come a variety of different colors and finishes, along with our latest offering in Nylon 12 [Versatile Plastic] Smooth.  

Get to market fast—and effectively

Products that are already in high demand can be 3D printed in customized bulk orders, and for businesses experiencing higher volume in orders, Shapeways recommends that they work with the User Application Team directly for streamlining production and bridging the gap from concept to printability and ultimately, quality manufacturing.

“Our goal is to make the customer experience as seamless as possible,” says Matthew Nadler, User Application Materials Specialist at Shapeways. “We unlock all that Shapeways has to offer for our customers, and enable them to leverage our full capabilities.”

Add-on services are available in manufacturing also, to include product assembly. Shapeways customers like LuxMea have been able to pass on the benefits of customized, on-demand printing and assembly to their own clients as bespoke masks—which include an ergonomic valve system design—are measured to fit with AI software and then completed with a personalized label.

Scale for success

Shapeways 3D prints the masks and also ships them out for LuxMea too, offering total order fulfilment that includes customized packaging for continued brand recognition, along with the opportunity to take advantage of other marketing opportunities at the same time, like adding custom inserts or promotional materials. Shapeways ships orders out to over 160 countries, with bulk pricing available. Proprietary software also makes it easy for other manufacturers to offer 3D printing with fast turnaround, including secure uploading and ordering, instant quotes, and streamlined ordering.

Scaling production is critical to modern businesses of all sizes serving a wide range of applications, and Shapeways is always ready to assist in helping customers grow—whether through 3D printing or other traditional manufacturing methods. In some cases they may begin on the smaller scale with low-batch production in highly customized, 3D printed products and then move on to more traditional methods like injection molding for precise mass production due to customer demand. In other cases, customers may want to navigate manufacturing processes in reverse, or begin employing a hybrid combination of additive and traditional manufacturing.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing creations for the classroom with accuracy, complex detail, and no limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Inclusive Manufacturing: Streamlining & Scaling Production for Customers appeared first on Shapeways Blog.

Developed in the mid-80s, 3D printing began as a way for engineers to make small prototypes. For decades, it was also quietly embraced behind the scenes by research labs, aerospace organizations like NASA, and a handful of automotive companies with deep pockets who realized the immediate potential for prototyping, making spare parts, and manufacturing jigs and fixtures. As major patents began to run out around 2014, 3D printing was thrust into the consumer spotlight. Spectacular headlines began to take over the press, garnering worldwide attention over a technology that to the average layperson seemed nothing short of magic.

The 3D Printing Industry Continues to Accelerate

For designers and manufacturers, the floodgates were opened. Advances in applications like medicine were some of the most highlighted applications due to transformative medical models, medical devices and implants, and surgical tools leading to life-saving and cutting-edge surgeries. They were joined by companies engineering drones, robotics, embedded electronics, and a long list of others. Recent market research now projects that the global 3D printing market will reach $62.79 billion USD by 2028, with a 21 percent compound annual growth rate from 2021 to 2028.

With the advent of expiring licenses which had been held so long, accessibility and affordability were cited as the ongoing reasons for the explosion in 3D printing technology, materials—and captivating innovation. 3D printing at the desktop became much more common, quickly catching on in primary and secondary schools, as well as for college and university labs. Suddenly 3D printers were in common use at the professional level in design firms, as well as architectural offices and medical research labs.

Industrial Parts Still Require Industrial 3D Printing Hardware

Desktop and professional-grade 3D printers can be purchased painlessly, but that is often where the ease ends as the technology is not always as simple as it sounds or looks. Many of the cheaper models may draw in consumers with hype, including kits that could cost less than a typical grocery shopping bill, but often present challenges for operators without significant tinkering or engineering experience. While much can go right, and it is very exciting, much can go wrong too, including the level of quality in manufacturing for prototypes and parts.

Harkening back to Ken Olson, co-founder of Digital Equipment Corporation (DEC), who famously said “There is no reason for any individual to have a computer in his home,” parallel contradictions may certainly prove to be true within the 3D printing industry. Desktop units may continue to become more user-friendly and higher in quality; however, they cannot take the place of their industrial counterparts in most cases, which is why so many businesses reach out to Shapeways for 3D printing—rather than taking on challenges such as the following:

• The expense of purchasing expensive equipment, along with making room for such items, and providing ventilation too.
• Hiring staff knowledgeable about 3D printing or instituting training programs.
• Dealing with the limits of non-industrial equipment.
• Handling scalability issues—especially trying to use desktop printers meant for small production jobs when parts need to be 3D printed in larger quantities.

From a Prototyping Tool to Production of End-Use Parts

With so many modern professionals worldwide realizing the truly infinite potential in 3D printing for new products, and the ability to make complex geometries like never before, the collective whole has continued to experiment and push the limits. As a result, newer and more industrial hardware and materials continue to emerge, along with the ability to go far beyond prototyping, and onward to the production of customized, quality parts meant for long-term functionality and high performance.For example, technology like Selective Laser Sintering (SLS) at Shapeways allows the transition from low-batch volume to much higher production levels with machines that can 3D print thousands of end-use parts at once.

With durable, versatile materials like Nylon 12 [Versatile Plastic], Shapeways manufactures many different types of prototypes and end-use parts, ranging from consumer goods to jewelry to production parts built for those applications. With over 90 different materials and finishes to choose from, customers like beer-brewers Tilt and jewelry designers Groen and Boothman work with Shapeways to manufacture functional, high-performance parts, and luxury keepsakes for their customers.

3D Printing Services Make Manufacturing Much Easier

Although it is not unheard of, most businesses do not have the time to open up their own 3D printing factories, nor the desire to do so as they are busy focusing on their own core specialties. Expense is also a huge factor, and for many businesses, spending precious capital in the wide variety of industrial hardware, software, and human resources required for additive manufacturing may not be a sound investment. 

Shapeways offers the full range of additive manufacturing solutions, including a complete array of manufacturing capabilities to ensure seamless production of quality parts.  The services are reinforced by a global network of manufacturing partners to make custom solutions possible. Production truly spans from end to end too, beginning when a customer creates an account or speaks with a Shapeways business development manager, and continues with:

• Instant price quotes
• Automated printability checks
• Expert support on bulk and custom printing
• Comprehensive quality management 
• On-demand production to include assembly and direct-to-customer fulfillment with customized packaging

Shapeways acts as a reliable manufacturing partner to fulfill requirements in additive manufacturing, and many businesses have chosen to work with Shapeways because they seek a streamlined end-to-end production process. As scaling demands intensify, Shapeways also provides customers with access to traditional manufacturing offerings, including injection molding, urethane casting services, and more.

About Shapeways

Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to make over 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Bolstering Manufacturing with 3D Printing appeared first on Shapeways Blog.

BotFactory’s insight into what engineers wanted came from their own weary experiences as students at NYU Tandon School of Engineering, where they missed a number of class deadlines while waiting on prototypes. The BotFactory quickly grew from concept to hardware, in the form of their initial machine, the Squink. George Kyriakou, BotFactory co-founder and COO, and his fellow engineers 3D printed the entire circuit board printer in their small headquarters. They were stumped by one part though: the vacuuming mechanism on the pick-and-place toolhead simply was not providing enough sucking action to do its job.

Ultimately, BotFactory realized they needed expert advice in refining the failing toolhead. Shapeways came into the picture upon the advice of a friend, leading them quickly to a new part. It was also the beginning of a great working relationship that has continued for years.

“We started with a very small part,” explained Kyriakou. “Our MakerBot Replicator 2 wasn’t able to make it completely air-proof, and we needed more advanced 3D printing technology for actual part usage.”

Working with Shapeways, BotFactory was able to source materials that worked best for them while making and perfecting the Squink. This was particularly easy due to the proximity of Shapeways in New York City, just a couple blocks away.

In the beginning, BotFactory was extremely happy with the ability to upload models online, find out if there were any printability issues, and best of all, receive instant quotes from Shapeways.

“Back then we were on a very tight budget and we were working with very low numbers, so being able to know exactly what to expect was very important,” said George Kyriakou.

In 2015 as BotFactory reached out to Shapeways for help, they were just beginning to see a glimmer of the future, with an ongoing need for more industrial 3D printed parts—especially with the complex geometries they needed to manufacture. There was also a lot of testing for materials before settling on Nylon 12 [Versatile Plastic] for many of their parts.

As BotFactory has evolved, Kyriakou mentioned the invaluable benefit in being able to work with their own account representative (Kevin Stott) at Shapeways, making the design and production process more helpful than ever as their 3D printing needs expanded.

“Words are not enough!” said Kyriakou in appreciation.

“In the beginning, although [the self-serve option] was very easy to use, as we started scaling up, we needed more. The ability to have an account representative who knows our product and knows our needs has been tremendously helpful.”

Although they still support their original printer, BotFactory has retired the Squink. Now superseded by the SV2 and an entire range of options to include the Starter, Enhanced, and Professional versions, BotFactory is working with Shapeways to 3D print numerous main hardware components for their circuit board printers. This includes the toolheads for inkjet printing, paste dispensing and pick-and-place—all the main components responsible for performing the fabrication and assembly of a PCB. Shapeways also 3D prints the head casings and other smaller components like mounting brackets.

The entirety of the mechanical engineering was carried out by Lead Mechanical Engineer Pranav Mahamuni, who stated “Shapeways is a key part of our product development cycle—we can count on meeting the strict tolerances and material capabilities that we need to make a precision PCB printer like ours.”

Ultimately, the goal at BotFactory is to create technology so mature and so approachable that they can make it available to every single electrical engineer. In the meantime, they are also working with the U.S. Air Force to develop on-demand 3D printing and assembly of their PCBs.

Check out ­­­­­­­­­BotFactory: Engineers Revolutionize PCB Manufacturing with 3D Printing, a case study offering a more in-depth look at how BotFactory grew from a small startup to a sophisticated technology company offering a new series of small circuit board printers.

Engineers from around the world have evolved in tandem with Shapeways, founded in 2007 in the Netherlands and now headquartered in New York City. Shapeways is able to look back on helping many talented individuals and promising businesses get their start in the technology and 3D printing industry—now with over 20 million products 3D printed for more than one million customers.

The post BotFactory Bridges the Gap: 3D Printing PCBs from the Desktop appeared first on Shapeways Blog.

Backtrack to the early days of 3D printing as Chuck Hull was presented with his own lab, and famously woke his wife out of bed late one night to see his first rudimentary 3D print in the form of a rapid prototype. Fast forward, and such a scenario could now be taking place anywhere in the world. Software, hardware, and materials are more accessible and affordable than ever, leaving the world ripe for change. The initial goal of bringing 3D printers forth into the world was to encourage creativity via stereolithography; however, SLA 3D printing was almost solely emphasized as a rapid prototyping tool for engineers in the beginning.

The secret was too big to keep

Patented in 1986, SLA 3D printing was soon followed by selective laser sintering (SLS) and then fused deposition modeling (FDM). 3D printing technology—and all the opportunity behind it—was quickly bursting at the seams as automotive companies, NASA, and other entities with deep pockets wanted to take a swift turn from the conventional world of subtractive manufacturing into the additive. A handful of inventive trailblazers in their own right most likely enjoyed 3D printing behind the scenes as long as possible, with the knowledge that such innovation would be impossible to hide forever.

It wasn’t long before interlocking and moving parts (along with the potential for integrating electronics) began to pave the way for a wide range of functional components in critical applications like aerospace, automotive, and medicine.

Critical industries began to invest

Progress was particularly impressive as industries embracing 3D printing were also heavily centered around the safety of human lives. No one wants to be responsible for a rocket engine failing, an automobile causing accidents due to a defect, or an implant being rejected or a device harming an individual seeking to get better with medical treatment. The fact that researchers and scientists invested so much faith in an alternative method of manufacturing quickly gained attention, with interest continuing to accelerate at rapid speed over the past decade.

The ability to prototype and create finished products—all from the 3D printer—has had a profound effect on manufacturing. Processes like selective laser sintering (SLS) can be performed at high speeds, producing strong and durable parts. Because supports are not required (due to unsintered powder bolstering parts during the printing process), design freedom is virtually boundless, thus releasing designers from the stress associated with adding supports, and removing them.

Post-processing takes on many forms, depending on the 3D printer and the materials involved, but finished parts may be left natural, polished, or even dyed. SLS 3D printing again, is a great example as 3D prints made with Nylon 12 [Versatile Plastic] can be processed for a smooth finish, or taken to a more refined level with a premium, scratch-resistant finish. A wide variety of hues are available too.

3D printing will continue to transform manufacturing

It’s obvious that business is booming within the billion-dollar 3D printing industry, offering a vast range of options for materials alone, to include thermoplastics, powders, metals, resins, and filaments. Factories are beginning to run on a whole new type of automation, to include technology propagating itself, from 3D printers made from 3D printed parts to 3D printed robots performing 3D printing activities (and let’s not forget, this could also be happening in space to build colonies and maintain and fix crucial parts).

Warehouse space may easily begin to dwindle as a requirement for many businesses, with on-demand production eliminating the need for inventory. Instead, high-performance, customized parts can be created on demand and completely to the preferences of the consumer. With 3D printing propelling consumer-driven personalized comfort, patient-specific treatment in medicine, and the potential for making intricately customized products—the drudgery of “one-size-fits-all” may disappear altogether, and quite soon.

Intense opportunity for customization is already stretching to a variety of applications, demonstrated through powerful case studies at Shapeways. Most of the incredibly talented and innovative customers have one thing in common: 3D printing began weaving its way into their manufacturing processes over the years and to this day is allowing them to improve with each model, part, or latest design generation. In some cases, other technologies are woven in with 3D printing too for maximum effect.

Shapeways customers have evolved in tandem with 3D printing  

In architecture, for example, the ability to offer a 3D printed model or mockup as well as a virtual tour has taken the experience between designer and consumer to an unprecedented level—allowing for better communication, quality—and in the end, satisfaction. The team at Verner Architects is able to make 3D printed prototypes on-site, test them, and then order customized parts on-demand.

“I’ve been aware of Shapeways since architecture school,” said architect David Swaim. “Once I graduated I worked at an architectural model shop where we would get little pieces of furniture that we could not build by hand printed and delivered to put in our models.”

Swaim’s previous positive experiences with 3D printing led him to introduce the technology into a recent high-end remodel in California. Ultimately, the project was much larger than the architects expected, and by the end also included a unique six-foot, 3D printed bathroom vanity inspired by the beauty of coral reefs. The results were outstanding, with the fixture meant to stand the test of time in terms of luxury and durability.

Additive manufacturing plays a role in many other unexpected areas too. Dutch design duo Hanno Groen and Joanna Boothman, Shapeways customers for years, relied on SLS 3D printing for their latest series of cuff bracelets. Many may be surprised to hear that industrial manufacturing plays such a large role in their work, but not only are the skilled designers able to create elegant, lightweight pieces of jewelry—their bracelets are durably, luxury items meant to be handed down over the years.

Each bracelet is “as unique as a fingerprint,” and the antithesis of mass-produced, disposable costume jewelry.

“3D printing gives us a chance to explore new avenues and get away from the mass production paradigm,” says Boothman.

Both designers also appreciate the way the Shapeways platform complements their artistic spirit—aside from aiding in the actual creation of jewelry—as they are able to work whenever the mood strikes and then upload their models quickly.

Boston-based industrial designer Evan Gant offers an artistic bend with his 3D printing also, designing a distinctive 3D printed pendant light that adjusts with a simple twist. Aptly named the Twist Light, Gant was using paper towel rolls for prototyping. Not only did he discover the wonders of using 3D printing to test parts—he also began manufacturing his lights with small-volume manufacturing through Shapeways.

“My favorite part of the design process is iterating and seeing the reaction to ideas,” explained Gant. “In a traditional process (like injection molding), a large portion of your time is spent optimizing from a mold, finding a vender that will make you parts, doing quality control, etc. You often need to make a lot of compromises to your design in the end.”

For the medical professionals, compromise is usually is not a luxury, with patients’ lives at stake. As the COVID-19 pandemic struck worldwide and supply chains began to show massive and unexpected vulnerability, Shapeways reached out to help the medical community by printing face shields for hospitals, using a modified version of the Prusa 3D design. The shields are manufactured via SLS technology and can be repeatedly disinfected after each use. As the need for face masks with good filtration, fit, and some modicum of smile became apparent too, Luxmea Studio stepped up to partner with Shapeways in creating bespoke face masks, ordered through a smart fitting process online.

The need for organization never ceases for medical processes and equipment either, especially as the coronavirus has raged on. Considering the needs of everyone involved—from medical equipment suppliers to nurses and doctors and patients—Voytek Medical worked with Shapeways to 3D print medical cable clasps printed in Nylon 12 [Versatile Plastic].

“Voytek Medical has been using Shapeways in every stage of production, from concept to prototype and end-user products,” said the Voytek team.

3D printing can transform your business too

As prototyping becomes more of a given, the industrial spotlight shines front and center on 3D printing for the manufacturing of finished products. Businesses of all sizes now rely on AM processes for innovating, designing, optimizing, and revolutionizing.

3D printing services from Shapeways such as SLS allow you to reap the rewards of high-performance, quality materials without having to invest all your business capital in the powerful hardware, software, and materials required for your build. Enjoy the benefits of Shapeways advanced technology and wide range of materials for printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Read about case studies, find out more about our solutions, and get instant quotes here.

The post Far Beyond Prototyping: The Additive Manufacturing Revolution Continues to Accelerate appeared first on Shapeways Blog.

To meet the growing need for businesses to quickly get to market, regardless of their industries, Shapeways has a wide variety of materials leveraging industrial 3D printing technology. Selective laser sintering (SLS) is one of many technologies that are perfect for prototyping.

What is SLS?

SLS is an additive manufacturing (AM) technology that uses a laser to sinter powdered plastic material into a solid structure based on a 3D model. SLS 3D printing has been a popular choice for engineers in product design for decades. It is both low cost and highly productive making it the ideal technology for rapid prototyping.

In the past, SLS rapid prototyping was limited to a small handful of large high-tech companies. Shapeways’ unique advances in machinery, materials, and software have revolutionized SLS making it now accessible to a wider range of businesses. This now enables a more diverse cross section of companies to access the many advantages industrial 3D printing has to offer!

Developing Product Concepts with Rapid Prototyping

Product changes occur frequently during the earlier phases of product design. In an ideal situation, designers can take their time designing and refining new product to meet their company’s needs while still hitting key metrics such as cost, consumer value and functionality.

It is not uncommon for time to be the most critical factor during the design phase. The need to have a functioning prototype in hand quickly (and affordably) often becomes the priority of the project.

For example, when pitching for new business the ability to quickly create 3D models of your proposed product concept can be the difference between a winning pitch and lost business. New client pitches often occur with little notice or prep time. That is exactly why having access to an industrial 3D printers to design and create a physical model is key.

Prototyping for Product Assembly and Functionality

The benefits of additive manufacturing is not at all limited to just the concept phase. SLS machines can produce parts that not only delivered quickly, but are also highly durable; making them ideal to review assembly and functionality.

As design and parts evolve, quickly creating iterative design changes to physically evaluate the assembly can reduce the time getting from concept to final product.

Whether you are working with simple moveable parts, or more advanced product like robotics and drones, 3D printing provides replicas of any single piece in a highly durable material. As you test out assembly, the ability to quickly produce durable 3D samples of newly modified parts gives companies a huge competitive advantage.

Rapid Prototyping Assists with Final Product Fit and Form

An additional benefit to rapid prototyping is the benefit it provides in terms of final fit and form. This can be seen across multiple industry disciplines such as medical diagnostic machines, drones, and robotics. Assuring a functional part fits within a medical diagnostic machine, such as a cooling fan, is critical to ensuring the machine works consistently. In addition, with drones and robotics, combining multiple parts into one by leveraging 3D printing can make the final product lighter in weight. However, if the complex geometry of the additive manufactured part doesn’t fit the final product, the issue of weight is irrelevant.

Additionally, rapid prototyping has other advantages for product fit. 3D models can be created to physically analyze final sizing without needing all internal components to be finalized. This is done by designing a hollowed out “shell” of the products exact form and size to verify fit. This size replica of your design is ideal for testing fit without creating a full model. The results are the same, but the speed and benefits are greatly improved.

Keeping Up with the Speed of Business

The ability to use 3D printing has revolutionized business.

The innovative SLS process to give any business the capabilities that were once limited to large high-tech firms. The advantages of additive manufacturing quickly allows companies to customize concepts, make changes for assembly, and ensure a perfect fit for final product assembly.

Shapeways can partner with you throughout the prototype phase to quickly get your concept to a final product. Understanding the different material characteristics with various 3D printers is what our team takes pride in. To find out more, contact our 3D printing experts and have Shapeways help with your next prototype.

The post Leveraging Rapid Prototyping – from Concept to Final Product appeared first on Shapeways Blog.

Prototyping

Having the ability to rapidly fabricate prototypes keeps workflows moving steadily and avoids costly pauses in the manufacturing line. This is where 3D printing is most used in automotive manufacturing, as it allows for unparalleled speed in producing, editing and evolving iterations. Prototypes can be made for any stage whether it be as proof of concept or high fidelity prototypes that will better validate parts through the whole manufacturing process. It also allows for manufacturers to test new components and continue developing the way parts are made and contribute to a vehicle’s performance. Small scale prototypes can also be created for marketing purposes, like Volkswagen’s 10,000 tiny metal cars for the launch of their electric car model ID.3 in 2018.

Customization

Many consumers jump at the idea of adding their own flair to the commodities in their lives. The ability to pick out colors, patterns and take part in the design process greatly increases customer satisfaction and is something that 3D printing has enabled manufacturers to do while still keeping costs low. Many automotive companies have begun to introduce custom flourishes and parts to their cars as mass customization becomes much more feasible with 3D printing. In traditional manufacturing, a mold and specific tools would be needed to create each personalized component, but using 3D printing, this is easily achieved by editing the 3D file. Thus, 3D printing allows for the production of small batches of custom design pieces without raising the cost that customization would incur with traditional manufacturing.

BMW’s Mini car makers introduced a personalization service in 2018 called “Mini Yours” in which customers can choose colors and finishes, customize door handles, LED lights and panels, and can even add their own text or signature to various parts.

Similarly, Volkswagen began rolling out individualized cosmetic parts such as key rings, gear shift knobs and tailgates, all of which can feature custom lettering of the customer’s choice to be printed in stainless steel using the HP Metal Jet tool.

Tooling & Manufacturing Aids

3D printing also gives manufacturers the ability to produce lower cost manufacturing aids and tools for custom parts like jigs and fixtures. A 3D printed mold for a new part can provide a higher level of design freedom and 3D printed tools can be lighter and stronger. It also allows for more ergonomic tools for manufacturers. BMW and the Department of Ergonomics at the Technical University of Munich created 3D printed orthotic thumb devices to support and prevent strain for assembly workers. The workers’ thumbs are 3D scanned and each device is molded to fit each person’s thumb.

Creating Complex Designs for New Parts

The ability to produce viable end parts, paired with the design freedom that 3D printing allows for means that more complex and perfectly suited components can be incorporated into vehicles, creating further innovation in aesthetic and performance.

Several German additive manufacturing (AM) companies collaborated on a prototype for a vehicle seat called ULBS that combines safety and comfort with ultra light-weight structure. The prototype uses a filament winding process with parts printed in plastic, stainless steel and backrest cushions printed in Thermoplastic Polyurethane (TPU).

When Volkswagen recreated their 1969 mini bus, they 3D printed aluminium cast wheels using generative design, a method that uses an algorithm to produce many versions of a design idea that the designer can then choose from. They created 3D printed hubcaps with a clear resin that were electroplated to have the appearance of metal. These details allowed them to put a modern design twist on an iconic vehicle.

Bentley’s design studio has taken advantage of 3D printing to produce parts with a high level of intricacy. They have produced grille mesh, side vents and door handles with micro-scale detail precision that would not have been possible using another manufacturing method. They are able to design parts with complex geometries that create a bold aesthetic that builds on their classic designs.

Spare Part Production

As automotive manufacturers begin using 3D printing for general end part production, it also becomes possible to print spare parts as needed. If someone driving an older can model needs a part replaced that is out of production, this leaves the driver in a difficult position. Being able to 3D print that missing part solves that issue without car companies having to maintain an ever expanding inventory of old parts they may never need again. It gives manufacturers the ability to produce rare and hard-to-replace parts on demand while optimizing their inventory.

End Part Production

We’ve seen how manufacturers can use 3D printing for prototypes and select customizable parts, but as 3D printing technology evolves, so does its ability to produce end parts for industrial use. For one thing, 3D printing allows automotive manufacturers to consolidate multiple parts into one, thereby decreasing the vehicle’s overall weight while increasing fuel efficiency.

The materials that 3D printing has to offer are rising to meet the standards for end parts as well. Shapeways has partnered with BASF to provide access to high performance materials including Ultrasint® PP nat 01 and Ultrasint® TPU01 that are well suited to functional automotive end parts because of their versatility and durability.

Another excellent material choice is DSM’s Arnite® T AM1210 (P). Available through Shapeways’ partnership with DSM, this Arnite material is ideal for automotive parts needing to withstand high temperatures. This powder is easy to print with and is also environmentally friendly, as it can be recycled back through the powder bed process.

Whether you’re in the automotive industry looking to incorporate 3D printing for your manufacturing process, or you’re looking for help with additive manufacturing for another industry, we can provide a custom solution to help you scale your business.

The post The Impact of 3D Printing in the Automotive Industry appeared first on Shapeways Blog.

Here are 5 drone projects that have pushed the boundaries with the help of 3D printing:

Disaster Relief X VEIN Drone by Team ROK

After the Great East Japan earthquake and tsunami brought disaster on a massive scale in 2011, Yuki Ogasawara and Ryo Kumeda of Team ROK were inspired to create a drone built especially for disaster relief and search and rescue. A few years later they used 3D printing and generative design to create their x-shaped X VEIN drone. Because disaster aid presents its own specific set of challenges, the team used 3D printing to be able to customize their drone based on their exact needs.

The design features freeform curves, and a 3D printed lattice-patterned body for maintaining minimal weight while still giving it the strength required to operate in difficult conditions. X VEIN is able to fly within a 500 meter range and can be equipped with thermographic and infrared-imaging and capture images that can be viewed in real time to access remote or obstructed areas and help locate survivors. Because many of its parts are 3D printed, if they are damaged on a mission they can be re-printed and replaced on site. 3D Printing was a crucial tool to be able to have the level of design freedom necessary to build a drone with these specific needs and it ensures that the drone can be further customized in the future depending on the situation at hand.

CargoCopter by KU Leuven Researchers

Built to deliver payloads over long distances, KU Leuven research team created the 3D printed CargoCopter, a hybrid drone that combines fixed wings and multi-rotors so that it can take off vertically, hover and then fly horizontally. It was designed to expand the range and speed of traditional multi-rotor drones and thanks to its hybrid nature can efficiently transition from take-off to long-distance flight. It can carry up to 5kg, has a range of 60km and can fly up to 100km/hour. The team used 3D printing to rapidly prototype over 3 years to arrive at this model and their designs were able to quickly evolve. Thanks to the customization flexibility of 3D printing they are able to optimize each new CargoCopter design based on the needs of its particular mission.

BLUEROV2 Submarine Drone by Blue Robotics

Aerial drones are not the only ones making use of 3D printing. When Blue Robotics set out to build their underwater drones, they needed parts that could withstand the harsh conditions of the ocean and had trouble sourcing ones that were durable enough and weren’t overly expensive. They then turned to 3D printing to be able to prototype their own parts at a much more affordable rate. Using 3D printing to prototype also led them to customize parts to fit their exact needs. The BLUEROV2 comes with a high definition, wide-angle low-light camera with two or four lights to illuminate the ocean around it. It can travel to a depth of up to 100 meters and is built to withstand currents. The ROV is designed with expansion and modification in mind, and is fitted with a customizable frame to accommodate a range of functions.

Piccolissimo The Tiny Drone by Matt Piccoli from UPenn

In 2016, Matt Piccoli from UPenn’s School of Engineering and Applied Science designed the world’s smallest steerable drone “Piccolissimo”. The tiny drone comes in two sizes: one weighs 2.5 grams and is the size of a quarter, and the other steerable version is 2 grams heavier and a centimeter wider. It was 3D printed using lightweight plastic. It has two moving parts, the robot’s body and motor, which spins one way 40 times per second, and its propeller spinning 800 per second in the opposite direction. Its motion is determined by how quickly the propeller and body are spinning, which can be controlled by infrared signals. The drone can carry a load of up to one gram, like a small camera or sensor. Its size suggests that it would be a fitting model for surveying or search and rescue missions, as a few hundred could be used to cover more ground than a single larger sized drone.

The Int-Ball by the Japan Aerospace Exploration Agency (JAXA)

The Int-Ball, or JEM Internal Ball Camera was built using 3D printing to float aboard the International Space Station taking video and photo documentation. The spherical drone arrived on the ISS in June of 2017 and weighs 1kg, has a 15cm diameter and moves with 12 propellers. The Int-Ball features both internal and external components produced using 3D printing and is designed to float in a zero-gravity environment with the ability to move autonomously or be maneuvered by operators on Earth. It is set to reduce the crew’s workload by 10% by taking on image capturing duties.

3D printing helps to redefine what is possible when it comes to exploring and achieving innovation in drone technology. Its efficiency in prototyping and customization make room for a higher level of productivity and imagination, improving the way drones are designed and manufactured. If you are looking to create the next innovative drone, 3D printing is essential to facilitating the most efficient and flexible production process.

See how Shapeways can help your drone business transition to 3D printing!

The post 5 Next-Level 3D Printed Drones That Are Pushing the Industry Forward appeared first on Shapeways Blog.

A Kickstarter Requirement

While there are multiple options and websites that function as crowd-sourcing platforms (i.e. asking customers to pre-pay or fund a new-to-market item before it goes into production to cover the upfront investment costs), Kickstarter is undoubtedly one of the most popular and utilized.

As part of their rules and regulations, Kickstarter requires a visual of the prototype along with a description and use guide. They also note that a graphical or computer-generated image of a product is specifically prohibited. Kickstarter requires that companies present a looks-like, functional working model as a prototype to both explain the product and to entice potential backers.

This is precisely why 3D printing has been such an effective and essential tool for companies looking to crowd source projects through Kickstarter. Other techniques for creating a working model may require substantial financial investment upfront, and/or increased working hours. Tooling, mold making, sculpting by hand as well as less effective techniques like “kit bashing” (mixing and matching parts from existing products to create something new) all lack the advantages 3D printing provides – custom-designed, precise and affordable models that can function as prototypes and final products.

So what type of products benefit from 3D prototyping for Kickstarter? The simple answer is – almost anything. 3D printing is not limited to any one category or industry, and can offer different benefits for different types of Kickstarter product pitches. Here are three examples from three different businesses that utilized 3D printing in their Kickstarter campaigns.

Customize Your Vision  

Boulton Eyeware ran a successful Kickstarter campaign where they received a total of £35,000  ($26,000) to fund their pre-production costs. Their unique concept was based on one simple premise: every human face is different. Just as customers have fitted suits created for their bodies, Boulton felt there was a market for custom sunglasses for each individual’s face.

3D printing excels in customization, which is why Boulton Eyeware turned to this process, not only for their prototype, but for actual production as well. In order to create a working prototype to use on Kickstarter, Boulton went through 70 different concepts refining and changing their materials and finishing until a satisfactory model was achieved. It was the ease of use, cost effective process and robust selection of material that made 3D printing the right choice for their custom product.

Customized For Coffee Lovers

The ability to experiment with functionality is another major advantage to using 3D printing for Kickstarter prototypes. Fellow started as a class project that blossomed into a startup business based in San Francisco. Their simplistic goal: to create the world’s best cup of coffee. 

Dubbing themselves “coffee loving nerds” the team at Fellow led by founder Jake Miller found inspiration from across the globe and throughout history. They reviewed coffee pot designs from as far away as Scandinavia, as well as mid-century industrial designs.

Where 3D printing came into play was in the functionality aspect.  In order to find that perfect design that would brew and pour the coffee of their dreams, Fellow engineers made hundreds of 3D prototypes, constantly changing, modifying and updating their design to achieve the ideal result they wanted.

Using 3D printing not only provided a cost-saving measure with the ability to constantly change designs at a low cost, but it allowed them to see how their product would take up space in kitchens and countertops. By working in 3D, their designs could be reviewed both functionally and aesthetically in the real world. It became much easier to review a physical model because it was to scale, letting designers hold, manipulate and brew coffee using their 3D printed models.

Getting into the Action

Turning to the toy category, Bobby Vale, a former designer at Hasbro, saw a hole in the consumer market for 6” highly articulated action figures that represented military soldiers and the different divisions of our service men and women.

Aiming to please the discriminating “adult collector” who looks for features such as sculpting detail, paint deco and above all a large amount of articulation points (for posing and display), Bobby was set up for success. He modeled his Valaverse military figures off of the successful Marvel super hero products he worked on in his previous position. 3D printing became the key tool to show off these features to potential funders on Kickstarter.

Both the durability and flexibility of 3D printing were important factors in creating the Valaverse 3D prototypes for Kickstarter. In order to show off the high level of articulation, each part needed to assemble and work just like a mass-produced action figure. The materials offered by 3D printing not only permitted his prototypes to articulate, but they could assemble and function exactly as finished products would. This permitted the most accurate and true-to-final prototype to illustrate his Kickstarter concept to potential backers.

All the Features You Need

3D printing is becoming more and more the go-to technology for prototyping visual models for crowd-funded campaigns.

At Shapeways, we offer 3D printing benefits that go above and beyond what consumers may find elsewhere. In addition to a vast selection of materials (over 75!) and the best quality checks by 3D printing engineers, printing with Shapeways requires no equipment to purchase or maintain. We handle all of the fast turnarounds and deliver exactly what you need to succeed for your campaign.

Whether you are looking for customization, to test out functionality, or demonstrate features that work like finished goods, 3D printing can be your best solution. The Shapeways team is here to provide all of your 3D prototyping needs in one place.

The post Kickstart Your Innovations With 3D Prototypes appeared first on Shapeways Blog.

Their latest endeavor Dice Miner is a dice-based game that was pre-sold through a Kickstarter campaign. Because of the high expectations Kickstarter funders have, an early visual of the product was necessary to show off the new game to potential backers.

In order to create these visual components, Atlas Games sought out our 3D printing services to prototype the game pieces they needed, and were able to utilize 3D printing for fast and cost-effective solutions from early prototyping to final-stage designs.

Jeff Tidball, Chief Operating Officer of Atlas Games, has a deep passion for games. For a look behind the scenes at Atlas Games’ newest creation, we interviewed Jeff to find out how the advantages of 3D prototyping was critical for Dice Miner’s Kickstarter success.

Could you give us a quick summary about Atlas Games as well as your latest game, Dice Miner?

Atlas Games is a tabletop game publisher with a 30-year history and deep catalog of board, card, and roleplaying games. We’re best known for card games like Gloom and Once Upon a Time. Dice Miner is a dice drafting game with 60 custom dice and a unique mountain component that organizes the dice across each game’s three rounds, showing which dice are available to choose at any given time as the game unfolds.

What was the purpose of using Shapeways to make prototypes for Dice Miner?

Dice Miner’s Deluxe Edition will have a plastic PVC mountain, so we used Shapeways to prepare early prototypes of that component. We used Shapeways for two purposes. First, to playtest using components as close as possible to the final version, to make sure they performed as we expected at the table. Second, to evaluate their producibility while holding physical objects, as opposed to needing to evaluate them only on screen, or in our imaginations. 

How did you come to the decision to use 3D printing instead of other manufacturing methods?

Other manufacturing methods, to produce only one or two copies of a component like Dice Miner’s Deluxe Edition mountain, simply do not exist. (Maybe we could have hired someone to hand-sculpt one? I don’t even know.)

Did you already have technical knowledge in 3D printing? If not, was there a learning curve to getting into this technology?

Prior to Dice Miner, I had done very little 3D printing for a previous game’s miniatures prototype, also with Shapeways. However, we had the help of a consultant we had hired to create our plastic components, so we were able to use his model directly to produce the prototypes we used. So there was not much of a learning curve, but that’s because we had hired folks to help us already.

What material(s) do you print in and why?

We went with [Versatile Plastic, which are] cheap and fast for our game components. We were looking solely at form and function, rather than having any particular materials requirements.

How much time and/or cost were you able to save by prototyping with Shapeways versus using another method?

I don’t really have anything like that [to compare], since the other options don’t really exist. I suppose you could think about the complete disaster that would arise if a $3,500 mold was created wrong — having a physical prototype can help avoid that instance. Although it’s a small change, spending one or two hundred dollars to hedge against that downside seems pretty reasonable. Creating early prototypes also helped us get an advanced copy to an outside previewer, which helped illustrate to potential campaign backers how the game is played. Waiting for copies of the game from the production line would have simply been impossible. Without a preview of the game, I suspect fewer backers would have been comfortable joining the Kickstarter. Again, no hard-and-fast metrics, but I suspect we’d have left money on the table without being able to preview the game in that way.

Not only was Atlas Games able to succeed on Kickstarter, but they surpassed their goal by almost $80,000. Our 3D prototyping solutions were instrumental in this process by providing a simple and cost-effective means to creating a visual preview of the game.

And more importantly, game fans would now be able to “draft the dice” in Dice Miner with the empowerment that they helped make the game happen by supporting it on Kickstarter!

Are you creating a new game or product for an upcoming Kickstarter campaign? Find out how Shapeways can help with your rapid prototyping needs today.

The post How 3D Printing Helped Atlas Games Achieve Kickstarter Success appeared first on Shapeways Blog.

Want to learn more? Here are 10 ways rapid prototyping with 3D printing streamlines the design process:

1. Optimize The Design Using 3D Software

By creating the blueprints for the prototypes and final design in 3D software, any edits or improvements to that design are reflected accurately and promptly. The design can be visualized enough at this initial stage to reduce any errors of communication and to make early improvements that will save substantial time during the prototyping and production stages. If the product or part requires customization, this design can be revisited and expanded upon at any time.

2. Take Advantage of Form Freedom

3D design allows for the creation of complex geometries that might not be as attainable in other processes. This allows for expanded freedom in the design and the final shape of the product can only be limited by the designer’s imagination. This flexibility makes it possible to produce a professional proof of concept of innovative and original pieces without sacrificing additional time or costs in the development process.

3. Save Time in Prototype Production

In traditional prototyping, the product designer or engineer would use materials such as cardboard, styrofoam or wood to create initial prototypes, then move on to creating functional prototypes using manufacturing processes typically used for finished products. This is often a costly and time-consuming process, and often not a practical use of resources when the product is still in the developing stages. With 3D printing, a prototype at any stage of the design process can be printed quickly and provide the exact information needed in that stage whether it is a proof of concept or a functional prototype. When developing a part, being able to reiterate quickly and affordably is crucial, and 3D printing facilitates that need for all stages of prototyping.

4. Save on or Eliminate Tooling Costs

3D Printing acts as an all-in-one production method for low-volume production and for rapid prototyping. The technology eliminates the need to gather other manufacturing components or machines. Manufacturing methods like injection molding are much more costly to set up, especially for small quantities, and make creating custom prototypes very expensive and time consuming.

5. Create More Time for Designing and Customizing

Instead of having to wait weeks for a prototype to be constructed by hand or for a mold to be made, prototypes can be 3D printed in a matter of hours or days depending on its size. It allows for mistakes to be fixed more quickly and for the design to evolve at a much higher rate, leaving more time for further innovation, customization or moving on to the next design.

6. Save Time Communicating Ideas and Information

When a product or part is being developed, it is extremely important to be able to communicate without misinterpretation and to leave as little to the imagination as possible when discussing with a client or any other involved parties. 3D printed prototypes look more professional and can communicate details better than a 2D drawing. This enables more viable and specific feedback for revisions to be made quickly and efficiently. The better the level of information in prototyping stages, the better the final product.

7. Choose from a Wide Range of Materials Depending on Each Iteration’s Purpose

Different materials can be used based on different prototyping stages to illustrate or explore the integrity of the design. Early iterations can be printed in more affordable plastics such as our Versatile Plastic, while later, more refined versions can be printed in different materials to fit the specific needs or testing requirements of the product. Many of our materials are end-use ready, saving you the need to look for a manufacturer once the product is market ready.

8. Minimize Material Usage Where Possible

In initial stages of prototyping different printing methods can be used to save on materials. If a version of a prototype is meant to show the shape alone, for example, it can be scaled down and hollowed out. Lattice or honeycomb designs can be used for surfaces to cut down on materials and costs while still communicating key information about the part or product. The on-demand nature of 3D printing eliminates material waste during the prototyping stages.

9. Use 3D Printing Services for Prototyping

You can save a lot of money on equipment start-up costs by working with 3D printing services like Shapeways. By printing with a specialized service you do not need to own any printers or materials, your model will be reviewed by engineers before they are printed, eliminating trials and errors encountered when using your own machine. You are guaranteed a high level of quality control, the use of industrial-grade printers and should you need technical assistance, your inquiries will be answered by experts in the 3D printing space.

10. Use Realistic Prototypes for Marketing and Sales Needs

Once the final design has been revised and refined to satisfaction, realistic prototypes can be used to get a head start on marketing and sales promotions. A visual model of the product can be used before money is spent on manufacturing to test with potential customers, for use on a sales floor or to send your products to beta testers to help validate the design.

3D printing is a crucial tool for designers to facilitate a more efficient prototyping process. It saves time and money and also generates a higher level of design freedom, and improves communication with clients and prospective customers. By making the prototyping process faster and without sacrificing on quality, this helps design innovation maintain a competitive edge.

Ready to start prototyping your next idea, part or product with Shapeways? Upload your design now or get in touch with our team to discuss your unique innovation.

The post 10 Reasons Product Designers Prototype With 3D Printing appeared first on Shapeways Blog.