Industrial Designer Paul Sohi is obsessed with 3D printing. He’s made it his life’s work to make it accessible to more people – a mission we share. His earlier efforts include developing the world’s first fully additively manufactured prosthetic used at the Paralympic Games. More recently, he has been evangelizing for Fusion 360 at Autodesk.

A skateboard was ideal for Paul’s latest project. He wanted to design a fun, common item to debunk many 3D printing myths still common today by proving that 3D-printed products are end-use ready, durable and not just for prototyping. Just as important, Paul wanted to prove that you don’t have to buy a 3D printer. He explains, “The number one misperception I hear from designers is that they have to buy a 3D printer. I want to show that Shapeways’ services are part of the Fusion 360 workflow.”

Paul used Fusion 360 Generative Design to make the skateboard trucks (the metal T-shaped pieces that mount onto the underside of the skateboard) durable while also minimizing materials to cut costs. He sent the files to Shapeways, and we delivered the trucks in two materials: titanium and aluminum, both manufactured using additive manufacturing. Paul constructed the entire skateboard from board to wheels to trucks, and headed to California.

Braille Skateboarding was founded by Aaron Kyro and creates videos to help spread the joy of skateboarding. They joined the project to see if Paul’s skateboard trucks could enhance Braille’s tricks. We wanted to show the skate trucks’ functionality all while capturing some great runs on a board made possible with 3D printing and generative design. More than just a 3D printing stunt, our team wanted to focus on making  skateboarding an even better experience with increased durability and mobility. We succeeded – Paul estimates the trucks are 45% lighter and multiple times more durable versus comparable skateboard trucks.

We captured videos of Braille’s tricks and details on how the skate trucks were made. Special thank-you to Paul, Braille, and Autodesk for making this so much fun. Shapeways loved helping to bring this idea to life.

The post 3D Printing Mythbusting with Braille Skateboarding appeared first on Shapeways Blog.

print in metal

Here’s a rundown of some recent developments in metal 3D printing:

Most state-of-the-art racing bikes are crafted almost entirely from carbon fiber, which is light and strong. However, Chris Froome’s Tour de France-winning bicycle features 3D printed titanium handlebars. The Engineer reports that 3D printing reduced production time for the handlebars by up to 75% compared with a carbon fiber process. No molds were needed, and the custom fit eliminated any need for adjustability, saving up to 17% of the weight of a traditional handlebar assembly while reducing drag.

Ship Technology reports that the Port of Rotterdam’s Additive Manufacturing Fieldlab (RAMLAB) teamed with Autodesk to develop a 3D printed nautical propeller. Their hybrid manufacturing process combined wire and arc additive manufacturing with industrial robot arms, subtractive machining (CNC), and grinding. The new process will help the port provide quick replacement propellers for ships.

[Credit: Michael A. Parker]

Spaceships are also increasingly relying on metal 3D printing. NASA has 3D printed entire rocket engines. Scientists at NASA’s Jet Propulsion Laboratory (JPL) created a 3D printed metal fabric to protect both astronauts and spacecraft from micrometeors. As 3DPrint.com reports, the chainmail-like textile, which is printed in one piece, reflects sunlight, provides thermal insulation, is foldable, and has high tensile strength.

Facial reconstructive surgery has benefitted from 3D metal printing. According to Additive Manufacturing, 3D printed titanium can be customized to the individual patient and aid in bone regrowth and stability. 3D Printing Industry reports that British manufacturing company Renishaw partnered with Western University to create a $5 million Additive Design in Surgical Solutions (ADEISS) center in Ontario, Canada, to produce metal additive manufactured medical tools and implants.

[Credit: NASA]

The Vader Systems MK1 Experimental desktop metal 3D printer, meanwhile, uses their MagnetoJet technology to propel liquified aluminum from an electromagnetic-field-encased 1,200° C chamber through inkjet-like print nozzles. Using wire feedstock instead of powders, it reduces costs and dramatically speeds up printing. The production model launches in 2018.

Shapeways’ interlocking precious metals are perfect for creating unique jewelry. Lead times for 3D printed steel were reduced by two days so you can create functional parts quickly. With the benefits of strength, durability, beautiful finishes, and a myriad of material choices, isn’t it time you took a dip into the white-hot 3D printed metal space?

try it yourself

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