Skip navigation
2016

cloudddm-factory-rnd-100662153-large.idge.jpg
3D Printing will be available at various UPS Store locations (Photo via Fast Radius & UPS)

 

Ever wanted something 3D printed but don't have the money to shell out for a GOOD in home machine? Or maybe there are no 3D printing services close by (like a hackerspace or some person with a printer)? With this technology on the rise, it's in-demand and UPS is here to answer the call. The delivery company recently announced plans to launch a full-scale on-demand 3D printing manufacturing network. The service will be made available in more than 60 UPS Store locations around the U.S. Starting this year and rolling into 2017.

 

For this new service, UPS teamed up with the On Demand Production Platform and 3D printing factory from Fast Radius, which is a provider of on-demand part manufacturing. In addition to this, the company will also collaborate with SAP for an end-to-end industrial offering that mixes SAP's supply chain offerings with UPS' on-demand manufacturing solution and global logistics network to make the process simpler. SAP and UPS teaming up also allows for manufacturing companies of different sizes to access on-demand features easily.

 

“UPS is a leader in bringing industrial-strength 3D printing to reality. By building this disruptive technology into our supply chain models, we also bring new value to our manufacturing customers of all sizes,” said Stan Deans, president, UPS Global Distribution & Logistics. “Additive manufacturing technology is still developing rapidly so ‘manufacturing as a service’ is a smart approach for many companies.”

 

So how does it work? Users visit the Fast Radius website to put in 3D printing orders, which will then be transferred to the closest 3D manufacturing or UPS Store based on the speed, geography, and product quality needed. Depending on the size of the order, some can be completed and shipped out the same day. If you're not in the U.S. There's no problem. The company said they'll take global orders as well. The new service will have big benefits for businesses looking to utilize 3D printing including, manufacturers who want to reduce inventory for slow moving parts, high quality rapid prototypes delivered quickly, and cutting down costs for manufacturers with short production runs.

 

Though many may not know it The UPS Store has been offering 3D printing services in certain locations since 2013, but not on such a wide scale. This made them the first retailer to make 3D printing service available in store. “Connecting all The UPS Store locations into a larger network provides more opportunity for new customers to access our printers and gives customers added flexibility to match their requirements with the appropriate UPS location,” said Daniel Remba, Small Business Technology Leader for The UPS Store, Inc.

 

With UPS getting in on the 3D printing game it should be no time til we see other retailers like Office Depot, FedEx, and even Kinkos offering their own services. The more accessible the technology is, the better.

 

If you don't know, I 3D printed a Spherical Raspberry Pi Case in a past project. I could have used a local option.

 

Have a story tip? Message me at:

http://twitter.com/Cabe_Atwell

This project introduces some tips to make a flexible but robust non-flat surface and some other common issues, explaining a possible solution through the making of a smartphone cover full 3D printed.

 

The object

First of all the finished object.

 

The creation shown in the making of video required four main steps and some experiments:

  1. Taking the model dimensions
  2. Designing the CAD model
  3. 3D printing the components
  4. Assembling the components

 

Calculating the model dimensions

Finding some difficulties to buy an original cover fast and at a cheap price I decided to take the measures directly on the LG G4 smartphone.

TIP #1 : When you should measure a real object to make something 3D printed consider that it is a good practice to exceed your dimensions of about 0.1mm This is just the excess that you find when - also in the case of a perfect 3D printed object - you will use some kind of support when printing. This depends on the kind of object you measure but the suggested value is always the worth to take in account. When printing holes that will host screws (e.g. Allen screws, not conical Parker) a minimal extra amount of material is present in the holes at the end of the printing process. So if the screw is 4 mm you should design the holes 4.1mm You will see that the screw will fit perfectly without problems and you save a lot of time to complete the printed object with hand tools.

When a magnet is positioned in a specific point The smartphone screen changes showing a round watch giving access to a minimal number of easy apps. Making some experiments a 3mm x 1mm Neodimium magnet is sufficient to generate the screen switch effect but should be positioned very precisely. Also in this case the exact position has been acquired manually to design a hole in the cover bottom side at the right point. The following image shows the final result with the magnet embedded in the bottom part of the cover (the side in contact with the screen).

20160522_121130.jpg

Two sides, two colors

Making a flexible and robust plastic cover in two different colours sounds nice, yes? But this choice has a reason. This is the case when we convert a limit of the 3D printer in a good aesthetic effect. The following tip can be applied to almost all the cases when this is generalised issue will occur.

TIP #2: To successfully produce a well done and robust 3D printed object a support is needed.

This extra plastic thin filament is generated by the slicer (depends on the user settings) making possible the creation of objects else impossible to 3D print. Unfortunately it is very difficult that after removing the support from the finished object things remain perfect as we can read here and there... As a matter of fact the printed side in contact with the support is very difficult to make clean and neat.

When designing an object for 3D printing and important factor to take in account is the need of a support extra filament: it is better to create the entire object in two parts or more to be joined in the final assembly than accepting the compromise of a bad refined surface.

This is the case where a better result in the printing phase is decided during the design.

The cover should follow the smartphone screen form factor: not a planar surface but a slightly curved one. The next images shows how the support printing process has been done:

20160521_143125~2.jpg 20160521_143257~2.jpg

20160521_151909~2.jpg 20160521_160502.jpg

Also after a very accurate removal of the support material this side remains with rough surface. IN our case the solution was to make a couple of 1mm thick slices - better in two different colours - printed with support one to the opposite side of the other. Assembling the two components the rough surfaces remain internal and are no longer visible. The following group of images shows the second part of the cover, printed with described method. The last image shows the dark side of the printed element after the support removal: As you can see it is rough and few refined than the opposite side.

20160522_120338.jpg 20160522_131507.jpg

20160522_135832.jpg 20160522_121140.jpg

Object design and components positioning

With the right dimensions of the parts and the cutting positions written down the 3D model has been designed using Rhino 4. The CAD choice depends most on the everyone personal experience and preferences: the best application in this case is always the one we know better. It is important to use a CAD program supporting the 3D model export in STL format ready for the slicing algorithm.

Cover V2.png Cover V2-3.png

Note the images above: the first shows the assembled object, while the second shows the components correctly positioned to be exported in STL format

TIP #3: Based on my personal experience I consider a best practice before trying to print a 3D model to setup it assembled on the CAD as it should really be. This is a useful method do debug the design being reasonably sure that the finished parts, when printed, fit as expected and we have not forgot some important detail in the model. The further step is orienting the component(s) aligned to the x-y plane at 0,0 coordinates. When the STL file has been loaded in the 3D printer application it is again possible to reorient it, rotate, mirror etc. but what happens if you forget to apply the right transformation? Better to prepare it in the CAD environment.

Setting the printing parameters

When all is ready we can finally slice the object(s) and print them. As many users know very well setting the 3D printer parameters is not always so obvious and it is almost impossible to apply the same setup to all the objects we create. Settings depends on the form, the usage, the nozzle diameter, the material and more and more. It is almost impossible to analyse all the parameters in a single article but the very important aspect is to focus what are the most influencing settings to reach the best result with a certain object. Depending on the object mechanical characteristics and shape these key settings may differ a lot.

20160522_140203.jpg 20160522_140155.jpg

The above images shows the assembled object with a correct (Is really correct? Anything is subject to further perfection) printer settings.

TIP #4: On top of our consideration any suggestion is always conditioned by the kind of filament we use; PLA has different rendering behaviour than ABS, Nylon etc.

Despite the settings strictly related to the filament quality (some colour filament have different behaviour than white or black, also of the same material) there are some general considerations that it is the worth to consider.

Printing thick surfaces we need to reach good reliability and flexibility. We should consider the thickness of the material in terms of printing layers. To get a good result with a 1mm thick object we should print a reasonable number of slices: it is a best practice adopting - when possible - a nozzle diameter 0.3mm or less for a good precision. Another good suggestion is to apply a 100% internal fill. Maybe the printing process will be slower but this gains in material consistence. For the same reason it is strongly suggested to slice 0.1 mm layers: we can count on 10 layers for the better robustness also for thick surfaces.

A last note: don't be too worried to print slow; 60-70 mm/sec with a well calibrated printer can be easily supported making a compact solid object.

For further references

https://drobott.com/item/338/Super-Lightweight-Interactive-LG-G4-Smartphone-Cove

3D Printed Super-Lightweight Interactive LG G4 Smartphone Cover

ee8ba9_0084071023484ae897d9574dd179011a-mv1.jpg
This motorcycle looks like it comes from another planet (image via APWorks)

 

3D printing can do a lot things from making clothes to making food. Now, thanks to the efforts of APWorks, it can make motorcycles. The Light Rider isn't the average hog you'll find riding down the freeway. For one, it looks like something out of the Alien franchise with its hollow, skeleton like design. It's also probably the world's lightest motorcycle weighing only 77 pounds. As mentioned, the bike was created by Airbus subsidiary APWorks and they used 3D printing to create it, but they didn't use plastic. Instead they got its odd shape by thousands of thin metal layers produced in a bed of metal powder. The entire frame is made out of Scalmalloy, which is aircraft grade aluminum. It's supposed to offer the strength of titanium, ensuring the bike is light, yet strong.

 

“APWorks used an algorithm to develop the Light Rider’s optimized structure to keep weight at a minimum while ensuring the motorcycle’s frame was strong enough to handle the weight loads and stresses of everyday driving scenarios. The result: a motorcycle that looks more like an organic exoskeleton than a machine. That was a very deliberate design goal for APWorks, which programmed the algorithm to use bionic structures and natural growth processes and patterns as the basis for developing a strong but lightweight structure.”  

 

3dbike.JPG

 

It's the 3D printing is what allows the bike to get its unique geometrical design. APWorks says the design is meant to be aerodynamic as a way to give the bike “superb stiffness and guarantees optimal use of material.” The bike is also meant to be environment friendly since it's electric. The Light Rider has a 6kW electric motor that can accelerate the bike up to 130 Nm torques. That's 37 miles per charge. The motorcycle can reach top speeds of 80 km/h (50 mph). It accelerates from 0 to 45 km/h (28mph) in three seconds. The oddball frame only weighs 13 pounds, which is roughly 30 percent less than most existing electric bikes. Can you imagine, a motorcycle you can actually pick up?

 

"With the Light Rider we at APWorks demonstrate our vision of future urban mobility", says engineer Stefanus Stahl. "We have used our know how of optimization and manufacturing, to create means of transportation, that match our expectations,” explains APWorks's Niels Grafen.

 

Believe it or not, The Light Rider is actually available for sale, but you can't find them at your local Harley Davidson dealer. Rather APWorks is slowly rolling out the new motorcycle and is planning to build 50 units with a price tag of $56,100 apiece. Those who are interested can pre-order The Light Rider on the bike's website. It's definitely one of the most unique looking motorcycles on the market, but it is a hefty price to pay for something that looks like no other bike on the road. If this goes well, maybe it won't before long until we see big motorcycle companies like Harley Davidson and Yamaha start making their own 3D printed bikes.

 

 

Have a story tip? Message me at:

http://twitter.com/Cabe_Atwell

Filter Blog

By date: By tag: