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BFB RapMan is Manufacturing Parts

Commissioned to find and write a compelling case study on the BFB RapMan, I knew it would not be a hard brief, in that uptake is pretty rapid at the moment. However, what I was not expecting, was to come across a user that is employing the kit form of the RapMan machine to manufacture end-use components! I was staggered, I have to say. This is immense. An additive technology, under £1,000, is producing plastic components for a finished product. Granted, the volumes are not huge — yet. But, the potential is there.

I am currently waiting for approval to get this story out there into the public domain, but just as soon as I do, I will be posting it here, as well as sending it as far and wide as possible.

I love it when this happens ....

..... when the light suddenly goes on for someone! 

Edward Machin from 'The Manufacturer' recently visited GKN and EADS on the same day. He blogged soon after. What he saw at EADS seems to have blown his mind. The following is just a snippet of what he wrote, but the full post can be viewed here: http://www.themanufacturer.com/uk/content/10276/We_are_the_dreamers_of_dreams

"Additive layer manufacturing (ALM) effectively ‘grows’ components layer by layer from a powdered material, be it plastics or metal....

Very simply, this stuff shifts the shifts that paradigms shift. Yes, these terms get tossed about like cheap orange frisbees at the first sign of a British summer, but genuinely, people, and to co-opt Lincoln Steffens, “I’ve seen the future, and it works.” Moreover, with its genesis in Rapid Prototyping’s underlying technology ALM appears to have found a soulmate in the direct manufacture of net-shape and high performance aerospace components.

The ALM project at Innovation Works, EADS’ research and technology production facility, is headed up by Dan Johns. A charmingly infectious chatterbox, he wastes little time in introducing me to a selection of structurally superior, ultra-efficient (with a percentage of raw materials reniserted into the stock in powder form) and aesthetically beautiful structures — in a way that carbon fiber-reinforced polymer seldom is. Did I mention drastically reduced lead times, to boot?

His team of technological merry pranksters, with breakdancing ecological evangelists and ex-national table tennis champions among their number, are perhaps more remarkable still. Now, I’ve never been one for sentimental blubbering, but the guys and dolls at Innovation Works truly live and breathe this stuff, and it shows. Heck, I’ll just say it; tis a beautiful thang." 

Following on from the recent article in the Telegraph covering EADS Innovation Works, I also happen to know that the BBC are interested in what is going on at EADS too. In terms of proving the reality and not just the hype — EADS really is leading the way and taking it much wider than it has EVER been before. 

The Transition Period

As a long term advocate of additive technologies I have been through the peaks and troughs associated with an emerging sector. However, I have never before been witness to the growing momentum behind these technologies that exists today.

It is not possible to point to one single factor, which is probably why there is strength behind the momentum as opposed to 'hype'. Rather, it is now possible to identify a cumulative range of events and circumstances that are contributing to this escalating energy behind both 3D printing and additive manufacturing.

As the world tentatively heads out of recession, albeit teetering on the brink with economic commentators uncertain about which way the cards will fall as of yet, the vendors of additive technology platforms have fared pretty well. Some better than others, as would be expected, but what it very telling is that none have gone into administration. All of them have managed to keep their heads above water. Stratasys recently released its end of year results for 2009, and the general pattern is probably similar across the board, in that unit sales were down on the previous year, but still healthy enough. Cost cutting and belt tightening helped to buoy up the figures some, and overall the rhetoric was positive. An industry that can demonstrate positive results after a devastating year — economically speaking — only points to further significant growth at a faster rate as global circumstances improve.

Awareness is another significant factor in this building momentum. It's been a slow process (akin to wading through treacle at times) but it is now spreading at an exciting rate. There is much more talk, debate and understanding of the additive manufacturing concept. From a personal perspective, I am finding that I rarely have to explain the concept itself anymore, as most people that I speak to have heard about it and grasp the basic idea. Rather it is a case of explaining the different processes and the range of capabilities. This is progress!

A further significant pointer that I became aware of yesterday is that a large retail outlet that has picked up on the technology. PC World posted an article on its website: http://www.pcworld.com/article/189880/affordable_3d_printers.html. It refers directly to HP's interest in 3D printers and I imagine this is what brought it to the company's attention. Also, the article talks about 3DP and AM as a technology of the future, but it is talking, and more to the point, it is taking the message wider. Just think of the number of people that would never come across a manufacturing or technology website but will visit the PC World website. There could be many more 'Eureka' moments as a result!

Many of the blogs relating to 3DP and AM are also becoming much, much more prolific with their posts. A great many of them distinguish between the industrial strength processes (Stratasys, 3D Systems, Objet, ZCorp et al) and the 'hobbyist' platforms (RepRap, Fab@Home, Makerbot and BfB RapMan etc). The hobbyist platforms being those 3D printers that come in kit form. I am not sure if the 'hobbyist' label works for me, I don't think it conveys the full potential of these machines, but I get the point and the differentiation.

As of today, I think the sector is mid transition — somewhere between niche and mainstream — and moving faster than it ever has before!

No Single Product Development Tool is King

For years (and years and years) I have tried to promote the message that no one tool within the product designer’s toolbox is more vital than another. The key to successful product development is to combine a number of advanced tools to achieve a propitious result.

My particular area of interest and knowledge is additive technology — for prototyping and for manufacturing — but within the discipline of product development this is only one component tool that can help to improve the overall process.

Off the top of my head, 3D design software, 3D scanning hardware and software, simulation software and 5+ axis machines are all advanced tools that are competitively available on the market to designers and engineers looking to enhance their product development procedures.

Within each ‘tool’ category there are a host of choices — product capabilities, costs and vendor selection are important issues, as is whether to invest in house or contract out — but the point I am making here is finding the right blend of technologies rather than picking up on one of them and believing that it will solve all problems!

As an example, there have been rumours rumbling around that some of the problems besieging Toyota in recent months are because the car giant has depended too heavily on simulation methods for testing. If this allegation is proven, this makes my point extremely well. Simulation is a brilliant tool; the developments in computing power and software interface make it a fast and accessible way of testing products under any conditions. That said, it cannot and should not fully replace physical testing with a physical model. Simulation can reduce the number of physical tests by arriving at an optimum solution faster and more economically than the traditional cycle of ‘make and break’; but it cannot be used in isolation.

Understanding how to integrate advanced technology tools for product development provides the most solid foundation on which to build an overall process that is most likely to bring success.

Attractive Matrix Applications

It was only a matter of time before the applications started filtering through for the Matrix 300 3D printer. I saw this machine when it was introduced over a year ago and it was launched commercially at the end of last year, at the TCT show. I had heard on the grapevine that there had been some sales of the machine and I am not surprised that things are going well.

The Matrix, from Irish company Mcor Technologies, is a 3D printer based on LOM (Laminated Object Manufacturing) technology. At the time of its introduction, this did raise some eye brows, because the original LOM process from Helisys died a death around the middle of the nineties and seemed to be forgotten. However, the Matrix differs from all of its competitors in a couple of interesting ways.

First and foremost, the printer itself requires a similar capital outlay to mid-range 3D printers (around 25,000 euros), but unlike every other machine out there the consumables are cheap and easy to access. The machine uses A4 paper (80 gsm). Which leads onto the other very attractive characteristic of the printer — it is extremely eco-friendly. Surface finish of the Matrix models are proving to be very competitive too.

Janne Kyttanen, Founder & Creative Director of Freedom of Creation has been producing some stunning models using the Matrix, his comment being; “Most refreshing stuff I have seen for a long time." 'Stuff' referring to the 3D process, not his own models.

The picture of his iphone cover above is a clear demonstration that there will be much more to come. I have long been a fan of the sculptures and products that the FoC guys produce, but it's always been out of my price range. It will be interesting to see if the retail prices of the FoC Matrix models are modified in line with their material costs!!!?

When Wohlers met Cameron

James Cameron that is, not David!

Terry Wohlers recently witnessed James Cameron being interviewed at the recent SolidWorld event, talking knowledgeably about 3D software and 3D printing in particular. The interview was followed up by a 1-to-1 conversation.

The full post can be found here: http://wohlersassociates.com/blog/2010/02/james-cameron-uses-3d-printing/

The gist being the positive effect on the 3DP industry when people so much in the public eye know about AND talk about the applicability of these technologies.

What was also very interesting was how Mr Cameron is renowned for "getting his hands dirty" in order to make stuff, both early on in his career as a machinist and even now, as (one of?) the world's greatest film directors.

This may sound strange coming from someone that has only worked with words her whole life, and watches in amazement from the sidelines as the real (and often dirty) work is carried out by the true pioneers of 3DP, but this is key! The desire to make things and to practice and learn. Innovation is born of an inherent creativity together with hands-on practical knowledge. It's not exactly a fast process, but one that fosters enthusiasm, passion and determination over a life-time.

I was talking to Dan Johns of Airbus recently (who, incidentally, was the ALM evangelist behind the Telegraph article I posted about last week) and this was central to his thinking too. I am sure he will not mind me saying that he does not profess to be especially academic, but as a child he spent hours and hours in his Grandad's shed, playing with a host of different tools and making things — all sorts of things. From this his passion for engineering and manufacturing was born. His imagination was totally captured by the emergence of rapid prototyping in the early 1990's and the potential that he saw then prompted him to take the time to fully embrace the capabilities and the limitations of the processes. His understanding through practical, hands-on experimentation, has driven these technologies to unprecedented depths within one of the largest Aerospace companies in the world. He freely admits there is still much work to be done, but his fascination and zeal for all things additive is only increasing as time passes.

Drive, passion and dirty hands — the roots of success. Without them, the rest of it cannot grow.