We are thrilled to be a part of this unique cycling project with Zipp Engineering. The Realize logo is displayed on this scientific, work-of-art. This kit also serves as a platform to help fund the World Bicycle Relief global initiative, please click on the link to learn more about WBR and great work they are doing to empower and mobilize the world by bicycles.
Recently we stopped in to visit our good friends over at Zipp to find out what they have been working on. I talked with Eric Hoiland (Design Engineer – Zipp) about the Super-9 Carbon Clincher Disc which is the fastest wheel ever. Realize had a small role in the design process and we are thrilled to be mentioned in any way with a product of this caliber.
Realize: Why a disc wheel as opposed to a spoked wheel?
Eric: A disc wheel is much faster from an aerodynamics stand point. The drag on this wheel versus a spoked wheel is leaps and bounds better, so if you are doing specific racing- like time trialing where drag is way more important than weight, everyone turns to a disc.
Realize: How did Realize help you with this project?
Eric: Realize delivered the prototypes of our hub shell. We recently moved from 10-speeds on the rear to 11-speeds so a couple things changed internally along with that, so I had Realize Rapid Prototype the shell and I was able to press in the bearings in the shell. I was able to get a really good dimensional check on all that stuff.
Realize: How often do you use Rapid Prototyping when working on new projects and parts?
Eric: I try to turn Rapid Prototyping as much as possible. It saves money and it’s faster. I would much rather catch a dimensional mistake on a rapid prototype as opposed to six real prototypes.
Realize: You could say that Realize may have helped to win a few races…
Eric: Realize had a direct influence this 11-speed hub that is now on the fastest disc in the world.
Realize recently created a scaled model version prototype of the Transamerica Pyramid.
We worked with designer, Adam Voorhees, who builds architectural models. He needed a prototype of the skyscraper at a scaled height of 53 inches to go into a museum exhibit. There was time spent upfront with Adam talking over the project with Brian Cazzell from Realize about file issues and other build options.
Once it was only a drawing, now it’s here. Realize President Todd Reese likes what he sees!
Adam was knowledgeable about our processes and what it was going to take to be able to build this. We were only concerned about the external parts of the building. It was a good clean file from the beginning and then we cut it into three sections and inserted a dowel pin system. We used Acura 60 and one of our SLA 5000 machines to create the parts.
The entire process took about 4 days- the build time for this project was approximately 84 hours.
We talked with the client to find out more about his experience and how this prototype will be used:
“The parts have been received, they look great. Everything with Realize went well – cost was on target, build time was quick, packaging was excellent, and Brian was extremely helpful. This model is going to be used for an exhibit on the architect, William Pereira” – ADAM VOORHEES
It all starts with this…
Three parts will become one- we are ready to send to the machine
From the ashes…we have our parts.
What is your role at Realize?
I create RTV (Room temperature vulcanization) molds from SLA masters. Make sure its delivered the way it was ordered by the client after coming out of SLA machines.
What challenges do you face during a typical week at Realize?
Deadlines are a big thing- making them. The complexity of the part- and how difficult the process can be getting it correct.
How does Realize do things differently than the competition?
We have a fast turn around and the quality of work is unmatched in my opinion. Talent level is excellent. They are always seeking experience and that sets Realize apart- my experience in this industry is over 20 years.
What are some of your favorite things in the world?
Model HO Trains, World War II history and airplanes. My Father was in the war and I was just always fascinated. Graphic design is a hobby on the side and I enjoy bowling, volleyball, and tennis.
Favorite meal?
Filet Mignon with mashed potatoes and gravy from Ruth Chris. To drink would be glass wine white and dessert entire lemon meringue pie.
What music are you listening to right now?
I’m into show tunes, movie trailer music, and my favorite bands are Chicago & Boston.
What fascinates you most about Rapid Prototyping and 3D printing?
The fast turn around the complexity that is generated. What used to take week or months can be done in hours now…in the future incorporating soft and hard materials will become a new direction, and we will be doing new and different types of projects.
You can take two movies with you to space…which do you bring?
Saving Private Ryan and Star Wars.
One word that describes you?
Unique.
One personal item you would like to Rapid Prototype?
Space 1999 Eagle One – It’s a spaceship from mid 1970s TV show.
Multi-Jet vs. Stereolithography
There are many different methods used in the additive manufacturing industry to deliver prototypes. I talked with Realize President Todd Reese about the methods currently being used in our facility. We have a new machine named Candice and she’s really into detailed parts.
3d printer at Realize – Candice
3D Systems Viper si2 SLA System
Multi-Jet Modeling is an additive manufacturing technology commonly referred to as 3D Printing. Unlike SLA, which uses a UV laser to draw/harden each layer onto the surface of a vat of liquid resin, our ProJet 3500HDMax employs a UV lamp to flash cure each layer of material that has been jetted on demand from a print head. Using MJM technology, there’s no laser beam diameter to compensate and the process does not suffer from an SLA phenomenon we call print-through. This enables our MJM to produce models with exceptional detail and crispness(see image below). The MJM process is also capable of build layers nearly eight times finer than SLA. Our SLAs are calibrated to run at 0.004″ and 0.002″, but our MJM can run at ~0.001″ and ~0.0005″. Unfortunately, MJM materials are not as robust as SLA materials at this time, but I would expect strides to be made in this arena in years to come. Both technologies have a place for serving a variety of applications.
– Todd Reese President Realize, Inc.
3D Printing/Rapid Prototyping & Manufacturing