What is that strange glow? No, this is not something out of a Sci-Fi movie, it’s just one of our machines doing it’s part to help create the best prototypes in the world. This is what it looks like when we are curing our platforms to get ready for the next build. We are using our old school post curing apparatus to the get the desired results.
One of the more interesting and exciting projects we have been working on at Realize involves customizing and creating parts for automobiles using additive manufacturing. We talked with the Senior Designer on the project about the creation of these 3D prototypes.
How did you use Realize and 3D Printing to help with your project?
Originally our Product Design and Development teams were looking for ways to replicate automotive sheet metal and trim based on 3D Math CAD data. We wanted something we could mount our actual parts to that would show how our parts were intended to perform on the vehicle if it was built to spec. Eventually our company decided to starting using 3D Prints to replicate changes to sheet metal and trim to show customers how a certain sealing environment changes would be helpful to our methodology. This would help our customers understand why we needed to make environment changes. Then we turned to using 3D Prints to make check fixtures for our sealing environments. During prototype phases, getting actual sheet metal to mount our parts to in the environment it was intended by CAD can be difficult. Also, a vehicle would have to be located for a meeting. Being able to replicate a portions of the body side, door and trim panels and include door swing gave us the ability to bring our sealing environments straight to the customer in an office setting for discussion. I cannot stress enough the complexity of some of the fixtures and jigs we have designed.
How do you think you will use additive manufacturing in the future and are there any new directions or capabilities you would like to see in the industry?
Our Teams are always looking into how we can take additive manufacturing to the next level. We strive on continuos improvement and are always fine tuning our fixture and jig designs in CAD to get the most testing possibilities we can out of them. In the beginning we had single parts printed to mount to. Now we are making multiple piece fixtures and jigs that you can simulate glass movement, door closing and a variety of environment possibilities with shims and hardware.
What were the biggest challenges with creating the parts we did for you?
Learning the properties of the various materials. Our customers have always demanded fast turn around times and we cannot always wait for our preferred materials for printing. In some cases we have had to choose something different than our normal selection so we can have the parts in our hands by a certain date for a customer meeting. Some times it works out for us and others it does not. We try not to stray away from what we know will work, however, some times we are forced to due to timing requirements.
What is something that you personally would like to have 3D Printed?
If I still had the files it would be the CAD parts I made back when I first started learning in CAD design 17 years ago. The only way to really understand what a software is capable of is to log hours on it and explore beyond what you are taught. So I used to stay after classes and design my own ideas and concepts and also on my lunch hours. This was back when SDRC I-Deas was popular and everything was still on Unix. It was also a few jobs ago. I saved a lot of those files on a hard disc many moons ago but couldn’t tell you what happened to it.
Every month at Realize we look for a featured item to create using 3D printing and for June we have selected Tyrannosaurus rex. Commonly referred to as T. rex, it’s one of the largest meat-eating dinosaurs that ever lived. We selected this in honor of the new Jurassic World film that was just released.
The new dinosaur park movie just crushed all expectations, Universal’s Jurassic World soared to a record $204.6 million debut in North America and $511.8 million globally. Globally, the movie posted the largest weekend bow in history, eclipsing Harry Potter and the Deathly Hallows — Part 2 ($483.2 million) and becoming the first film to ever cross $500 million in one weekend.*
Realize, Inc. 3D Printed item of the month for June: T. rex
Here is our 3D Printed T. rex! We used Accura 25 resin and it was created in our iPro machine. Don’t forget, there was a scene is Jurassic Park 3 that referenced a “Rapid Prototyper!” It was a pretty big deal when 3D printing/rapid prototyping was mentioned in Jurassic Park III back in 2001. In the film, a group of paleontologists re-create a velociraptor’s resonating chamber using a 3D printer.
The 3D Printed T. rex in honor of Jurassic World release. Realize, Inc.
(*Source: The Hollywood Reporter)
We are building something new each month using 3D Printing technology and for March we decided to create the World’s First (that we know of) 3D Printed College Hoops Tournament Bracket. We hope you enjoy all that March Madness has to offer and we will update the 3D Bracket all the way through until a champion is crowned in Indianapolis.
The Realize, Inc. College Hoops 3D Printed Bracket: The Final Four
The Realize, Inc. 3D Printed College Hoops Tournament Bracket.
The Realize, Inc. 3D Printed College Hoops Bracket – Sweet 16
Hydraulic Housing, A60 Resin and cast 316 stainless, side by side.
Realize CLient Profile: ICS/Girard
We help ICS and Girard Equipment by providing them with QuickCast patterns created from one of our SLA machines. This type of work is unique from a standard SLA job because in the end, the pattern will be used to make a metal part. These individual SLA patterns are used by foundries as part of a process called investment casting which will produce one metal part for every SLA pattern used. More specifically, the work we do for Girard helps them create short run metal prototypes for the tanker trailer industry and when they reach out to us we are able to supply them with fast turnaround, high- quality QuickCast patterns. We asked ICS Foundry Manager Bill Laiacono a few questions about the industry and how they use additive manufacturing for their business.
Tell us about your business.
ICS is a captive foundry, supplying stainless steel investment castings to Girard Equipment, Inc., manufacturer of vents and valves for the bulk liquid transport industry.
How do you use 3D Printing/Additive Manufacturing/QuickCast to help with your projects?
Mainly prototyping. With the help of Realize, Inc., we can take a part from idea to cast and machined stainless steel in less than a week.
What is your overall feedback about our services and are there any examples of how Realize has helped your business?
Every interaction with Realize, Inc. has been a positive one. Realize has always been responsive, quick to produce and very reasonably priced. Customer service is pleasant and accommodating too.
How can Realize can help your business in the future?
By simply providing the same quality, value and responsiveness we have come to expect from Realize.
Why do you think there is such a growing buzz about the 3D Printing/Additive Manufacturing industry?
The diversity and range of 3D printing has grown immensely. Because of 3D printing, items can now be realized in a matter of hours that used to take weeks. The results are almost instant.
What is something that you personally would like to have 3D Printed?
A custom wall mounted bottle opener. I appreciate the simple function of a unique bottle opener.
3D Printing/Rapid Prototyping & Manufacturing