All posts tagged: consrutction

Multi-Jet vs. Stereolithography

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.

mereedMulti-Jet vs. Stereolithography
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Realize Employee Profile- Jennifer Voyak

What is your role at Realize?

Office Manager is the title but I prefer office guru. A Lot of accounting work, quoting, answering phones and run errands. I do pretty much anything that’s asked of me. I reek havoc on this place.

Name some of your favorite things in the world.

My daughter Reagan who is 9 years old…working out…I do a lot of cardio and love to run outside, 5-6  days a week. My husband is pretty cool…16 years of bliss this year in October…spending time with the fam is my fav.

How does Realize do things differently than the competition?

Staying up to date on technology and what is going on in the RP and 3Dprinting world. There is a focus on keeping things running like a fined tuned machine.

Favorite meal?

Vegetable fried rice from Mark Pi’s, Diet Mountain Dew and an egg-roll. For dessert tuxedo cheesecake from The Cheesecake Factory..and a Miller Lite beer.

What music are you listening to right now?

It depends on my mood…this morning it was 80’s hair bands…GNR, Motley Crue. My fav all time are the Crue, Jason Aldean, and Bon Jovi in leather in pants.

You can take two movies with you to space…which do you bring?

Sixteen Candles and Rock of Ages with Tom Cruise..

One word that describes you?

Outgoing.

What impresses yo most about the Rapid Prototype Industry?

The fact that it even exists its amazing! What it can do..is just incredible to me.

How do you explain to friends what Realize does?

I say that I work for a company that builds prototypes….and the say, “what is that?” My answer is something like, “we get files and then create something in a machine.”

What is the most challenging part of your job?

Right now quoting is the biggest challenge…the process is smooth but making sure its solid and correct is the toughest part.

One personal thing you would like to Rapid Prototype?

Our black lab that passed away a few years ago Bocephus.

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mereedRealize Employee Profile- Jennifer Voyak
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Realize Employee Profile – Tami Tomey

What do you do at Realize?

I work in accounting. Accounts receivable and payable, I also track how are customers come to us.

What challenges do you face during a typical week at Realize?

Managing changes that come up. Gathering all the details that go along with client invoices.

How does Realize do things differently than the competition?

I think they are really connected to their employees and clients in a unique way, more than most companies. They are just in tune with what is going on at all times with projects.

What are some of your favorite things in the world?

My children. I have three kids…12 ,10 & 7. I’m a single mom so most of my free time is spent with them. But I do love the beach and gardening. Some of the items I grow include watermelon, corn, cucumbers and strawberries.

Favorite meal?

Filet from Ruth Chris, broccoli, glass of white wine …strawberry cheesecake.

You can leave work right now and do anything you want, where are you going?

Bora Bora with a friend…scuba…relax…layout…explore the island.

What music are you listening to right now?

I listen to everything…something country most of the time…Prince was a favorite growing up.

What fascinates you most about Rapid Prototyping?

I can’t believe how you just plug information into a machine and out comes the product!

You can take two movies with you to space…which do you bring?

Tombstone and Dumb and Dumber.

One word that describes you?

Sassy.

One personal item you would like to Rapid Prototype?

A black Lamborghini.

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mereedRealize Employee Profile – Tami Tomey
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Realize Client Profile – Zipp

There are many exciting things going on at Realize. The focus of our business is advancing the excellence of our clients projects. Zipp Speed Weaponry, based in Indianapolis, serves a select group of elite companies and athletes, globally located and committed to bicycle & wheelchair competition. Zipp meets customer’s needs for the highest performance, superlative quality components through innovative design and manufacturing utilizing the best material and technology available. Basically, really cool bike stuff! Check out this video about how we work together.

We talked with Design Engineer Ben Waite about the latest happenings at Zipp.

Ben Waite – Design Engineer

1- Tell me about your business?
Zipp is a manufacturer of the highest end bicycle components for road riding and triathlon.  Our parent company, SRAM, manufacturers a wide variety of bicycle components for all types of riding.  We have 2500 employees worldwide and our mission to enhance the rider’s experience through comfort, speed and reliability.

 

2- How is Rapid Prototyping used by your company?

We use rapid prototyping for a variety of reasons.  We use them to perform form and fit testing that we cannot do in the 3D CAD space.  Rapid prototyping is obviously quicker than getting parts CNC’ed, but it is also exponentially cheaper.  We can iterate a design a few times and get a rapid prototype each time for a fraction of the cost of machined parts.  This expedites time to market and allows us to be fully confident of our designs when we invest in very expensive molds. For some products, namely handlebars, rapid prototyping allows us to test out ergonomics that are nearly impossible to understand in CAD.  Comfort and bike fit is a key part of the rider’s experience and we want to make sure that they are getting the most from their invest in Zipp products.

Seatpost prototypes

3- What services and projects did you partner with Realize on?

I think the better question is what projects do we *not* partner with Realize on.  I believe every handlebar project I have worked on has made use of rapid prototypes in some manner.  In fact, there are many projects that did not come to fruition that we used rapid prototypes on. For wheels, we also use Realize to make rapid prototypes that we can take to the wind tunnel and test the aerodynamics of a particular design.

 

Zipp Wheel

4- How was the experience working with Realize? Realize is top-notch.  Their delivery is lightning fast, the quality is amazing and it is quite obvious they value their customers.  And they are just good guys (and gals!) that you would like to hang out with on the weekends.

 

5- Where is your business headed in the future?

We will continue to use Realize in many capacities to further our product development.  I hope that one day we can work with Realize to make functional rapid prototypes that are strong enough to ride and test.

6- If you could select one personal item to be created or duplicated using Rapid Prototyping technology, what would that be?

Easy question – I would rapid prototype an updated design to one of the fastest bikes ever produced – the Zipp 3001.  Zipp started making this bike decades ago but it still beats many of today’s “super bikes” in the wind tunnel.  With a couple of tweaks, the wind wouldn’t even be able to come close to seeing it!

Zipp 3001

mereedRealize Client Profile – Zipp
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Let me give you a hand with that prototype

Realize, Inc. Robotic Hand Project

 

Custom Entertainment Solutions needed a hand with a recent project. The Realize team was excited to be their partner in this venture. Brian Cazzell is the Client Success Manager at Realize in charge of their account. We asked him what made this particular prototype concept so cool.

“The cool factor for me is that these rapid prototype parts are durable enough to use in a working robotic hand.  I think the biggest challenge of the project was making sure all of those channels were clear throughout the entire palm where they needed to route their wiring to the fingers.  I took it as a personal challenge when this client first contacted us because he said he was turned down by at least 3 other Rapid Prototyping shops that didn’t want to touch this project! He was told it was not possible to manufacture those parts…and we made it happen. He was so excited when he received the parts because he knew that he finally found a viable way to produce his extremely complicated model.”

Josh Gray at Custom Entertainment Solutions was pleased with our work.

“Realize came through for us with a new robot hand design that other companies said they could not build. With Brian Cazzell’s help inside Realize, not only did they say they could do it, they DID it, and Brian made sure all of the small features and channels were hand-cleared and ready for us to run tendons through. Very complex work and they nailed it!”  Josh Gray, President, CES.

Here is look at the finished product!

http://youtu.be/KWy3zEfWjfA

http://www.youtube.com/watch?v=UG4arMMdvrw&feature=youtu.be

 

mereedLet me give you a hand with that prototype
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