All posts tagged: rapid prototyping

The Realize Q&A with Tim Caffrey




The Realize Q&A with…Tim Caffrey, Associate Consultant, Wohlers Associates, Inc.

Tim Caffrey earned a bachelor’s degree in mechanical engineering at the University of New Mexico. Caffrey was employed by The Boeing Company for 10 years, including four years directing the operation of the company’s in-house additive-manufacturing (AM) services. Caffrey served as plant manager of Plynetics Express—which was, at the time, the world’s largest AM service provider. His 18 years of writing experience includes aircraft engine maintenance and pre-fight test procedures for Boeing, engine case repair procedures for Pratt & Whitney, technical content for the web, and advertising copywriting at Walmart’s corporate headquarters.

Caffrey has worked closely with Wohlers Associates since 2000 on this annual industry study and many other projects. Caffrey’s role at the company expanded in 2011 and has since been working on a wide range of consulting projects. He also speaks and represents Wohlers Associates at national and international events.

Realize is scanning the globe for Additive Manufacturing industry experts to share their views about where we are today and where the future will take us.

 

Where do you see the industry going in the next 5 years?

 

The industry will continue to grow in two distinctly different directions. On one end of the spectrum, we’ll see the low-cost personal 3D printers improve in performance, offer additional materials, and drop in price. We (Wohlers Associates) don’t think every home will own a 3D printer though; the more likely scenario is web-based service providers and 3D print shops analogous to today’s 2D print shops like Staples, Office Depot, and FedEx Office. On the other end of the spectrum, we’ll see industrial systems designed for specific applications, specific industries, or even specific individual parts. Speed, max part size, and the selection of materials will all increase. We’ll see hybrid systems that perform more than one operation, both additive and subtractive.

 

There has been a ‘new generation’ of users exposed to AM/RP/3DP over the past few years, along with a huge media buzz.  How do you see this camp and the ‘old school’ camp coming together?

 

Initially, these two camps were indeed cut off from one another. One user went to RAPID and to user group meetings. The other user went to maker faires and community hacker meetings. Now we’re seeing overlap at new types of shows, like the “Inside 3D Printing” series. Also, we’ll begin to see new 3D printers that can be used by both camps in the $3,000 to $8,000 price range. These will be purchased by the “old school” companies and by the makers, and that’ll have a unifying effect.
Still, one could argue that these two camps should be separate. They share one thing: layered additive manufacturing. But a $1,000 open-source material extrusion system has absolutely nothing else in common with an electron beam, metal powder bed fusion system in a production environment making orthopedic implants, for example. These two users have vastly different requirements and needs from their respective user communities.

 

What challenges/opportunities do you feel service providers, like Realize, face today?

 

In some ways, nothing has changed. SPs need to find and keep customers. How? Delivering a service that is valuable to the customer, delivering something the customer can’t (or doesn’t want to) do themselves.
There’s an educational aspect. Explaining the differences in quality, materials, repeatability, etc. Also, offering A to Z service, from CAD to urethane castings and high-quality finishing. Even a knowledgeable OEM that owns a machine or two probably does not have all these capabilities in its arsenal.

 

What are some misconceptions about the capabilities of the technologies?

 

1-That it’s a pushbutton technology. As you know, there’s a lot of work, craft, art, and science required pre- and post-build.
2-That everyone will someday own and operate a 3D printer.
3-That you can make an airplane engine fuel nozzle in a $795 printer.
4-That the industry just appeared overnight.
5-That printing guns is a safety and security issue. Really, it’s just another extreme endorsement of 2nd amendment rights.
6-That 3D printing is a less-expensive form of manufacturing. It’s can be, but not necessarily.
7. That 3D printing is more energy efficient than conventional manufacturing. It can be, but not necessarily. Most analysis to date suggests just the opposite.

 

How do you think 3D printing can change the way we live in the future?

 

I like to think we’ll develop into smarter consumers and product designers, and reverse the “Walmart-ification” of retail, which I define as the selling and buying of millions of cheap junk items that break too soon. We’ll see products that are well designed and manufactured, they might be personalized, they may cost more, but they will last longer and function in a better way.
As I said, we don’t think there will be a 3D printer in every home next to the HP inkjet printer. Even people that design or co-design online will still go the the 3D print shop around the corner or click the “Print” button on the online part portal.

 

How would you describe AM/RP/3DP to someone who has never been exposed to it?

 

The software slices a computer file of a 3D geometry into very thin layers. The AM machine builds the 3D part by successively stacking these thin layers. Each new layer bonds to the layer before it. There are seven different ways these layers are created, from glueing sheets of paper together to using a laser to melt metal powder. The machines run unattended, but a significant amount of labor is needed for preparing the file and the machine and for cleaning and finishing the parts after the build is complete.

 

mereedThe Realize Q&A with Tim Caffrey
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Realize assists with the fastest disc in the world!

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.

mereedRealize assists with the fastest disc in the world!
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Realize is leaping tall buildings

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.

mereedRealize is leaping tall buildings
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Realize Employee Profile: David Strait

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.

mereedRealize Employee Profile: David Strait
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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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