Category Archive for "3D Printing/Rapid Prototyping"

Manufacturing Technology: 3D Printing vs CNC

3D printing has undoubtedly become a tool-of-choice for makers and educators alike. The rapid growth in 3D printing technology and its popularity has manufacturers worried that at-home 3D printers may one day soon replace traditional manufacturing. From our experience though, a maker or entrepreneur is going to benefit the most from a convergence of these two manufacturing methods.

Below we will discuss the benefits and pitfalls of both 3D printing and CNC milling.

Methodology

CNC milling machines “take a block of solid material (e.g. aluminum or wood) and use sharp rotating tools or cutters to remove all parts that are not needed. Milling is a subtractive method. CNC mills are computer-controlled. The computer feeds the machine-specific code that controls the cutting tools (just like the G-code used by 3D printers). The models for CNC mills are created using 3D modeling software, so-called CAM (computer-aided manufacturing) software applications.” (All3DP.com)

3D Printing starts from scratch and builds a three-dimensional product layer by layer. This technology is referred to as additive manufacturing. Just like with CNC milling machines, a computer feeds the machine specific code that controls the design process.

Material Selection

CNC mills can work on a “huge variety of materials: metal alloys (e.g. aluminum, steel alloys, brass, copper), softwoods and hardwoods, thermoplastics, acrylic, modeling foams, machining wax (for creating a positive model for casting). You may need different cutting tools for different materials, but the tool-to-machine interfaces are usually standardized—so the tools can easily be exchanged.” (All3DP.com)

At-home desktop 3D printers are usually restricted to a few materials, typically thermoplastics or resins. Thermoplastics can be mixed with other materials such as ceramics, wood, metal, but the workpieces produced on a 3D printer will not be as robust as workpieces cut from a block of metal or wood. Commercial or specialty 3D printers can print with more exotic materials (i.e. bioprinting and food).

Range of Applications

With the range of applications for these two technologies, there is a lot of overlap. (Here we will focus on the applications either technology supports, while the other does not.)

CNC milling is the better solution when you need to manufacture extremely robust, precise and/or heat-resistant products. 3D printing is the better solution when you need quick prototypes to test designs, small batch runs or are interested in exotic application fields—bioprinting, architectural purposes and printing food.

Material Waste

By design, there is less waste with 3D printing. The technology only requires the material needed for building the product. With CNC milling, you need a block of material that is the size of the product it will produce—a great deal of material is then removed, and often times the excess material cannot be recycled.

Both technologies have their place in the manufacturing landscape. Where one technology falters, the other excels. When designing your product, keep in mind that using both technologies during product development might be just what you need.

Have questions about the manufacturing process? Send us your questions, info@3d-innovations.com,we are happy to help.

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Designing & Prototyping with 3D Printing

3D Printing Services | Rapid Prototyping Services | 3D-innovationsIt’s no secret that additive manufacturing (also known as 3D printing) is shifting the manufacturing landscape and transforming supply chains. 3D printing is redefining how companies design, develop and manufacture products. Product designers are experiencing what it means to design without traditional limitations of design for assembly, allowing them to radically reinvent products based on performance rather than manufacturability. Below are four reasons as to why you should be integrating 3D printing into your product development lifecycle if you aren’t already.

Timelines & Budgets.

These are the biggest challenges to any product development team. Producing prototypes and delivering accurate designs to clients has never been easier than it is today with 3D printing. With a 3D printer, CAD models can become real life touchable designs in a matter of hours.

Multiple Design Iterations & Prototyping.

In product development it often takes many iterations of a product before a design is settled on. People have different ideas on how the product should look and function. While a 3D CAD model makes it easier to share design thoughts, nothing compares to holding a physical product in your hand to help communicate an idea.

Once a design has been finalized, a functional prototype is needed to help with other aspects of the business (securing funding, marketing, presentations etc.). In today’s competitive startup market, a functional prototype is no longer optional, and investors (whether VCs or through crowdfunding) want to see how your product actually works and that you have come up with something that is indeed manufacturable.

Manufacturing Flexibility.

3D printing helps reduces the capital involved in achieving economies of scale, thus lowering any barriers to entry for production. This is a major benefit for hardware startups that previously had to find funding before even approaching the idea of manufacturing their product. With 3D printing, startups can now manufacture small batches at an affordable rate and customize products based on customer demands.

Market Testing.

Gauging customer support early in the product development lifecycle is vital for success. You want to get a functional prototype in the hands of your test market as soon as possible so that you can incorporate their feedback into the design. They will be able to share insight regarding product material, product fit, weight, visual appearance and usability. Having access to a 3D printer will let you update designs quickly and communicate design changes.

While 3D printing is making quite an impact on businesses today, it is hard to remember at times that the technology is still evolving and maturing. With the evolution of 3D printing technology, we can only imagine how it will look in five or ten years.

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3D Printing Continues to Transform Manufacturing in 2017

Additive Manufacturing, commonly known as 3D printing, is ripe for innovation in 2017. 3D printing technology has been evolving at a rapid rate since it caught the attention of makers and the public alike in 2009. Though the technology dates back to 1986, it wasn’t readily accessible to the public until 2009, when the first commercial 3D printer kit was offered for sale. Since 2009, additive manufacturing technology has transformed in itself, while simultaneously transforming the business and manufacturing landscapes as well. Below are three ways that additive manufacturing will continue to alter the manufacturing industry in the coming year.

Transform the Manufacturing Industry Landscape

Over the past ten years, 3D printing has transformed from a primarily prototyping technology to one suitable for making quick-to-market products, specialized designs, and low-volume production runs. It is natural to assume the technology will continue to advance and become more sophisticated.

“Two-thirds of manufacturers use 3D printing in some way, and 25% plan to adopt it in the future.” (CES 2017)

While companies are not giving up their existing manufacturing methods, they are beginning to integrate 3D printing into these more traditional practices. Manufacturers see 3D printing as a way to cut down on the time and costs of injection molding processes, thus making product development cheaper and more efficient. For product development and on the manufacturing floor, CAD software allows for quick design updates and 3D printing is able to quickly adapt to these changes. Additive manufacturing will continue to be a supplement to existing manufacturing techniques.

Smart Automation Will Take Shape

As the technology advances, automated 3D printing systems will become more advanced. The current pre-programmed automation efforts are error prone and lack the ability to self-correct. New, intelligent, automation is right around the corner. This new automation will be able to self-correct and adapt to changing design modifications. “The process will monitor itself as it is being printed and either correct the process or reject the part when problems occur. The nature of 3D printing and the continuous, high-inspection requirements make ‘smart automation’ a better fit in the long-term for the manufacturing processes than older programmable robotic approaches.”

Reduce Time-to-Market Even Further

In Gartner’s 2016 annual predictions about the future of 3D printing, the report indicates that 3D printing will continue to reduce new product development timelines—as much as 25% by 2020. Companies across a wide range of industries have been using additive manufacturing to speed up prototyping processes. Using 3D printing, companies are better equipped to turn out prototypes, test them, present them to clients, adjust and tweak them, and repeat. As Gartner states, “The number of iterations enabled by rapid and iterative prototyping results in short new-product development time, lower development costs and fewer finished goods defects.”

3D printing is having quite an impact on the industrial sector and demonstrating huge potential for the future of consumers. What shape that potential will take is still unfolding before us.

Garnter’s full report can be found here.

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Product Design: Custom Electronic Sensor [Case Study]

3D INNOVATIONS CASE STUDY

The challenge: Develop and prototype a custom circuit sensor application.

3D Innovations was contacted to assist in the product design and development of a custom circuit board sensor device prototype. The exact application was to measure specific amounts of units through an on board sensor that would store and transmit the data to a cloud storage system.

custom circuit board design

Using the client’s requirements, the 3D Innovations team was able to produce a schematic design to develop the circuit layout and determine Bill of Materials (BOM) requirements and the associated cost. Gerber files were generated and used for the manufacturing process. While the option of 3D printing the circuits was available, the conventional method for fabrication and assembly was utilized.

Integrating best practices for PCB design, development cost was reduced by 230% and prototypes were built in several weeks, saving 3-4 weeks in lead time. UL and FCC certifications were conducted to ensure testing compliance and approval. A production ready design was then delivered for manufacturing.

Results: A product ready design was delivered for manufacturing, while development costs were reduced by 230%, saving 3-4 weeks in lead time.

“Working with 3D Innovations, our sensor device was able to come to life and allowed for a quicker market introduction.”

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Product Design: FOG Safe [Case Study]

3D INNOVATIONS CASE STUDY

The challenge: Design and development of a prototype mold for final product testing and market integration.

The FOG Safe is an environmentally conscious product designed to keep fat, oil and grease from drains and ultimately our environment. By reducing fat, oil and grease waste material from our drains, we not only greatly reduce our carbon footprint, but protect our landfills, gardens, water sources, streams and oceans from harmful chemicals. With this waste reduction goal in mind, the FOG Safe was created.

FOG_Safe grease catchment_product design

Using our product design and 3D Printing process, prototype molds were created to produce a low volume quantity for final testing and marketing integration. The data obtained during this testing phase has allowed FOG Safe to receive several patents and other IP protections for the product. Utilizing 3D printed molds, as compared to traditional molding materials, saved our client more than $8,000 in tooling expenses and reduced the product development time from months to weeks.

Results: By creating less expensive tooling we were able to save our client over $8,000 in tooling expenses. The functional prototype has been effective in conducting testing and developing use cases. The overall product development cycle was reduced by months using 3D Printing technology over aluminum or steel molds during the prototyping phase.

With the assistance from 3D Innovations, a prototype part and tooling was able to be developed in a much shorter time period than traditional manufacturing and mold making methods. The assistance they provided helped to produce a design that was used for manufacturing, patent applications, and packaging design.”

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Product Design: Making Dental Care Fun [Case Study]

3D INNOVATIONS CASE STUDY

The challenge: Develop a product that makes dental care fun for children.

When SmileyRides™ approached our 3D Innovations team, the startup had an overarching goal: Make dental care fun and interactive for children, while promoting life long healthy oral hygiene habits. With an idea and rough sketch in hand, we were able to take our client’s vision and turn it into a functional prototype for product testing, manufacturing and patenting.

smileyrides dental product designAfter assessing this project we knew that 3D Design and 3D Printing technology would be the most flexible method for producing this product. 3D Printing is significantly cheaper than traditional manufacturing methods and with this savings, we were able to product multiple prototype concepts for consumer testing. Having these prototypes to validate the design and hand out to their target market for testing proved to be invaluable.

With our digital design process, we were able quickly produce mock-ups and validate the design, which helped reduce the product development timeline by two months. The detailed design we provided was manufacture ready and provided a seamless transition into the production manufacturing stage. Utilizing 3D Printing technology resulted in a cost savings of over $10,000 in machining and mold expenses.

Results: A functional prototype was developed using digital design and 3D printing technology, which resulted in a cost savings of over $10,000.

“3D Innovations is nothing short of amazing. From my initial consultation of an idea I had in my head and a novice drawing, they were able to bring my idea to reality better than I could have ever hoped for. 3D Innovations was detailed in every aspect, produced everything in a prompt, professional manner, and was extremely knowledgeable about the processes and the products. Honestly, I don’t know how I would have been able to get my business to where it is today without them. 3D Innovations is invaluable to me. They answered all my questions no matter how small or how big. 3D Innovations produces top of the line quality and is a pleasure to work with.

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Product Design: GoPro Mount Accessory [Case Study]

3D INNOVATIONS CASE STUDY

The challenge: Develop a hands-free GoPro mount accessory.

Our 3D Innovations team worked closely with a group of young entrepreneurs during Startup Weekend Honolulu 2015 in the product design and development of a hands-free GoPro mount accessory. With only 54 hours to develop and prototype the idea, time was of the essence.

go pro accessoryThe initial concept was to develop a clip that would attach a Go Pro camera to the front of your hat for hands free video action shots. Using our 3D Design process, we were able to take the initial idea and develop a functional design. Numerous factors needed to be accounted for throughout the product design phasesize, weight and materials. 3D Printing technology was utilized to accommodate the rapid product development cycle. Several versions of the prototype were produced in a short period of time, which allowed the team to test and conduct customer validation studies.

With the final design, this accessory can now replace over a dozen mounts for GoPros, iPhones, audio recorders and lights. The easy to use and compact hands-free mount design makes it easy to take along on your next adventure.

Using our 3D Design and 3D Printing process, we were able to save over $4,000 in prototyping costs while reducing the development time from weeks or months to just days. The utilization of 3D printing technology led to significant cost savings, which allowed the team to develop several versions that were validated through the customer discovery process and led to the final production-ready design.

Results: Designed and developed a functional prototype in 54 hours.

“Working with 3D Innovations allowed us to turn our concept into a prototype and help win the 2015 Startup Weekend Honolulu event. With the assistance from 3D Innovations, we have a concept that can be brought to life through crowdfunding sites such as Kickstarter. This will help us raise the necessary funds to mass produce this product.”

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3D Innovations is a Product Development Company – from the 3D Design to a fully functional 3D Prototype & Product.

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Upcoming 3D Academy Event: 3D Printing & CAD Design Using LEGO (October 10-14th)

September 14, 2016
3D Innovations

3D Printing and CAD CampPlay-Well TEKnologies and 3D Academy collaborate to create an in depth and immersive camp experience for your child through the “3D Printing and CAD Design using LEGO®” program.

Everyday students will learn the fundamentals of 3D Printing, CAD Design and Spatial Environments to create their own custom and one-of-a-kind LEGO component to take home. In the other half of camp, students will take part in Play-Well’s LEGO Engineering program and have access to over 20,000 pieces of LEGO while creating motorized and architectural projects such as Steerable Motorized Gear Cars, Pneumatic Claws, Mechanized Battle Walkers, Conveyor Belt Systems, and Towering Skyscrapers. Students will be introduced to the world of 3D Printing, CAD Design, Engineering, Physics, Architecture and prototyping all while having fun in a LEGO-centric camp environment.

Visit www.play-well.org or contact Wrenn Okada at 808.221.4870 or wrenn@play-well.org for more information.

3D Printing and CAD Design using LEGO
  • Grades K-2nd & 3rd-6th (Two Age Groups)
  • Manoa Innovation Center (2800 Woodlawn Drive)
  • October 10-14 (M-F, Fall Break) / 9:00am-4:00pm
  • Price: $260 for 5 day Camp

Register online at www.play-well.org/hawaii

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3D Innovations is a Product Development Company – from the 3D Design to a fully functional 3D Prototype & Product.

Startup Connector is a Manufacturing Accelerator helping companies commercialize—turning ideas into products.

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The Benefits of a Functional Prototype

September 6, 2016
3D Innovations

Rushing through the product development phase can be tempting because all hardware startups want to launch as soon as possible, however one step you can’t afford to skip is that of building a functional prototype. Building a prototype does take time, but in the end, the amount of time and money it will save you makes up for the extra couple weeks. If you find yourself on the fence about creating a prototype, here are a few facts to consider.

Why prototype my idea?

industrial_design-handleRefine your design. While a product idea might look great on paper or when speaking about it, the actual design might need to be reworked. Your design needs to be functional and manufacturable, and a prototype can make sure that both of these requirements are met. There is no better time to work out the “bugs” than at this stage, when changes are still inexpensive and easily made.

Gather market feedback. Get your functional prototype into the hands of your target market. Asking customers to imagine a product can be quite a challenge and the feedback you receive will not be all that beneficial. On the other hand, presenting this group with a prototype lets them touch your idea and get a real feel for the product and its functionality. With accurate market feedback you will be in a better position when it comes to finalizing the design and launching your product.

Rally financial support. Are you planning on reaching out to VCs or crowdfunding your product? If so, a functional prototype is a must. VCs want to see that you can deliver an actual product and are ready to move into manufacturing. Crowdfunding campaigns are much more successful when they can demonstrate functionality with a prototype.

File a patent. Obtaining a patent is a way to secure your intellectual property and in doing so there are many documents that need to be filed. Having a prototype will make technical drawings easier and you will be better able to describe your product in the USPTO application.

While there are many more reasons to build a prototype, these four stand out because of the real financial impact they have on your startup. When it comes time to launch your product, you want to be confident and prepared for what lies ahead.

Ready to take the leap into prototype development? We can help! Contact us at info@3d-innovations.com to get started.

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3D Innovations is a Product Development Company – from the 3D Design to a fully functional 3D Prototype & Product.

Startup Connector is a Manufacturing Accelerator helping companies commercialize—turning ideas into products.

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3D Printing Technology: What Does The Future Hold?

August 10, 2016
3D Innovations

Additive manufacturing, also known as 3D printing, is a process for making a physical object from a three-dimensional model, typically by laying down many successive thin layers of a material. This manufacturing process has been around for over 30 years, and in the last 5 years it has risen in popularity. While there is definitely “hype” surrounding the technology, there is also a lot that this technology is capable of—it is a driving force in hardware product development and the maker movement.

Below are two TED Talk videos that explain 3D printing and what the future may hold for this technology.

What is 3D Printing was 100x Faster? By Joseph DeSimone

In this TED Talk Joseph DeSimone talks about his inspiration for a new 3D printing method that was inspired by Hollywood, or more specifically Terminator 2.

“Now, we were inspired by the “Terminator 2” scene for T-1000, and we thought, why couldn’t a 3D printer operate in this fashion, where you have an object arise out of a puddle in essentially real time with essentially no waste to make a great object? Could we be inspired by Hollywood and come up with ways to actually try to get this to work? And that was our challenge. And our approach would be, if we could do this, then we could fundamentally address the three issues holding back 3D printing from being a manufacturing process.”

What’s Next in 3D Printing? By Avi Reichental

3D printing technology is changing the face of medicine—personalized medical devices are transforming an industry. “3D printing is changing personalized medical devices as we know them, from new, beautiful, ventilated scoliosis braces to millions of dental restorations and to beautiful braces for amputees, another opportunity to emotionally reconnect with your symmetry.”

With the elimination of complexity restraints, 3D printing is opening the doors to designs that have just not been possible before with other manufacturing methods. While 3D printing will not be the end of manufacturing as we know it, it is shaping the industry to meet today’s demands.

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3D Innovations is a Product Development Company – from the 3D Design to a fully functional 3D Prototype & Product.

Startup Connector is a Manufacturing Accelerator helping companies commercialize—turning ideas into products.

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