stack these things so I’ll talk a little
bit about myself I’m an adult stir
designer from Dublin Ireland I worked in
Shanghai China for five years I’ve just
recently moved here to Varna with my
wife I have to say I’m loving Bulgarian
life so far SuJu Luke ANCA and of course
rikiya I’m learning the essentials in
Bulgarian I’m sorry that this speech
can’t be a Bulgarian but I do I do try
my best to learn the essentials you know
for example Varna maretto Sunita Varney
[Applause]
so anyway I’ll get answered by 3d
printing so 3d printing a lot of you may
have heard about 3d printing in the news
as this new technology that will
revolutionize the world
well 3d printing actually isn’t a new
technology 3d printing was invented back
in the 1980s by an industrial designer
in America called Chuck Hall during the
80s 90s and early 2000s we saw 3d
printing hit the market in large factory
floor machines large industrial machines
would limit a choice and huge expensive
costs only in the past five to ten years
have we seen 3d printing hit a new era a
new form that we call desktop 3d
printing but in desktop 3d printing
there are many different forms in itself
from what we call the riprap kit is a
kit that you assemble yourself to more
polished and plug-and-play
desktop machines so what is treaty
printing 3d printing or formally known
as additive manufacturing is the process
of creating an object through a layer by
layer a fashion what I mean by this is
if you could imagine an orange now
imagine cutting that orange up into
slices
now put those slices back together as
they were cut and this is a very basic
explanation of what your treaty printing
is I’ll give you another example imagine
a chocolate syringe and a piece of paper
draw a circle on the piece of paper of
chocolate let it cool for 10 seconds and
then draw another circle on top of that
circle repeat this process over and over
again and you will have effectively
created or treaty printed a chocolate
cylinder so in a similar process a
technology called FDM fusion deposit
machining is one of the main
technologies in 3d printing what happens
is it takes a material normally what we
call filament it’s like a spaghetti
shape it goes into the printer the
printer heats it up to 210 degrees for
PLA and and other materials are higher
temperature and what happens is it turns
that filament into molten plastic it
then deposits that plastic on a layer
and as you can see in the gif it builds
it up layer by layer let me give you an
example of a current process in
manufacturing today which is called CNC
milling or subtractive manufacturing so
in subtractive manufacturing you get
your raw material as a block you then
put this large block onto the machine
and the machine then mills or cuts away
at the block so that you obtain your
object through the last fashion this
creates a lot of waste and as I just
explained 3d printing hopefully you can
see the benefits over the CNC milling
but in 3d printing there are many
different technologies even within la as
you can see there are seven on the board
and in fact that’s grown to almost ten
just couldn’t fit it on the side today
we’re going to be focusing on desktop 3d
printing most of the ones that you see
here such as the material jet the
binding jetting the vaporizing and the
direct energy depositing these are
technologies normally found in large
industrial 3d printers and their
benefits would be that they can’t really
print directly in metal and can print in
multiple materials at once but as I said
we’re gonna be focusing on desktop 3d
which consists of FDM fusion two puzzle
machining and SLA they’re stereo
lithography so stereo fog Rafi what is
it all about how does it work imagine a
transparent bath and you put a UV resin
in that bath
now imagine lowering a bed to the bottom
of the bath and a laser or projector
projecting a shape onto that bottom of
the bath what happens is that projection
cures or hardens this liquid then the
bath is raised half a millimeter or less
and the liquid then fills up vodka and
in the process starts again by hardening
that next layer one of the main benefits
of SLA is that you can get ultra high
definition prints the surface quality
and this is one of the best in all of
the technologies but one of the biggest
limitations is that you can only treat
ePrint in one plastic one material so
the main technology that I’ll be
focusing on today is what’s called FDM
printing so even in FDM printing there
are advantages and disadvantages what
are the main advantages is the choice of
material the material strength that you
can get in FDM printing is uncompelled
on the larger industrial 3d printers
that printed metal to give you an
example of how strong a 3d printed part
can be earlier this year we treaty fully
treaty printed a car jack and we lifted
the full weight of a car you could see
this here with my colleague where he’s
actually cranking up the lift and you
can see that it’s fully taking the
weight of the car this is this is
standard evenness at the time we weren’t
sure it’s gonna work and this was
printed in what’s called PC max
polycarbonate the other advantage of FDM
printing is the material properties in
heat it’s heat resistant si can go up to
110 degrees for PC what this means is
the glass transition temperature or its
softening temperature the temperature in
which the material softens is above 110
degrees so it can effectively
be printed a cup and have boiling liquid
a boiling water inside now that has only
been brought into the industry on this
year and it’s revolutionized the
industry the last benefit that I’ll talk
about is the material choice so the
material choice can range from PLA to
ABS pcs to flexible TP use you can have
flexible parts to more fun and playful
filaments such as this is poly wood it
mimics the surface quality of wood to
composite materials which use metal
fibers inside the plastic to mimic the
effect of wood are the effect of metal
sorry but of course with anything there
are limitations what are the main
limitations are the support structure so
complex geometry requires a support
structure to hold up that during the
process now I call these limitations
because the three that I’ll talk about I
will also show how we are tackling this
within the industry today surface
quality surface quality is one of the
main problems that plagued all 3d
printing as I refer to earlier 3d
printing is the process of layer by
layer so that same process creates a
layer effect on the surface of your
model and a lot of people don’t like the
surface they want a smooth glossy
surface that they expect from injection
mold apart the next is printer cost even
though 3d printing a desktop 3d printing
have dramatically dropped in price over
the past five 10 years they’re still at
a pricing point where new users are a
little bit hesitant to adopt the
printing but let me talk about how we’re
tackling the support structure so
desktop 3d printing can be categorized
in two main criteria what’s called the
print volume so how big the printer can
print an object and secondly a single or
dual extruder system what this means is
a dual extruder system can print in two
materials simultaneously
what this allows the industry to do is
print such as this a vase in two colors
at the same time or two materials at the
same time this is a very complex bunny
and we call it a bunny pill and it
requires a lot of support under certain
areas with the dual extruder system
we’re able to then print dedicated
support material for that support
structure this allows us to break away
to support structure very readily
another development that’s been
happening again is in the materials side
of 3d printing and with what we call the
dissolvable support material this is a
short video to show how alpha 2d a dual
extruder printer you place your part
that’s been printed in PVA this material
is called poly vac polyvinyl acetate and
it dissolves in water so within an hour
all your support is been dissolved for
you there’s no manual labor and you can
create unbelievably complex geometry
such as this this kind of geometry would
be impossible to manufacture to any
other technology that was printed in one
piece surface quality is the next
limitation that we’re going to challenge
or tackle so a company called raze
treaty have adopted the process of
improving the hardware of the printer
itself in fact I have the race 3d here
printing on the right hand side on my
left and you can go up and see that
after the speeches and you can have a
look and there are some examples of
prints there for you to feel and touch
but the market standard for resolution
or the layer effect is between 100 and
200 microns
what Ray’s treaty has been able to do is
take the market standard and bring it
down all the way to 40 microns 40
microns to give you an example what that
is is 0.04 of a millimeter that’s
the next approach that we’re taking in
the industry for the surface quality is
actually a project that I was very happy
to lead I worked with a very very
talented team of engineers in us and
what we did was we produced a material
on a polisher or a machine that works in
tandem works together so what happens is
the material is printed like any other
material and it comes out of the printer
you place it in the machine it lowers
into the chamber and the chamber then
takes alcohol and it vaporizes it
creates a mist within two chamber to
polish the outside of the surface this
means that you don’t have to hand polish
your parts it is done for you within ten
minutes or longer depending on the size
of the part for example here this is an
engineering block that was printed in
poly smooth you could see here on the
left that this is before the polishing
process and after just ten minutes the
polishing process has polished it up to
a put to a part that honestly you would
expect to receive from an
injection-molded mass-manufactured part
you can see a little bit of scarring
here and the beautiful thing about this
technology is that it can actually
polish up some defects on the surface as
well if you don’t believe me about the
surface quality here is a close-up of
that same part so the last limitation
that I’ll talk about today is the
affordability so one of the main
limitations for new users who adopting
treaty printing is the old front cost of
the printers themselves the running
costs on a material cost of treaty
printing is relatively low compared to
ink cartridges that of 2d printers but
in the same comparison to D printers
will set you back between 50 to 300 euro
for the printer itself whereas 3d
printing on average will cost you 1000
to 3000 euro for the printer this is a
large upfront cost for new users so what
we’ve done a profile is we’ve engineered
and designed our machine so that it is a
more affordable printer for new users
we’re bringing an ED 2017 and it’ll be
at 299 euro and we really believe that
this is going to bring 3d printing into
a new era with new users adopting 3d
printing so that’s all great but how do
you go from ideation to creation as a
new user how do you create those models
that a printer needs to print there are
many different software’s such as online
tutorials they’re ours
I pass Alex iPhone applications that
allow you very simply to create a model
and be ready for 3d printing some
examples here are parts that we printed
for the home decoration all of these
were free 3d models so as a new user at
the beginning you’re a little bit
hesitant the learning curve or 3d
modeling might be a bit intimidating so
you can start off by downloading I
believe this over 1 to 2 million on
three websites that I know Thingiverse
3d shook and my mini factory so you can
download apart you can customize it to
your taste by choosing what color you
want you can even resize it and print it
out at home on your home desktop printer
there are also companies such as nervous
systems nervous systems allow you to
modify on the fly their products this is
a I believe it’s a necklace it allows
you to choose your design change the
shape to your tastes and then it allows
you to download that model ready for 3d
printing for free but 3d printing is not
only for students or for my generation
3d printing can be a very exciting
adventure for young children as well I
got the opportunity to work with a very
talented designer early this year and
there’s a short video I’m going to show
you on how he implemented 3d printing in
his process in designing small tools
designer and create the
I remember when I was I used to create
my story now children and their free
imagination free because they can create
a story so early this year I also got
the opportunity to work with some design
firms Garibaldi’s design firm in
Shanghai that design luxury watches what
they did is they approached us to
prototype the design so that they can
evaluate how the form the ergonomics
will act this is extremely important
process for any designer because they
feel they feel that they can’t evaluate
the product from through a digital
screen they need to feel the form and
function of a product what was most
interesting about this process was the
evolution of the clasp so as young
designers they over engineered the clasp
and by through the process of 3d
printing evaluating and redesigning they
were able to cut their material costs by
15% on each watch simply by evaluating
reforming 3d printing and I think it’s a
very good example of a company that’s
utilized 3d printing in their process
you could see some of the prod
prototypes here where they went from
different concepts down to their sample
part from the manufacturer and today
they’ve launched 500
watches worldwide the next process they
use 3d printing was in fact in my own
process workflow when designing for the
polisher
we went from sketching rough sketching
our idea onto paper
we thence solidified our idea and
created pad drawings and 3d models so
from those car drawings the treaty
models the next step was to get a
working prototype and what was important
for a working prototype is that the
material that is made from would be
strong and will be chemically resistant
because of the alcohol inside the
chamber so we used the PC that you we
previously mentioned we were able to
hand sand Prime and spray so that we can
achieve a finished product and this is
honestly a working prototype but still
working today over eight months and
we’re very very proud of it we didn’t
just use 3d printing in the final design
we also used it through the evolution of
the product itself so here you can see
some of the proof of concepts we went
this is the heart of the product the
self what’s called a nebulizer the part
that actually turns the alcohol into
mist so we went from very rudimentary
shapes all the way down to a smaller
form factor and including the
electronics in it so we went from like I
said very very rough 3d prints for the
base here and a lot of the components
inside went with a larger and we went
through our process and through the
entire process 3d printing was
absolutely vital so what’s important
here is to note that how quickly we were
able to evaluate and to prototype its
each iteration we didn’t just design one
product and say that’s it that’s going
on to the shelves for customers no we
wanted to improve the product it true
out of each iteration and we were able
to do that all in-house that’s
incredible I’ve been in a process where
we’ve outsourced sampling or we’ve
outsourced prototyping so that we can
get a working prototype or a
proof-of-concept this is a time
consuming process so being able to do it
in house was invaluable the last slide I
want to share with you guys is honestly
one of the biggest and best case studies
our treaty printing I’m very very
excited about actually so print plus is
a Dutch company started up by three
young designers straight out of college
so their aim was to design a set of
headphones but with a twist they were a
startup company young designers so they
had never designed for mass
manufacturing they didn’t have the
experience that some designers with 10
20 years experience have when designing
for mass manufacturing they also didn’t
have the funding or money to pay for
these upfront costs that the Chinese
manufacturers ask which can be between
5,000 to 20,000 for a mold or for a part
so what they did was they set out to
design a 3d printable a headset that
they can send to users to print at home
what’s amazing about this is they were
able to then from a product that would
probably be between 14 to 16 parts in
there they were able to narrow it down
into simply six so this allowed them to
focus on the electronics rather than the
hardware by doing so they were able to
put more money and time into electronics
and able to produce electronics that you
would expect from a high-end
manufacturer such as Bang and Olsen or
boss so as I say here know molding costs
no plastic manufacture needed and in
fact a more simplified assembly these
are huge saving costs the next is the
customization so for as a customer
you’re get you get the hardware sent to
you and you print it at home this allows
you to design how you want you can
change the color you can change the
design to how you feel on the day this
is a huge huge possibility for customers
the next is the package is smaller its
lighter
so therefore the delivery cost is lower
from factory to factory overseas and
domestic this is a game
further saving pasta and it’s absolutely
vital printout replacement parts for
customers who may break the headset
that’s a nightmare to try go through the
normal process of working with customer
service in this factor you’re able to
treaty print your own replacement parts
and finally all these saving costs are
passed on to their customers so they’re
able to produce these at twenty two
dollars rather than a hundred and forty
dollars so anyway I hope that shows you
how well 3d printing can be brought into
your workflow and I hope you enjoy the
presentation
[Applause] here