MCADCafe Weekly Review May 25th, 2018

Carbon is an additive manufacturing system company that bridges hardware, software, and molecular science to further digital 3D manufacturing that goes far beyond prototyping. With Carbon’s Digital Light Synthesis (DLS) technology and its SpeedCell system, manufacturers can explore new business opportunities such as mass customization, on-demand inventory, and differentiated products made with unique functional materials.

Carbon’s vision is a future fabricated with light, where traceable, final-quality parts are produced at scale with Continuous Liquid Interface Production (CLIP) technology. CLIP is a fast photochemical process that eliminates the shortcomings of conventional 3D printing by using light and oxygen to rapidly produce objects from a pool of resin.

Carbon entered the market just over three years ago with its innovative resin-based 3D printing technology, bringing to market its first 3D printer, the M1, a year later. The SpeedCell system with the M2 3D printer and Smart Part Washer was introduced in 2017.

Carbon M1 3D Printer Demonstration

The Process

Despite industry advances, traditional approaches to additive manufacturing force trade-offs between surface finish and mechanical properties. In contrast, DLS (Digital Light Synthesis) technology, enabled by Carbon’s proprietary CLIP process, is a unique technology that uses digital light projection, oxygen permeable optics, and programmable liquid resins to produce parts with excellent mechanical properties, resolution, and surface finish.

Traditionally 3D printed parts have been notoriously inconsistent. Conventional 3D printed materials often exhibit variable strength and mechanical properties depending on the direction in which they were printed. DLS parts behave consistently in all directions. The resolution and gentleness of the process — where parts aren’t harshly repositioned with every slice — make it possible to exploit a range of materials that have surface finish and detail needed for end–use parts.

CLIP is a photochemical process that carefully balances light and oxygen to rapidly produce parts. It works by projecting light through an oxygen-permeable window into a reservoir of UV-curable resin. As a sequence of UV images are projected, the part solidifies and the build platform rises.

The heart of the CLIP process is the “dead zone” – a thin, liquid interface of uncured resin between the window and the printing part. Light passes through the dead zone, curing the resin above it to form a solid part. Resin flows beneath the curing part as the print progresses, maintaining the “continuous liquid interface” that powers CLIP.

Once a part is printed with CLIP, it’s baked in a forced-circulation oven. Heat sets off a secondary chemical reaction that causes the materials to adapt and strengthen.

University Students Learn Hands-On Skills for Solving Automotive Engineering Problems
May 23, 2018  by Mitch Bossart, Industry Writer for GoEngineer

GoEngineer sponsors the University of Texas at Dallas (UTD) in competing against international university teams.

The Formula SAE® Series competitions provide opportunities for undergraduate and graduate students to conceive, design, fabricate, and develop short-wheelbase formula-style vehicles. The challenge is to develop a vehicle that can successfully compete in all the events described within the 175-page FSAE rules document. All teams entering the competition must meet strict requirements pertaining to performance and driver safety.

For example, failure during a technical inspection means a team is not allowed to operate their vehicle under power, which means they can’t compete against other teams in the dynamic events.

The Rigors of Product Development

“This is the real deal,” says Dave Schaller, Education Manager at GoEngineer. “Formula SAE pulls no punches. University students get to experience the rigors of product development—the successes and failures.” Requirements include vehicle configuration, driver’s cell, minimum material requirements, main and front roll hoops, bracing, safety equipment, fasteners, and much more.

However, there are few restrictions on overall vehicle design, so students can express their ingenuity and take innovative approaches to vehicle design. The competition provides an opportunity to demonstrate engineering know-how among similar peers from around the globe.

Managing Time and Partners

Part of building a successful product is meeting tight deadlines, which the students face at multiple junctures in the process. “One of the biggest things we’ve done is make sure to allot plenty of time for our design and manufacturing phases,” says Arye Levi, Chief Engineer, UTD Motorsports. “We spent the better part of a year and a half designing the car and getting that all set up. It’s been a learning process and we’ve been able to get our parts in at a steady rate, and getting our guys trained, and the car is coming together.”

“Dave [Schaller] has been a huge help to us in the whole process. Not only was he there with the Creaform 3D scanning, but he also gave us advice on rules and regulations for the chassis when we were still in the early design phase, and also on the intake manifold printing,” continues Levi. “A lot of the changes for manufacturability were at his recommendation since he knew a lot about materials, and of the specific 3D printing challenges that were involved with them.”


3D Design Optimization

UTD decided to take an innovative approach to designing the manifold. The FSAE rules require that all teams have a single-throttle body inlet and a 20mm restrictor, which is approximately a circle less than an inch in diameter—all the air going to the engine has to pass through that small opening.

“Optimizing air flow through the manifold is really important for power and efficiency,” says Levi. “So we needed to have a smooth geometry that would let the flow coming out of that restrictor be as laminar as possible. We did not want turbulence or other unintended consequences that could further interrupt the flow to our cylinders.”

The team used SOLIDWORKS CAD and Flow Simulation to achieve their desired designs, and they relied on GoEngineer’s Stratasys 3D printer. They used Ultem 9085, a thermal plastic that is both heat resistant and chemical resistant—very important when a component is right next to an engine operating at high temperatures.

If You Build It They Will Come

The competition is just months away and the team is excited to see how they’ll fare against other schools. “I’ve always wanted to go into automotive,” says Levi. “Back in my sophomore year in college, I was in the computer lab just messing around on SolidWorks, designing car parts for fun, when I overheard a group of guys talking about Formula SAE.” That’s how the Formula SAE team got started at the University of Texas at Dallas.

UTD Motorsports started with just five members and has ballooned to over 70 members from various disciplines. Today they have a complete car design and are looking forward to the race in June. “It’s coming together to get this thing ready for competition,” concludes Levi. Both GoEngineer and the students are excited to see what happens at the event.

Kenesto: 30 day trial

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