Clean up after anything is not usually an especially enjoyable endeavor, even where subtractive or additive manufacturing processes are concerned. This is where post processing comes in.
The Problem with CAD In Subtractive Manufacturing
To cut parts using a CNC cutting machine, it has to be programmed with the path of the desired shape or nest of shapes. Most parts are designed with a CAD program where they are saved in a CAD drawing format, such as DWG, STEP, or several others.
But you can’t just take the CAD file and send it to a cutting machine. It has to be interpreted first, so the CNC on the cutting machine can understand it. The problem with CAD file formats is that:
They usually contain a lot of information that the CNC cutting machine doesn’t need or would find confusing, such as title blocks, Bills Of Material, dimension lines, borders, welding symbols, etc.
They usually have multiple layers, some of which are useful to the CNC and some of which the CNC needs to ignore.
They sometimes have many parts in one file, some of which might need to be cut on the CNC cutter, and some might need to be machined, cast, or sent to an EDM.
They don’t have all of the information needed by a CNC machine. Machines need to be told when to turn a process on and off, how to lead-in and lead-out from a part, etc. All of this information is referred to as the process technology.
Last week marked the 50th edition of one of the world’s biggest technology spectacles – CES 2017 – showcasing the connected future of technology. With more than 3,800 exhibiting companies and exhibit space of more than 2.6 million net square feet, CES 2017 hosted some the world’s biggest companies in addition to hosting more than 600 startups. More than 175,000 industry attendees, including 55,000 from outside the U.S., convened in Las Vegas to discover the latest and greatest in many segments of the technology industry.
Probably one of the big trends at CES 2017 was Amazon’s Alexa assistant integrated into all sorts of gadgets everywhere, including cars! Not to be outdone, at this year’s CES, though, no fewer than 56 exhibitors were under the 3D Printing banner – many that you’ve heard of and a few that you probably haven’t. Although there were some basic retreads on previously released products, there were significant developments presented, and the ones that caught our eye were in the areas of materials (metals and ceramics) and affordability (sub-$500 machines).
It’s almost the end of November, so with just over a month left of this year, it’s not too early to start thinking about what we’ll be covering in 2017. The calendar below reflects what we perceive as some of the most important topics today, as well as feedback from our readers and other supporters.
The main theme for each month will be covered in an extended article or series of articles so that the topic can be covered in a more comprehensive way. We’ll also be covering some of the major MCAD events throughout the year, reporting what we see and hear from vendors, partners, and attendees.
We’ll also be covering some of the major MCAD events throughout the year, reporting what we see and hear from vendors, partners, and attendees. All of the events we attend will include daily written coverage and Tweets throughout event days, as well as video and audio interviews.
If you have any thoughts of topics you would like to see covered in 2015, feel free to contact me at jeff@ibsystems.com or 719.221.1867.
We look forward to an exciting 2017and providing you with the MCAD content you want most for improving your design, engineering, and manufacturing processes.
Keep MCADCafe.com your source for all things MCAD because 2017 is going to be a great year!
2017 MCADCafe Editorial Calendar of Monthly Topics
January 2017 – CAM Trends
February 2017 — Cloud Computing with MCAD Applications
If there ever was a company that has struggled to reinvent and find itself, as well as its former stature in consumer and commercial technology, it’s HP.
There was a time when HP had no equal in several product segments, such as test & measurement, calculators, pocket PCs/personal assistants, etc., but those days are long gone. Sure, the company reigns in printers, and their desktop and mobile workstations are good, but not nearly as compelling as in the good old days.
HP’s reign as the world’s largest manufacturer of personal computers came to an end in the second quarter of 2013. At the time sales figures showed that Chinese PC manufacturer Lenovo shipped more computers during that period than HP, which had held the crown as the largest PC maker since at least 2006.
In an attempt to return to its former glory days, HP split into two public companies with one side focusing on its cloud and enterprise market (Hewlett-Packard Enterprise), and the other on personal systems (computers) and printers (HP Inc.). To make this happen, the company also cut thousands of jobs in the process.
For as long as I can remember, HP has produced an incredible range of products for science, engineering, and consumer customers. More recently the company has had a huge presence in computers and 2D printers.
Now, HP has vision for 3D printing for manufacturing parts on a relatively economical machine it calls the Multi Jet Fusion (MJF) 3D printer. The company claims these parts will have similar quality and characteristics as injection-molded parts, and will print at speeds that HP claims to be 10x compared to similar competing technologies. More about these claims to follow.
However, I have to wonder if HP will be able to fulfill its promise.
The HP Multi Jet Fusion Printer
HP wants to deliver SLS-quality parts on a system targeted at the professional 3D printer market. So-called professional 3D printers can be run in office environments and use photopolymers as material and inkjet printheads for material deposition. HP’s Multi Jet Fusion uses a printhead to jet a resin onto a powderbed where it will be fused.
In a Multi Jet Fusion technology white paper HP states, “Compared to SLS, HP Multi-Jet Fusion technology helps reduce the overall focused energy requirements needed to attain full fusing, resulting in more consistent material properties.” So SLS has higher “focused overall energy requirements,” yet the strong thermal bonds this energy creates is exactly what make SLS so desirable. So, exactly what is this process and can it really create material properties that match SLS and even injection-molded parts?
Tim Heller, Director 3D Printing, Hewlett-Packard At IMTS 2016
Historically, parts made from 3D printers, such as the MJF have lacked the robust mechanical properties of injection-molded parts. SLS is the only viable additive manufacturing technology capable of matching injection-molded parts in tensile strength and long-term stability. Materials undergoing the fusion process have issues that point to a natural limitation, not a technological oversight that HP or any other manufacturer can truly fix.
Last month at IMTS 2016 we checked out a lot of new and improved manufacturing technologies, including several innovative developments in 3D printing/additive manufacturing. A couple of the most unique technology introductions were from Stratasys.
The company demonstrated its next-generation manufacturing technologies as part of its Shaping What’s Next vision for manufacturing that builds on its industrial FDM 3D printing expertise in response to the needs of customers’ most challenging applications, addressing manufacturers’ needs to rapidly produce strong parts ranging in size from an automobile armrest to an entire aircraft interior panel.
Stratasys developed two new prototype machines that they called demonstrators to prove their practicality – the Infinite Build 3D Demonstrator and the Robotic Composite 3D Demonstrator.
Stratasys CMO, Tim Bohling, Leads Tour of Company’s 3D Printing at IMTS 2016
The Infinite-Build 3D Demonstrator
The Stratasys Infinite-Build 3D Demonstrator was designed to address the requirements of aerospace, automotive and other industries for large, lightweight, thermoplastic parts with predictable mechanical properties. The 3D Demonstrator featured a new approach to FDM extrusion that increases throughput and repeatability. The system also employed a unique “infinite-build” approach, that prints on a vertical plane for parts that are virtually unlimited size in the build direction, such as entire airplane panels.
The Infinite-Build demonstrator is called that because, by flipping the vertical FDM process on its side, “We’re able to print parts in that vertical plane direction essentially as large as we want,” said Rich Garrity, president of Stratasys Americas.
Held every two years at McCormick Place in Chicago, the International Manufacturing Technology Show (IMTS) is the one of the largest (over 110,000 attendees), most comprehensive (~2,400 exhibitors), and longest (six days) manufacturing shows conferences in the world, certainly North America. This year’s event marked IMTS’s 31st edition. First timers and long timers are overwhelmed by the sheer size of this event. At over 1.3 million square feet, you better dress comfortably and prepare for an overload of manufacturing technology sights and sounds.
Because IMTS is so comprehensive and massive, planning is everything, and as you walk around the various pavilions, you start to get a sense of trends and likely future impact of just about all of the technological aspects of design, engineering, and manufacturing.
Below are the major manufacturing trends that I experienced this week. Starting next week I’ll detail what I considered to be the most significant technologies and products showcased at IMTS this time around. Next week, I’ll also go over the major software developments that were introduced — mostly CAM, but some significant stuff.
All 3D printers need host software to function. That’s a given. Host software sends the commands to a 3D printer that tells the printer how to build an object. Most host software communicates with the printer via a wired USB connection. For almost all 3D printers, a computer running the host software must stay tethered to the 3D printer at all times while it is running. Obviously, this is not always a great situation, hence the advantage of being wireless.
There are basically two ways to perform wireless 3D printing. First, a G-code file can be saved onto an SD card using a computer, then the SD card can be transferred to the 3D printer where the print job is initiated via a controller into a 3D printer.
This arrangement allows wireless 3D printing, but it lacks most the advantages of a truly wireless setup. The 3D printer can still be placed away from a work area, but beyond that, using the SD card transfer method is really no different than transferring data over a cable. The second way to do (truly) wireless 3D printing is by running the host software on a small embedded device, like the Raspberry Pi, that is connected to the 3D printer.
Which Is Better, OctoPrint or AstroPrint?
This is analogous to using a dedicated computer for 3D printing that stays connected to the printer at all times. But, instead of using a computer for this purpose, the host software can be run on something, such as a Raspberry Pi, which is just powerful enough to run the software.
The two most popular host software packages developed for wireless 3D printing are OctoPrint and AstroPrint. AstroPrint is, in fact, based on OctoPrint, and claims to have an optimized codebase for running on embedded computers. The AstroPrint team has made changes and additions to the software, making the two host software offerings quite a bit different in many ways.
While OctoPrint and AstroPrint do share some similarities, they are also different, primarily with regard to their intended users.
With all the fanfare that took place a couple years ago with the launch of cloud-based Onshape, we thought we’d weigh in with partner Geometric’s announcement of its STL Workshop.
Onshape is by no means the first cloud-based/mobile CAD application. It was and still is, however, a unique true cloud-based technology and not a desktop/cloud hybrid.
Onshape began with what was one of the best and worst kept secrets in the engineering software arena. Worst, because even early on, it was evident that the technology would be cloud based, even if virtually no details were disclosed. Best, because virtually no details were disclosed, and that just added to the anticipation for the official launch of Onshape.
One of the inherent advantages that Onshape has always had is the fact that it was created from scratch by a team used to creating things from scratch with no legacy baggage to overcome and work around. Of course, the development team has not done everything themselves, because Onshape includes software components from Siemens PLM (Parasolid; ironically the same modeling kernel used by SolidWorks) and D-Cubed. This component licensing has let the Onshape team focus its efforts on what it does best.
Shapeways, a leading 3D printing service and marketplace for consumers, announced a collaboration with HP Inc. to help drive HP’s Jet Fusion 3D Printer. Shapeways said it is the first company to receive an early prototype unit in its Eindhoven, Netherlands factory and is working closely with HP. Once publicly available sometime later this year, Shapeways hopes the new commercial HP offering will provide its 3D community with a superior quality black nylon material that will 3D print in greater detail, with a faster lead time, and at a lower cost than current dyed nylons.
Shapeways produces roughly 3,000 unique products every day and over 1 million unique products annually.
“We chose to work with Shapeways because they are the leading authority in bringing creative ideas to life and are the largest consumer 3D printing portal, with 3,000 products made every day,” said Stephen Nigro, president of HP’s 3D printing business. “The HP Jet Fusion 3D Printing Solution will enable Shapeways to bring high quality parts up to 10 times faster than before for lower cost.”
HP’s Virginia Palacio and Stefan Rink, Shapeways VP of Manufacturing, with the new HP Jet Fusion 3D Printing Solution, the world’s first production-ready commercial 3D printing system, installed in Shapeways’ Eindhoven factory.
According to Shapeways, in addition to offering superior quality, this new technology could potentially reduce standard shipping from the current seven business days to next day delivery. (more…)
Held every two years at McCormick Place in Chicago, the 
