BigRep Innovation Award’s Lindsay Lawson: Bending the Rules of 3D Printing

To create something truly original, sometimes you must throw the rulebook out the window. Berlin-based artist Lindsay Lawson knows all about challenging the boundaries of what is possible, especially when it comes to technology – in fact, it’s an essential facet of her work creating sculpture and other artworks for 3D printing. Lindsay has had her works exhibited extensively across Europe and the United States, where she is originally from. When she is not exhibiting in cities like Vienna, Los Angeles, London or Rome, Lindsay works with BigRep on special projects that challenge its large-scale printers to develop interesting and complex 3D-printed objects.

It was Lindsay’s experience raising artistic works from the 3D print bed, fusing form and function, that made her a clear choice for the jury in the BigRep Innovation Award’s open call to students in Canada. As part of the four-person jury, Lindsay will help decide the ultimate winner of a Canada-wide competition, with a $3,000 cash prize, for the most innovative design of a 3D-printed chair. Following a public vote, a select number of entrants’ designs will be presented to the jury members, who will all be looking for originality, strong understanding of 3D printing principles, aesthetic innovation and structural integrity.

We sat down with Lindsay to find out how she approaches 3D printing in her work, and get her tips for competition entrants.

BigRep: Could you please tell us a bit about how and why you developed your expertise in 3D printing as an artist? 

Lindsay Lawson: My artistic practice is centered around sculpture and video. While my initial foray into 3D modelling was animation, I soon wanted to translate those skills into 3D printed sculptures. Any type of art-making is somehow affected by the tools and materials one chooses to use. With 3D printing the process is how to turn a virtual form into a physical object, and that opens up many new paths to creating something interesting.

BR: With your use of 3D printing technology in your work, how do you balance form + aesthetic with function + structure? What are the challenges you encounter in striking this balance?

LL: The key is to design objects that are particularly suited for additive manufacturing, otherwise it’s like eating soup with a fork. I’m all about printing fast and light so I like to design objects that require no support with minimal infill and few perimeters. Often this means bending some rules of 3D printing – for example, sometimes I like to over-extrude so that I get a thicker wall on a single perimeter print rather than making it double perimeter, therefore cutting the print time in half. But if you’re going to break some rules it’s crucial to design intelligently for the technology you’re using, rather than working against it.

I particularly like to work with some of our more challenging 3D printer materials like transparent PETG, wood filament, flexible TPU. By “challenging” I mean that these materials may not print certain geometries as well as standard materials like PLA. I recently designed some light fixtures that were printed with transparent PETG because the material has a beautiful, silver luster when it refracts light. That project required that I first consider the limitations of FFF in addition to the printability of PETG to inform the functional design of the structure. For me, aesthetic decisions always come last.

How to Submit Your Design

BR: Do you have any words of advice to any students for whom the Innovation Award is their first official design award submission?

LL: If you want to 3D print an object, there is no point in designing something beautiful that can’t be printed. My biggest advice for Innovation Award submissions would be to understand how FFF works and then use the constraints of the technology as a starting point for inspiration.

BR: Which news sources, blogs or publications do you devour for inspiration and industry news?

LL: Since my background is in art, I pay a lot of attention to contemporary art publications and exhibitions, but for design inspiration I like to look at Dezeen and designboom. There are many innovators here at BigRep, so I get a lot of industry news shared from curious colleagues.

Read more here from two other BigRep Innovation Award jury members about their approach to designing furniture for 3D printing. Full competition details, including the entry form, can be found here.

Lindsay-S-115x115

Lindsay Lawson is an artist and a 3D printing specialist, NOWLab @ BigRep

Big Inspiration: Marco Mattia Cristofori on Furniture Design and the Terra Stool

The Terra Stool, a model of furniture design

With a deadline of 11 February, creative young Canadians have just under a month left to submit their innovative 3D-printed chair designs for the BigRep Innovation Award. Over the final weeks we will be interviewing three inspirational design professionals, all 3D printing experts, to spark the creativity and guide the efforts of our competitors on the way towards the finish line.

For the first in the series we sat down with Marco Mattia Cristofori, Product Designer at BigRep, to talk about his latest design, the Terra Stool, which is printed on a BigRep ONE. Marco explains how he developed this intriguing, head-turning piece and gives some handy hints on how best to approach the process of furniture design for production on a BigRep large-format printer.

Could you tell us a bit about your background and experience as a designer?

As an architect who decided to focus on smaller-scale designs, working as a Product Designer at BigRep has opened up new creative possibilities for me. When I started here large 3D prints seemed complex and time consuming to produce, but I discovered that the reality is very different. On our printers you can produce literally whatever you want, only your creativity is the limit and the day after you make a design, you have a prototype. The extra options the printers give me inspire me to move in new directions.

Regarding my background, I’m originally from Italy, and during my formation process I had the chance to live in Spain, the UK, Turkey and before moving to Germany. I worked for two years in an architecture studio based in Istanbul, where I was involved in projects on different scales – from urban planning to furniture design. I discovered that what fascinates me most is designing items for individual use in specific situations, like for sleeping, eating or, in this case, sitting!

How did you approach designing this stool for large-scale 3D printing?

The inspiration for this design was the Ocke Stool which is a really impressive design by Beatrice Müller, a former Product Designer at BigRep. I wanted to re-work the concept in a way which let me experiment with new design ideas and explore what the BigRep machine is capable of. To direct myself I set two constraints: to avoid using any support structure, and to exploit the flexibility of the ‘layer-by-layer’ process of FFF by making every single layer in the design different. An early decision after setting these rules was to have the seat rooted to the print bed which would make avoiding using support structure easier.

The Terra Stool, a model of furniture design
The Terra Stool was designed by Marco Mattia Cristofori. Each 3D-printed layer of the stool has a unique shape

Your re-designed stool draws upon natural design/bionic principles? What’s the thinking behind this? 

I decided to use a bionic shape partly because organic shapes tend to vary constantly in their cross-section so this would fit my aim to avoid layer repetition. The beautiful thing is that this typology of design helps to improving the stool’s strength. The gradual curvature of the supporting sections enables this by giving a load applied to the top of the stool an easy path through the object. The sharp angles on rectilinear designs can be weak points which are less able to deal with such forces.

An engineer at BigRep, Paul Worms, showed me some studies and images explaining these bionic principles. If you just look at the way the trunks of trees emerge from the earth, and branches emerge from the trunk, you clearly see this idea of the gradual curvature of structural sections.

What material did you use for this design? What features our Canadian entrants look for when choosing a material?

I chose our most-used 3D printer filament PLA, which allowed a nice polished finish to the seat top when it is printed flat on the print bed. It also meant that I had to limit overhang angles in the design to a maximum of 60 degrees in order to meet my rule of not adding any support material.

I suggest Innovation Award competitors think about other options. For example, it can be nice to use dual extrusion to combine two materials for a new effect, as in [sg_popup id="44" event="click"]this table[/sg_popup] BigRep produced in 2017. In that design we used on of our transparent materials which can produce interesting outcomes, especially if you experiment with infill pattern. Our PRO HT filament is a high-performance ABS-like material, its tensile and impact strength properties open up additional design possibilities.

Terra-Chair-With-Small-3D-Model-Macquette-2

As a designer, what news sources, blogs or publications do you devour for inspiration and industry news?

I still keep up to date with new developments in architectural design, I really like ArchDaily. I find that I can be inspired by ideas expressed in architectural language, and it influences my product designs. I also really like Dezeen which is more design-focused. And then there is iGNANT! I discovered this around six years ago and it’s a super nice, simple blog that covers different creative media. They’re from Berlin and posted this piece on our colleagues at NOWlab, which is actually about some nature-inspired furniture.

What advice would you give a Canadian student preparing a designs for the February 11 BigRep Innovation Award deadline?

I could talk for hours on this … but let me just say three things. The more research you can do into ideas which inspire you and into 3D printing technology the more likely you can create a really strong, boundary-pushing concept. Also, I would definitely recommend you set some rules for your design and make some quick decisions early on to take some pressure off the process and give a clear direction to your creativity. And the most important thing? Manage your time from there so that you have time to produce a design that expresses your unique perspective, in plenty of time for submission before 11 February!

More information about the Innovation Award, including entry requirements and student resources, can be found HERE.

marco-m

Marco Mattia Cristofori is architect and 3D printing specialist at BigRep GmbH

Connect with Marco on Linkedin HERE.

Will Metal Plating Unlock New Industrial Applications for Large-Scale 3D Printing?

After metal plating, the same Plastic 3D Printed Part has a number of improved properties.

When thinking about how large-scale 3D printer technology can add value to industrial design and manufacturing processes, there are two main technologies to consider – additive manufacturing with advanced polymers, and metal 3D printer technology. In both cases, the new technology by replacing a traditional manufacturing method digitizes the process and because of that saves time, reduces costs and increases design freedom.

In recent years, more engineering-grade materials have become available for use with plastic 3D printers and these offer a good solution for metal replacement applications, including for end-use parts. But what if you could combine the advantages of plastic and metal together in one solution? That is where metal plating of large 3D printed plastic parts comes in.

WHAT IS METAL PLATING?

Metal plating is a method of depositing a thin layer of metal, usually Copper or Nickel, on an object made of a different material. This is done in order to improve one or more of the object’s properties, for example strength; thermal or electrical conductivity; chemical resistance or heat deflection temperature. The result – a hybrid product and a new set of potential solutions for metal replacement applications.

Before and After Shots of a 3D Printed Component plated in Copper. Metal printing

Our experts with +25,000 hours of experience in industrial 3D printing are waiting to sink their teeth into your unique and challenging use case.

APPLICATIONS FOR METAL-PLATING

Metal-plating could enable the introduction of cost-effective hybrid products in heavy industries such as Defense, Electronics & Medical Devices. We can imagine products with the following properties provided by the metal layer:

  • EMI/RFI Shielding
  • Electrical Conductivity (Plastic antennas, Wave-Guide)
  • Barrier Characteristics (offering protection from humidity, chemicals, fumes…)
  • Enhancing Mechanical Properties – over the original plastic parta design flexibility
  • ESD Protection
Before and After Shots of a 3D Printed Component plated in Copper
3D printed component before and after copper plating

ADVANTAGES OF METAL PLATING OF LARGE 3D PRINTED PARTS

Over the past few years a range of 3D printed parts have been successfully metal-plated. Mostly these have been small and medium-sized parts. What would be the advantages of plating large 3D printed parts?

One of the barriers of producing large parts, in prototyping or end-use manufacture, is production cost. BigRep 3D printers allow one to affordably print large parts, up to 1 cubic meter in size. Adding a metal-plating option for such prints gives us a new way to produce large hybrid products which is suitable for advanced applications and at the same time implies cost reductions over solid metal production.

TESTING LARGE-SCALE METAL-PLATED PARTS

Currently BigRep and Polymertal - a global leader in metal plating solutions - together with a large Israeli defense company, are testing a unique large metal-plated part which was printed on a BigRep ONE. Up to now this part has been manufactured out of aluminum in a manual short-series production process.

In the coming weeks the 3D-printed version of this end-use part will be assembled and tested on an Unmanned Aerial Vehicle. Success in testing would mean the defense company has a new option of preforming a fully functional test of such parts which allows for faster design and testing cycles before moving on with manufacturing.

When the companies share their test results, expected in around a month, we will also have a better indication of just how big the potential is for metal-plated 3D-printed parts to replace traditionally made large metal parts.

Learn more about modeling, building and testing custom products fast and cost-efficiently.

Gil-Lavi-115x115

With over 22 years in the printing industry, Gil Lavi is a Sr. 3D-Printing Specialist with vast experience in implementing diverse 3D-printing technologies in design and manufacturing processes.

Connect with Gil on Linkedin HERE.

Reflections on 2017 – BigRep’s emerging global position in the Industrial Additive Manufacturing space – MADE IN GERMANY!

BigRep STUDIO, compact industrial 3D printer

BigRep’s 3rd full year in business has been one of big strides forward across the board. From doubling sales, to exciting new products and collaborations, to increasing confidence about the position we have carved out for ourselves in a fast-growing 3D printing industry, it has been a great 2017.

The backbone of our business is our resource base and in this respect, we have seen significant changes. We were pleased to announce key new investments this year from Klöckner & Co and Körber. We also made some important appointments, including those of Moshe Aknin and Frank Marangell who each have CVs bulging with world-class 3D printing industry experience.

As President of BigRep America, Frank Marangell’s arrival signalled the opening of our US office. We have wasted no time in developing a strong US team and our engagement with this crucial market kicked off with a presence at signature additive manufacturing shows AMUG in Chicago and Rapid + TCT in Pittsburgh. In a similar vein, this year we continued to grow our network of resellers, so that we can now say BigRep is a company with a global reach to match our technological ambition.

3D PRINTERS, FILAMENTS & NOWLAB: AN INCREASINGLY CUSTOMIZED 3D PRINTING PACKAGE

The development of that underpinning technology continues apace. This year we have been busily shipping our new BigRep STUDIO machines, as well as introducing new specialist 3D printer filaments and 3D printer software solutions. But we do not just sell machines and materials. The value we can add through hands-on work with clients to tackle big additive manufacturing challenges in their specific use cases became very clear this year. Our research and innovation hub NOWlab drives this work forward. NOWlab is playing a central role in our ground-breaking end-use parts manufacturing project with Deutsche Bahn, as well as numerous projects in other industries.

BigRep’s experts are waiting to sink their teeth into your unique and challenging use case.

Click here for more Info

 

The above activities are all part of BigRep’s maturation into a company with a clear and valuable role in the 3D printing industry. That transition requires that we work to our strengths and find industry-leading strategic partners with whom to work. For this reason, our production agreement with long-established German industrial firm Heidelberger Druckmaschinen AG was an important piece of groundwork in establishing BigRep.

C-level-BigRep-web

GROWING INTEREST IN INNOVATIVE ADDITIVE MANUFACTURING PROJECTS

So, it has been a year of great progress for BigRep, in three key areas: the basic infrastructure to build industrial machines; our 3D printing product and service package and developing industry track record; and our growing strategic connections for the future. These developments have delivered us greater exposure and interest from a range of stakeholders and at different cross-industry events. The August visit to BigRep’s offices by Ramona Pop of the German Green Party was just one of many from potential clients and a wider audience enthused by industry 4.0. I was pleased to share a platform at bitkom’s September 3D Printing Summit with colleagues from Braunschweig University of Art and Audi to talk about our fantastic car seat project. Our work with Deutsche Bahn has created a buzz and led to my appearance with Managing Director of ‘Mobility goes Additive’ Stefanie Brickwede at CREATING URBAN TECH in October.

November’s formnext show, the high point in the year for the additive manufacturing industry, was our opportunity to assess how far we’ve come in 2017 and to further shape our vision for the future. The message I took from a supremely busy four days engaging with colleagues across industry is that we are moving in the right direction with our technology, with our research-oriented and tailored approach to clients, and with our strategic plan to build machines for industrial users. Looking forward to 2018, our mission will be to push ahead on these core aspects of our work. Our headline task within this is to apply BigRep’s 3D printing technology and NOWlab’s ingenuity to a new round of even more impressive end-use applications. For that we need professional clients willing to think big and trust in the research processes necessary to realize further breakthroughs in additive manufacturing technology.

René

René is the founder and CEO of BigRep GmbH, driving it to be one of the world-leading 3D printing companies, with his many years of experience in business development and innovative technologies.

Connect with René on Linkedin HERE.

Global industries are boarding the additive manufacturing train – in Berlin!

Deutsche Bahn 3D printed part

To say we’ve been focused on tapping new potential this year would be an understatement. Front of mind for BigRep has been work on exciting projects and partnerships to discover new end-use manufacturing applications for our advanced large-scale 3D printer technology.

In late October I had the pleasure of sharing a podium with Deutsche Bahn’s (DB) Stefanie Brickwede at the dynamic CREATING URBAN TECH conference in Berlin, to discuss the successful cooperation between BigRep and DB. We spoke on this again at formnext on 14th November in Frankfurt. BigRep is a member of Mobility goes Additive, a network which DB initiated to develop additive manufacturing solutions for the logistics and mobility sectors. We have been working together to explore how DB can use BigRep’s additive manufacturing technologies to further their business and improve efficiency.

DB and additive manufacturing
BigRep CEO René Gurka & Deutsche Bahn’s Stefanie Brickwede at CREATING URBAN TECH

We can highlight three key outcomes of the partnership to date. All three are typical of the benefits industrial organisations encounter when utilizing our technology.

Firstly, Deutsche Bahn has identified that 10-15% of their demand for spare parts could be met with 3D prints. This approach can reduce production time and costs, and facilitate a dramatic reduction in necessary spare parts inventory. They expect to 3D print an impressive 15,000 spare parts in 2018.

Secondly, they are finding potential to use additive manufacturing to develop new kinds of end-use products. This article describes one example, a new design for a printed part with braille on its surface.

Finally, DB believes that the development of new 3D printer materials will be the key to determining how much end-use manufacturing it can do in future with 3D printing technology.

This joint project we have with Deutsche Bahn illustrates the new value that comes when companies invest together in exploring how new techniques can be applied to existing and upcoming design challenges. It, as well as developments within Mobility goes Additive, also shows that Berlin is becoming a hub for innovative developments in the emerging additive manufacturing sector.

But the story, and especially that final point, also illustrates that we have choices to make. We have the option to pursue networking opportunities in this technology to their limits and develop the next generation of high value technologies. Or, if we pursue these opportunities less aggressively, other firms and other cities will get there first and reap the rewards.

additive manufacturing - 3d printing filament
Developing new 3D printer materials is a core aspect of BigRep’s development of new additive manufacturing applications

We are conscious of this choice when it comes to Deutsche Bahn and Mobility goes Additive, and will seek to sustain our close working relationship to develop new 3D printer materials, hardware and techniques to fully explore the potential for this cooperation. What I discussed at CREATING URBAN TECH, as well as at formnext in Frankfurt (on 14th November), is that we need to apply the same thinking to Berlin and its own potential in terms of additive manufacturing. I believe that to take ourselves from a promising hub to that central, world-leading position, we should formally nurture networking activities between businesses and other research organisations in the sector, for example, with a Centre of Excellence in Additive Manufacturing in Berlin. Can we 3D print that?

Learn more about modeling, building and testing custom products fast and cost-efficiently

René

René is the founder and CEO of BigRep GmbH, driving it to be one of the world-leading 3D printing companies, with his many years of experience in business development and innovative technologies.

Connect with René on Linkedin HERE.

Formnext 2017: what prospects for the industrial 3D printer sector?

Representatives from across industry meeting at the BigRep stand at Formnext 2017

Formnext 2017 was another great event for industrial 3D printer enthusiasts. More companies have joined the race to bring 3D print technology to maturity and we saw plenty of new products on offer. Overall, a clear message came across – that additive manufacturing is here to stay and will continue to dramatically change the way we design and manufacture products.

Before discussing which technology and/or company is most likely to lead the industrial 3D printer market in coming years, we will investigate two key areas – 3D print solutions for prototyping and for manufacturing.

3D PRINTERS FOR PROTOTYPES

Within this segment of the market affordable 3D printers for plastic prototyping are making headway. These are not necessarily cheap 3D printers, but machines which strike a lower-cost balance between functionality and price. In the past such machines had few features and competed mainly on price. At Formnext 2017 we saw more sophisticated machines which can be used for specific applications such as dental and other fit-form-function applications. This means that higher-cost machines dedicated to prototyping must offer unique features to be attractive. BigRep offers industry exactly this kind of added-value through its large-scale industrial 3D printers and growing range of specialist 3D printer filaments.

BigRep ONE 3d Printed Furniture Prototype at Formnext 2017
BigRep ONE 3D-printed furniture rapid prototype: large-scale & weight-bearing

3D PRINTERS FOR MANUFACTURING

3D printing for manufacturing can be divided into two areas – plastic and metal 3D printing. With plastic, advanced polymers can replace metal for certain applications in Medical, Aerospace and other industries. In such cases if superior mechanical properties and/or larger parts can be delivered we have a more attractive solution. If printing speeds increase, plastic 3D printing could also potentially replace injection molding in some manufacturing applications.

The second manufacturing area, metal 3D printing made a big splash at Formnext 2017. On the one hand the prices of some lower-spec machines seem to be falling, making metal 3D printers more accessible. At the same time, new heavy metal printers are aiming to deepen the automation and integration of 3D printing in manufacturing processes with a focus on quality, variety of materials and printing speed.

End-use spare parts produced for Deustche Bahn on display at Formnext 2017
At Formnext 2017 BigRep showcased end-use spare parts produced for Deustche Bahn

LOOKING FORWARD – WHAT WILL BE THE NAME OF THE INDUSTRIAL 3D PRINTER GAME?

If we look at it from the industrial user’s side, before purchasing a 3D printer the following elements are usually considered:

  • The company behind the product – is it a short or long-term player?
  • Quality, accuracy & repeatability – the basics of effective additive manufacturing
  • Reliability & ease of use – for minimum hassle
  • Variety of materials - for a wide range of applications
  • ECO system - inclusion of a dedicated Software solution. This is particularly critical in the metal printing space
  • Printing speed – this must increase to increase productivity, especially in manufacturing
  • Reasonable cost per value – an essential requirement of the end user
Exploring with industry how 3D printing can bring it new value and competitive advantage

SO WHICH COMPANY AND/OR TECHNOLOGY HAS THE POTENTIAL TO LEAD THIS INDUSTRY?

It depends on how you measure it, but no doubt a strong combination of a ‘new generation’ technology with a focus on printing speed and advanced materials, plentiful long-term funding, and a winning business strategy will be key success factors for any 3D printer company. Above all one factor will be most important – the people behind the company. Without a professional, experienced, and totally dedicated team driving it forward, any new amazing technology cannot make it. At Formnext 2018 we will see who and which technologies are making the best progress.

All parts below were printed with BigRep Large Scale 3D-Printing Technology

Gil-Lavi-115x115

With over 22 years in the printing industry, Gil Lavi is a Sr. 3D-Printing Specialist with vast experience in implementing diverse 3D-printing technologies in design and manufacturing processes.

Connect with Gil on Linkedin HERE.

Cutting up to 80% off Large Metal Part Production Time: Sand Casting Using Large-Scale 3D-Printing Solutions

Sand Casting

In our first two articles about large-scale 3D printing applications we covered Fit-Form-Function and Molds & Tooling. This time we will examine the benefits of integrating 3D printing into the Sand Casting process.

What is Sand Casting?

Sand Molded Casting, also known as Metal Casting, is a process by which a special mold from sand is created to form metal objects at very high temperatures. The technique is widely applied in heavy industries such as Aerospace, Automotive, Railway and Shipping as a solution for short-run production. Here’s how it works:

flow-chart

The Sand Casting Process

Sand Casting is a relatively simple process enabling manufacturers to produce metal objects. However, there are several challenges involved, including:

  • High costs
  • Manual labor required
  • Lengthy process duration
  • High margins of error
  • Limitations in producing complicated patterns

How can large-scale 3D printing help?

Traditionally, the replica is made manually using different materials types and techniques. The process is not 'digital’, meaning it takes longer to complete and can result in accuracy issues.
Integrating large-scale 3D printing into a sand casting process offers the following benefits, as compared to a standard sand casting process:

  • Reducing replica and pattern production time
  • Creating a highly accurate replica from a digital file
  • Significantly lowering costs
  • Replica design flexibility

These advantages are even greater when the pattern-making process is done in-house instead of being outsourced. Production time can be reduced by up to 80%, once the process is fully managed and controlled internally.

Learn more about modeling, building and testing custom products fast and cost-efficiently.

Gil-Lavi-115x115

With over 22 years in the printing industry, Gil Lavi is a Sr. 3D-Printing Specialist with vast experience in implementing diverse 3D-printing technologies in design and manufacturing processes.

Connect with Gil on Linkedin HERE.

Launching the BigRep Innovation Award – Open Call to Canadian Students

After much work across months and time zones, we are thrilled to launch the inaugural BigRep Innovation Award in cooperation with our partner NOVACAD Systems. The Award is an open call for Canadian students to submit an innovative 3D printed chair design, in pursuit of seeing their creation made a reality on the BigRep ONE and a C$3,000 cash prize. The winner will be decided by our four-person expert jury, following a public vote.
We looked to two of our jury panelists to provide some inspiration and direction to potential entrants on designing for 3D printing: NOVACAD Systems’ Gregor Ash and BigRep’s very own Amir Fattal. They shared their insights on how large-format 3D printers are changing the rules of furniture design and production, and offered some wise advice on harnessing the potential of the technology.

Amir,do you have any tips for young designers as they approach designing a chair for 3D printing, i.e. finding inspiration for structure, colors, materials?

3d-printing-inspiration-object-chair-stool-sofa

The Ocke Stool. Take a seat, and get inspired

Amir Fattal: First, I would really try to understand the technology - what its advantages and disadvantages are - and then I would try to work to its strengths. In the case of FFF, a key advantage is that you can realize complex geometric structures with internal features as intricate as those on the outside.
Sometimes building a support structure is a method of making it possible to print at a certain angle. If you can avoid that need with a clever bit of design or, if needed, build the support structure in a smart way, this can help increase the quality of the final print. I draw design inspiration from a number of design sites, such as de zeen and Design Boom.

How do you see large format 3D printing changing manufacturing and design?
Gregor Ash: Well, just the name entails the fact that designers are now able to produce their designs at near full or full scale, which is a huge game changer. They've been relegated in the past to smaller models and having to do testing on a very small limited scale. So, this combined with some incredible things happening with materials and that fact that designers are able not only just to prototype, but also to produce finished products, will change the way people conceive and produce their ideas.

3d-printed-sofa-chair-bigrep-large-scale

Another demonstration of the diversity of forms which can be 3D printed

Do you have any tips for the latter stages of the design process? What do entrants need to make sure they get done/avoid falling into/focus on as the submission deadline closes in?
Gregor Ash: We're looking for design and function as well – the whole idea of ergonomics and comfort. So, having a sense of how conceptual design from an aesthetic point of view connects to the concepts of materiality, in terms of how the item is constructed overall and going to hold together, is essential.

What is the most exciting design/object you have seen printed recently on a BigRep ONE? 
Amir Fattal: One of my favorite designs is the Ocke Stool that was created in-house by our designer Beatrice Mueller. This is a design which utilizes the steepest angle you can print in FFF without using a support structure. The design grows from the print bed upwards in a very similar way to how a natural structure like a tree or leaf develops. The print emerges directly from the machine as a complete chair, needing no other post-processing.

Ocke-stool-design-award-apply-now

The Ocke Stool: clearly thought out and executed

More information about the Innovation Award, including entry requirements and student resources, can be found HERE.

Advanced Applications: Molds & Tooling – Large Scale 3D Printing

In the last article we discussed the use of large-scale 3d printing in design and concept modeling processes. It is now time to examine more advanced applications. As heavy industries look for ways to save costs by implementing 3D-Printing in short run production/manufacturing, we turn to the question of whether and how large-scale 3dp solutions can face this challenge.

"But large-scale FDM 3d-printing is not there yet," you might say. "How can one use this technology to produce end use parts?" Well, not only is it possible, but it also has the potential to solve unique challenges manufacturers are facing today with production of large objects.

All parts below were printed with the BigRep Large Scale 3D-Printing Technology

MOLDS AND PRODUCTION TOOLING

3d-printing provides developers and manufacturers with an efficient way to produce one or several custom design products. In the following example, a large mold was printed and was used as a lay-up tool for a composite structure to produce the final part. Here's an overview of the process:

Mold1

Step 1 – Printing a large-scale mold

Mold2

Step 2 – Coating & post-processing

Mold3-2

Step 3 – Carbon fiber sheet coating

Mold4

Step 4 – Resin injection (vacuum infusion)

Initial production was completed with injection of the resin into the mold. After post-processing and finishing it was installed on a racing car as a fully functional end use part:

Race-Car-BigRep-1

THE BENEFITS

  • Achieving higher accuracy compared to non-3D printing methods when working with wood and foam
  • Drastically shortening the production time of an end-use part
  • Making considerable cost savings compared with producing the same part with a CNC machine.

ANOTHER GREAT EXAMPLE

A fabricated forming mold to produce a new bus lighting panel design, using a similar process:

BusTech1

Step 1 – Printing a large-scale mold

BusTech2

Step 2 – Producing the end use part

THE BENEFITS

  • Shortening production time by 50% compared to working with CNC
  • Costs lower than they would be using alternative techniques or other more expensive 3D printing technologies

Learn more about modeling, building and testing custom products fast and cost-efficiently.

The Benefits of Using Large-Scale 3D-Printing Solutions

Motorcycle body as a large-scale 3d printing solutions

One of the latest solutions to arise in the 3D printing industry is large-scale printing. Large 3D printers are mostly based on FDM technology and by their nature affordable, easy to use and to maintain. The most popular available material is PLA; easily accessible and with few printing challenges. Additional materials are available with better mechanical properties for more advanced applications.
Now comes the obvious question: who could enjoy the benefits of large-scale 3D printing and what are the benefits of using it?

All parts below were printed with BigRep Large Scale 3D-Printing Technology

DESIGN & CONCEPT MODELING


Once size limitation is no longer a factor, large parts can be produced at very low cost to simulate large products. Post-processing will bring the final model closer to the original product, and some of printed elements can be used as an end-use product.

Bathtub

Bathtub after Post Processing

Ocke-Stool

The Ocke Stool

Children-Lamp-1

Children's Room Lamp

THE BENEFITS

  • Shortens the time from idea to a full-scale prototype, compared to alternative non-3D printing manual techniques (working with wood, foams, fiberglass)
  • Considerable costs saving
  • Freedom to design unique geometries and to create tailor made products.

FIT-FORM-FUNCTION

Printing of one large full-scale part or several individual parts that are assembled to a prototype of a large product or device.

Driving-Seat

Driving Seat

MRI-Machine

MRI Machine

THE BENEFITS

  • Produce a prototype of the final part/product to perform fit-testing with other parts, design verification and basic functional testing
  • Accelerating design and manufacturing processes
  • Save costs compare to alternative solutions

Learn more about modeling, building and testing custom products fast and cost-efficiently.

ENTERTAINMENT & ADVERTISEMENT

This is another example of an industry that traditionally produces models and objects in a manual process using different techniques. Using a large-scale 3D printer enables the creation of unique marketing and promotional elements.

StudioDesk
Rocket
3D Printed Illuminated Sign

3D printed sign

THE BENEFITS

  • Traditionally all parts and models in this industry are made manually. Large-scale 3D printing dramatically reduces manual labor, saves time and costs compared to traditional processes
  • Offers freedom of creativity to design and produce customized products and elements
Gil-Lavi-115x115

With over 22 years in the printing industry, Gil Lavi is a Sr. 3D-Printing Specialist with vast experience in implementing diverse 3D-printing technologies in design and manufacturing processes.

Connect with Gil on Linkedin HERE.

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