HOW TO: 3 Steps to Hide the Seams and Become Design Leader

Hiding the seams with Marco

Why is it important?

If one has a good knowledge of slicing software, they can reach a higher quality of the printed object. That naturally influences the general outlook of the one. Important aspect of the final print are the seams. They might spoil the effect of the design. The continuity of the print can be lost at start and end points of every layer. Hiding the seams is important in case of creating a prototype that is true to the final product as possible. Furthermore, it’s especially meaningful if you want to print the ready-to-use objects with important details.

In 3D models a slicing program transforms the model into G-code. The code includes any preferred optimizations and parameter changes. Thanks to that, the person printing the object has much more control of the quality and final outlook of the print. If the software is not set up properly, it automatically generates random starting points in different locations. That can affect the quality of the print. However, when the settings can be changed. It means that user can also change the whole project into one united object. That includes hiding the seams or unwanted curves.

In BigRep we understand the need for the best possible finish effect of the project. That is why we try different slicing methods, to find the perfect one and apply it for the full print height. In our case it is very important due to the large-scale printable quantity.

The tutorial


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The tutorial explains how to avoid this problem and how to, using Simplify3D slicing software, step-by-step generate optimal start points. Marco Mattia Cristofori, the Architect and 3D Printing Specialist at BigRep, explains that a few additional modifications of the start and end location of the layers can make it sure that the seam is created in an optimal spot on the print. Often there is a natural groove or corner in a print that is a hiding spot for the seam. For example, on the manifold pictured and printed on Bigrep STUDIO, the curve on the right-hand side covers up the seam nicely. “We can make the seams follow the exact path we want them to follow,” said Cristofori. “So, instead, we can optimize this when we generate the G-code”.

hiding the seams

3 STEPS TO HIDE THE SEAMS

You can hide the seams on your print in 3 easy steps:

1) Import your model on Simplify3D and figure out how many processes you need to split the part in. Make sure the seams follow the path you want.

2) Edit singularly each process on the LAYER section changing the X & Y setting where the seams should be set up closer to.

3) Slice the part generating the G-code and check for possible improvements. Try different variation of the X & Y settings until you achieve the result you need.

However, Simplify3D is not the only possible tool. The list and description of popular slicing software can be found here.

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From 3D Scanning to 3D Printing – Finding 3D Solutions in Florida

3d scanning - Neometrix 3D solutions

When it comes to finding an individual solution for various Floridian industries, NeoMetrix is a go-to name, providing 3D scanning and engineering services. Surrounded by around 19,000 manufacturing companies, they have found a way to stand out in this sunshine state. Being active in a handful of major industries and knowing how important it is to understand the specific needs of their customers, they were bound to be a great fit for the BigRep reseller network.

It has been 15 years since Dan Perreault launched NeoMetrix Technologies, Inc. As the President & CEO of this Orlando-based company, he started out as a reseller of one of the world’s leading producers of 3D scanners and providing engineering services.  His experienced team offers a range of services and supplies from scanning and tooling to prototyping and designing.

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Perreault describes the company as a solution-oriented organization. “We don’t want to sell boxes, we want to offer real solutions to companies,” he said. In terms of improving their productivity, the BigRep printer gives them not only larger format prints, but also reduced costs of materials, compared with other filament providers. For NeoMetrix, the BigRep STUDIO has turned out to be the perfect tool for expanding their cooperation with customers. “With BigRep,” Perreault continued, “the overall cost of machine ownership is much lower than competitive systems.   It’s our position that this attribute will allow more customers to take advantage of this technology.”

3d scanning of a statue

Florida is an ideal environment for working in the 3D printing industry, thanks to the broad array of industries operating out of the southern state. Perreault said, “Thinking of Florida you think… theme parks!” Indeed, this magical place opens many windows for large-scale 3D printing. “We definitely have a lot of opportunities in the entertainment industry. There is also a large aerospace presence here too.” In addition to that, NeoMetrix is active in the automotive, manufacturing and education fields, and have a wealth of experience working on projects for art and sculpture-making using 3D scanning and printing technologies.

The importance of having the knowledge and experience in the 3D scanning industry cannot be understated – it has helped make NeoMetrix one of the 3D leaders in Florida. It’s not only their excellent service in a diverse range of fields that makes them unique in the market, but also the customer-focused attitude they have. The depth of understanding their customers’ values and demands has put them in the perfect position to demonstrate the business benefits that come from large-scale 3D printing.

“We want to understand what it is customers want to do, how are they doing it now, and how we can help them do it better – and perhaps the BigRep way.”

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Driving 3D Printing into Future Factories: BMW Group Personal Mover Concept

Personal Mover Concept by BMW research center

As a result of improving technology, our world and our everyday lives are going through drastic changes, particularly in regard to mobility. We can drive, we can fly, we can cruise and we can innovate – we’re moving in completely different ways according to our shifting needs.

bmw1

To make the working lives of their employees easier and more efficient, renowned global automaker BMW Group has created the Personal Mover Concept. BMW Group Research and Innovation Center in Munich designed this impressive electric one-person means of transport. The idea behind such a unique project was simple:

Employees at BMW Group plants and logistics centers sometimes cover up to 12 kilometers per day on foot – and having to carry small parts and work materials often makes it even harder. Sites such as the BMW Group Research and Innovation Center in Munich or the BMW Group plants in Dingolfing and Spartanburg are sprawling campuses, where many employees have to cover huge distances to do their jobs. (source)

The thought was, why not sort a solution for that? Or, to take one step further, why not use additive manufacturing technology to print a solution?The Personal Mover Concept is 60 cm wide and 80 cm long, so even with one person on board, there is still a space for long or heavy objects. It can reach speeds of up to 25 km/h and turn on the spot to the left or right up to 90°. The handlebar contains the entire electrical system, the battery and the drive wheel. Having in mind the safety of users and pedestrians, the Personal Mover Concept includes a bell, brake and a dead man’s control. One of the most innovative facts about this object is that the handlebar stand has been 3D-printed on the BigRep ONE. As Richard Kamissek, Head of the Operations Central Aftersales Logistics Network department said, “It had to be flexible, easy to maneuver, zippy, electric, extremely agile and tilt-proof – and, at the same time, suitable for carrying objects. The Personal Mover Concept can do all of this – and is also fun to drive. We hope to start using it as soon as possible!”

BMW Plant Commuter

Being a part of this innovative idea is not only making us proud, but also giving us food for thought. If, thanks to 3D printing technology, mobility advancements are helping us improve the automotive, aerospace and electric vehicle industries, are there any limits for how far transport can go? Large-scale 3D printing can truly change the way companies innovate. We see everything from prototyping to the whole production process, where 3D-printed objects are present in everyday life and being used all over the world. Starting with factories, we expect to see these kinds of mobility tools in use at airports, shopping malls or warehouses.

3D printing can improve our environment in faster, more cost-efficient and creative ways. That makes it the ideal technology for supporting the mobility innovations and creates a range of the excellent opportunities for various industries. We were thrilled to learn of this smart project, and we cannot wait to see what tomorrow will bring for the 3D printing industry, BMW Group and for the entire network of BigRep customers and partners.

Bosch Rexroth and BigRep Announce Development Partnership to Introduce New Dimension of Industrial Additive Manufacturing.

Bosch Rexroth and BigRep Announce Development Partnership to Introduce New Dimension of Industrial Additive Manufacturing.

Technological advances and integration will establish 3D printing as an industry 4.0 application.

BigRep, the global leader in large-scale 3D printers, and Bosch Rexroth, one of the world’s leading suppliers of drive and control technologies, today announced a development partnership: For the first time, 3D printers by BigRep will be equipped with state-of-art CNC control systems and drives by Bosch Rexroth, firmly establishing Additive Manufacturing as a key industry 4.0 application in industrial production technology while also making 3D printing a truly IoT-ready “made in Germany” machine with full connectivity and data.

“Across industries, customers are looking for reliable, controllable and efficient 3D printers in order to manufacture top quality parts”, says BigRep CEO Dr. Stephan Beyer. “As BigRep is the first to integrate CNC-grade control systems in 3D printers, we will re-define Additive Manufacturing. The Rexroth controls are also an excellent platform for providing our 3D printers with full connectivity for existing production and automation systems. This will establish 3D printing as a key industry 4.0 application.

” Thomas Fechner, Director of the Business Unit New Business at Bosch Rexroth, says: “This partnership demonstrates that Bosch Rexroth is constantly developing sustainable technologies and new factory automation solutions for the Factory of the Future.“

Additive Manufacturing is establishing itself as a manufacturing technology for the Factory of the Future and has already had a significant impact on prototyping and small serial production. Bosch Rexroth, too, is committed to this innovative technology. On the one hand, the specialist for drive and control technologies is using the process to enable the fast and cost-efficient creation of models, patterns, prototypes, tools and end products. One the other hand, the company offers 3D printing components and solutions.

By combining the experts in drive and control technologies with the experts in large-scale 3D printing, the additive industry will see faster and more cost-efficient creation of models, patterns, prototypes, tools and end-use products. BigRep and Bosch Rexroth are committed to reshaping manufacturing.

About Bosch Rexroth
As one of the world’s leading suppliers of drive and control technologies, Bosch Rexroth ensures efficient, powerful and safe movement in machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation. With its intelligent components, customized system solutions and services, Bosch Rexroth is creating the necessary environment for fully connected applications. Bosch Rexroth offers its customers hydraulics, electric drive and control technology, gear technology and linear motion and assembly technology, including software and interfaces to the Internet of Things. With locations in over 80 countries, more than 30,500 associates generated sales revenue of 5.5 billion euros in 2017.

To learn more, please visit boschrexroth.com

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Two Swiss Experts Form a 3D Alliance

“Made like a Swiss watch,” says Daniel Broglie, CEO of Chromos AG to us when we call for a chat. “Right on time, 2PM!” It’s immediately reflective of the value the Swiss CEO – and indeed, perhaps Swiss businesses more broadly – place on precision and timing. As Broglie explains, Swiss companies across industries put huge emphasis on being the best in their field.

They tend to have strong research and development foundations and a lot of companies are highly specialized in what they do – they’re proudly niche, specialized. There’s the material competence, combined with the fact that many of companies do highly specialized tooling for automotive and other core traditional industries. Broglie explains of Swiss industry, “On the one hand, we have to think about production. But on the other side, we have to be thinking about how we can adapt for future success.”

With its beginnings as a 2D printer supplier and ink distributor, the Zurich-based Chromos AG may not have seemed like a clear contender to be a leader in the Swiss 3D printing field. Though it was the company’s philosophy of helping customers to transform their businesses that had them put on their large 3D glasses, so to say.

chromosag-02-web

“We help our customers to find new ways of working – to move from conventional ways of working into the future. It’s not just the printing or the hardware, it has to do with change,” said Broglie. It is this deep knowledge about the ways businesses can shift, strong partnership network and a robust contact base across Switzerland, that formed the basis for a powerhouse cooperation in the field of additive manufacturing.

Chromos AG has a history with Bern-based 3D printing experts Form AG, as supplier for them. It turned out the two companies had a mutual interest in BigRep machines and were brought together by BigRep’s Sales Director EMEA & LATAM, Ingolf Nachtigall. They decided to cooperate – finding Form’s strength in applications and using the machines, to be a good fit with Chromos’ customer consulting, sales and after-sales experience (provided by service division Imsag). “We were convinced that this is a really perfect match,” said Broglie. “We can benefit from each other and learn.”

Chromos AG and Form AG have gone on to found Plattform3, which is a 3D-printing-focused venture to consult Swiss companies on using large-scale BigRep technology to improve their production. Form AG is a pioneer of new technologies in a range of fields, including 3D modelling. Recently they worked on a fascinating advertisement project for the Samsung SSD 850 Pro internal storage device, in which they designed the Samsung Robot ‘Victo’ (watch the robo-battle ad here) and also printed a full-scale example of it on the BigRep ONE.

chromosag-03-web

Stefan Ingold, CEO of Form AG, is thrilled with the partnership with Chromos and BigRep and believes it can further convince Swiss companies that it is crucial to engage with large-scale 3D printing technologies as soon as possible. “Ensure your finger is on the pulse, and benefit from the sheer unlimited possibilities of 3D printing,” said Ingold. “3D is also about implementing visions: using technology to develop something unprecedented, exploring new horizons, reinventing oneself, and surprising and inspiring customers.”

Education is a big part of this, because additive manufacturing technologies are an investment for the long run, not a fad. Many Swiss industries are listening closely, but perhaps just not yet sold on the benefits for their business. BigRep is a proud partner with Chromos AG, Form AG and their Plattform3 in this process. “BigRep shares cool applications, and if this helps our industries to see the potential, then that is a great thing,” said Broglie of BigRep’s resources, such as blog articles, videos and use case e-books. “We feel BigRep really wants to understand what customers are doing. We like their partnership approach as well.”

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Lean on PVA, When You Need Support

PVA - 3D printing support material

Many of us wish our worldly worries could just dissolve away, but it never seems to work that way. Though if it’s about support structures for large-scale 3D objects, then BigRep’s PVA is the cure for all concerns.

PVA (polyvinyl alcohol) is commonly used in industrial 3D printers with dual-extruders, like the BigRep ONE, to provide support for an object with overhang issues. Some complex prints involving multiple extended overhangs (of over 45°) can only be performed by printing such a support structure. Otherwise, the printed structure would warp or simply collapse – nobody likes that.

BigRep PVA is unlike any other 3D printing filament on the market. It is non-toxic, odorless and easy to extrude, as well as being water soluble. The warmer the water, the faster it dissolves, so users can spend more time creating those tortuous prints and less time refining the results. Moreover, it has been optimized for improved melt flow characteristics, meaning users need not spend their precious time unclogging the hot end. A new video by BigRep shows how easy the process can be, as well as the quality prints resulting from PVA integration.

Wheel Rim

For complex geometries, PVA can be the ideal support structure to enable printing of angles over 45 degrees. Designed by Marco Mattia Cristofori, this 3D-printed wheel rim challenges aesthetic norms for such vehicle parts. The intertwining braces are designed such that they would not be possible with CNC and other traditional methods of milling a wheel rim. Furthermore, for Cristofori’s design, there was no need for manual post-printing curing, sanding, or grinding, thanks to the PVA support – it melts right off the final print.

3D Printed wheel rim

BigRep Longboard

3D printed on the BigRep STUDIO, this BigRep bionic longboard is a model of structural integrity and fascinating aesthetics. It was printed using BigRep PLA with PVA support and integrated carbon pipe, as designed by Beatrice Müller. Once the print had been soaked in water for 20 minutes, BigRep’s team was able to use a soft spatula-type implement to begin scraping the residue off the print.

Longboard

While BigRep already sells a range of high-quality, meticulously engineered 3D printing filaments through its online shop, there is always room for consultation on additional materials. When customers are looking for a specific kind of filament for a custom application, BigRep’s team is pleased to take on the challenge – read more about collaborations between BigRep and Deutsche Bahn, Etihad Airways Engineering and BASF.

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