5 Next-Level 3D Printed Drones That Are Pushing the Industry Forward

As the applications of drones varies and grows, it becomes more and more important to develop specific designs that are based on its particular function. A drone built for delivery requires different specifications than a drone built for surveying or image capture. 3D printing is driving this evolution of drone technology by providing access to affordable rapid prototyping and customization and allowing faster innovation to occur. Whether it’s for disaster relief, mapping, or carrying heavy payloads, a drone can better serve its function with the time and cost efficiency and attention to detail that 3D printing provides.

Here are 5 drone projects that have pushed the
boundaries with the help of 3D printing:

Disaster
Relief X VEIN Drone by Team ROK

After the Great East Japan earthquake and tsunami brought disaster on a massive scale in 2011, Yuki Ogasawara and Ryo Kumeda of Team ROK were inspired to create a drone built especially for disaster relief and search and rescue. A few years later they used 3D printing and generative design to create their x-shaped X VEIN drone. Because disaster aid presents its own specific set of challenges, the team used 3D printing to be able to customize their drone based on their exact needs.

The design features freeform curves, and a 3D printed lattice-patterned body for maintaining minimal weight while still giving it the strength required to operate in difficult conditions. X VEIN is able to fly within a 500 meter range and can be equipped with thermographic and infrared-imaging and capture images that can be viewed in real time to access remote or obstructed areas and help locate survivors. Because many of its parts are 3D printed, if they are damaged on a mission they can be re-printed and replaced on site. 3D Printing was a crucial tool to be able to have the level of design freedom necessary to build a drone with these specific needs and it ensures that the drone can be further customized in the future depending on the situation at hand.

CargoCopter
by KU Leuven Researchers

Built to deliver payloads over long distances, KU Leuven research team created the 3D printed CargoCopter, a hybrid drone that combines fixed wings and multi-rotors so that it can take off vertically, hover and then fly horizontally. It was designed to expand the range and speed of traditional multi-rotor drones and thanks to its hybrid nature can efficiently transition from take-off to long-distance flight. It can carry up to 5kg, has a range of 60km and can fly up to 100km/hour. The team used 3D printing to rapidly prototype over 3 years to arrive at this model and their designs were able to quickly evolve. Thanks to the customization flexibility of 3D printing they are able to optimize each new CargoCopter design based on the needs of its particular mission.

BLUEROV2
Submarine Drone by Blue Robotics

Aerial drones are not the only ones making use of 3D printing. When Blue Robotics set out to build their underwater drones, they needed parts that could withstand the harsh conditions of the ocean and had trouble sourcing ones that were durable enough and weren’t overly expensive. They then turned to 3D printing to be able to prototype their own parts at a much more affordable rate. Using 3D printing to prototype also led them to customize parts to fit their exact needs. The BLUEROV2 comes with a high definition, wide-angle low-light camera with two or four lights to illuminate the ocean around it. It can travel to a depth of up to 100 meters and is built to withstand currents. The ROV is designed with expansion and modification in mind, and is fitted with a customizable frame to accommodate a range of functions.

The tiny drone named Piccolissimo. Image source: PennToday

Piccolissimo
The Tiny Drone by Matt Piccoli from UPenn

In 2016, Matt Piccoli from UPenn’s School of Engineering and Applied Science designed the world’s smallest steerable drone “Piccolissimo”. The tiny drone comes in two sizes: one weighs 2.5 grams and is the size of a quarter, and the other steerable version is 2 grams heavier and a centimeter wider. It was 3D printed using lightweight plastic. It has two moving parts, the robot’s body and motor, which spins one way 40 times per second, and its propeller spinning 800 per second in the opposite direction. Its motion is determined by how quickly the propeller and body are spinning, which can be controlled by infrared signals. The drone can carry a load of up to one gram, like a small camera or sensor. Its size suggests that it would be a fitting model for surveying or search and rescue missions, as a few hundred could be used to cover more ground than a single larger sized drone.

The
Int-Ball by the Japan Aerospace Exploration Agency (JAXA)

The Int-Ball, or JEM Internal Ball Camera was built using 3D printing to float aboard the International Space Station taking video and photo documentation. The spherical drone arrived on the ISS in June of 2017 and weighs 1kg, has a 15cm diameter and moves with 12 propellers. The Int-Ball features both internal and external components produced using 3D printing and is designed to float in a zero-gravity environment with the ability to move autonomously or be maneuvered by operators on Earth. It is set to reduce the crew’s workload by 10% by taking on image capturing duties.


3D printing helps to redefine what is possible when it comes to exploring and achieving innovation in drone technology. Its efficiency in prototyping and customization make room for a higher level of productivity and imagination, improving the way drones are designed and manufactured. If you are looking to create the next innovative drone, 3D printing is essential to facilitating the most efficient and flexible production process.

See how Shapeways can help your drone business transition to 3D printing!

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Industrial 3D Printing for High-Performance Parts

One of the most exciting aspects of exploring our platform at Shapeways is learning more about how users on all levels are innovating today, and how you might be able to expand your own concepts and designs further through 3D printing. There are a variety of different, affordable services and products offered; however, one of the most important facets that must always be considered — from Shapeways to the entire 3D printing space worldwide — is materials. You can modify printers and write new software all day long, but without a good selection of feedstocks to choose from, quality results are nearly impossible.

BASF (known as a worldwide leader in development and production of chemicals) began partnering with Shapeways this year in providing new materials through their BASF 3D Printing Solutions subsidiary. Our new Powered by Shapeways platform enables users to choose from BASF’s Forward AM materials, expanding accessibility and options for high-performance parts.

The new material portfolio includes ­­­­­Ultrasint TPU01, Ultrasint PP, Ultracur3D RG 35, and HP High Reusability PP.

Ultrasint TPU01

Ultrasint industrial grade powders are meant for 3D printing complex geometries that are accurate, strong, and durable. This thermoplastic polyurethane material is suitable for 3D printing functional end-use components, and is recommended if you require excellence in quality and flexibility for parts, along with the following features:

  • High level of detail
  • Good surface quality
  • Recyclability (Ultrasint TPU01 offers up to 80% reusability ratio)
  • Airtight parts (down to 1mm wall thickness)
  • UV resistance
  • Hydrolysis resistance

Approved for contact with skin, TPU01 is popular in automotive applications due to the open lattice structure encouraging both heating and cooling for interior parts like headrests or seats. Materials can be customized for individuals, and especially in areas typically experiencing heavier loads. Many of the best advantages of 3D printing technology can be used with TPU01 in particular, to include exponentially less time spent in development, production, and assembly time — along with elimination of tooling requirements and cost. Texture can be customized in terms of hardness/softness, and a variety of accompanying finishing options are offered too.

Another unique
benefit of TPU01 is that it can be used to 3D print protective gear for
the automotive industry; for instance, a protective glove was created for
workers at Jaguar Land Rover, offering support to prevent injuries due to
repetitive tasks. This type of gear is strong, yet lightweight and can be
completely customized for the wearer, including special modifications for the
job requirements of the individual. Again, this design is possible due to the
flexible lattice structure of the material. While it is flexible, hardness can
also be customized during the design process.

3D printing is employed in many footwear applications these days, and by users of widely varying experience and resource levels—from leading sports shoe companies to designers fabricating elegant flats or heels at their studios or from home workshops. Midsoles typically represent the 3D printed portion of shoes, with TPU01 allowing for consumer-specific customizations for greater comfort — designed around the wearer’s step, gait, pressure, and support — whether for sports, running, or other needs. Shoes can be made quickly, affordably, and on-demand.

TPU01 can also
be used to 3D print midsoles that are eco-friendly, requiring less material, as
well as offering improved aesthetics and performance. Personalized touches can
be applied afterward with a variety of different finishes and color choices.

Download the material data sheet from this page.

Ultrasint PP nat 01

A polypropylene material suitable for rapid prototyping as well as large-volume production of smaller parts, Ultrasint PP is a popular and affordable plastic with good market recognition. This material yields parts with excellent quality, balanced mechanical properties, and liquid, hydrolysis, and chemical resistance.

Ultrasint PP is
meant for production of smaller components like fluid reservoirs,
interior and exterior automotive parts, air ducts and piping, clips, covers,
hinges, and more. Parts like sensor covers can be made for critical aerospace
applications also, with prototypes fabricated from the same material and
process as the functional part. Live-hinge and snap-fit “barb” fittings can be 3D
printed too, with options for color and surface.

Download the material data sheet from this page.

Ultracur RG 35

Ultracur RG 35 is a highly reactive photopolymer suitable for a variety of parts used for multiple purposes, to include:

  • Connectors
  • Snappers
  • End-use components

Recommended for parts that require rigidity, Ultracur RG 35
offers excellent resolution in printing, low shrinkage, accuracy, and both
speed and ease in production. 

Download the material data sheet from this page.

HP High Reusability PP

A material specialized for use in HP’s production-grade Multi Jet Fusion 3D printers, HP High Reusability PP is suitable for making parts that are chemically resistant like piping and fluid systems, as well as automotive parts for the interior, exterior, and under the hood.

Download the material data sheet from this page.

Here at Shapeways, we have always offered a rich foundation for providing a wide range of materials suitable for industrial use. And while there are certainly no rules within the 3D printing realm about using (as well as continually developing) and experimenting with materials, our partnership with BASF has yielded a treasure trove of quality materials for the automotive industry, as well as for critical applications used in aerospace, architecture, and medicine. Recently, our team has also focused on offering 3D printing for robotics and drone applications.

Whether you are a busy designer or an engineer hoping to have a prototype or functional part 3D printed quickly, you will find an inspiring range of materials available at Shapeways. Without having to invest in industrial printers or materials on your own, you can benefit from our long-term experience and investment in proprietary, advanced technology.

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Kickstart Your Innovations With 3D Prototypes

The advent of crowd funding has opened up an entirely new model for bringing innovative products to market. And with the added advantage of 3D printing, crowdsourcing products as a path to the consumer market has become more effective, efficient and successful.

A Kickstarter Requirement

While there are multiple options and websites that function as crowd-sourcing platforms (i.e. asking customers to pre-pay or fund a new-to-market item before it goes into production to cover the upfront investment costs), Kickstarter is undoubtedly one of the most popular and utilized.

As part of their rules and regulations, Kickstarter requires a visual of the prototype along with a description and use guide. They also note that a graphical or computer-generated image of a product is specifically prohibited. Kickstarter requires that companies present a looks-like, functional working model as a prototype to both explain the product and to entice potential backers.

This is precisely why 3D printing has been such an effective and essential tool for companies looking to crowd source projects through Kickstarter. Other techniques for creating a working model may require substantial financial investment upfront, and/or increased working hours. Tooling, mold making, sculpting by hand as well as less effective techniques like “kit bashing” (mixing and matching parts from existing products to create something new) all lack the advantages 3D printing provides – custom-designed, precise and affordable models that can function as prototypes and final products.

So what type of products benefit from 3D prototyping for Kickstarter? The simple answer is – almost anything. 3D printing is not limited to any one category or industry, and can offer different benefits for different types of Kickstarter product pitches. Here are three examples from three different businesses that utilized 3D printing in their Kickstarter campaigns.

Customize Your Vision  

Boulton Eyeware’s custom-made eyewear. Image source: Boulton Eyeware.

Boulton Eyeware ran a successful Kickstarter campaign where they received a total of £35,000  ($26,000) to fund their pre-production costs. Their unique concept was based on one simple premise: every human face is different. Just as customers have fitted suits created for their bodies, Boulton felt there was a market for custom sunglasses for each individual’s face.

3D printing excels in customization, which is why Boulton Eyeware turned to this process, not only for their prototype, but for actual production as well. In order to create a working prototype to use on Kickstarter, Boulton went through 70 different concepts refining and changing their materials and finishing until a satisfactory model was achieved. It was the ease of use, cost effective process and robust selection of material that made 3D printing the right choice for their custom product.

Customized For Coffee Lovers

Fellow’s Stagg EKG Electric Kettle and Atmos Vacuum Canisters. Image source: Fellow

The ability to experiment with functionality is another major advantage to using 3D printing for Kickstarter prototypes. Fellow started as a class project that blossomed into a startup business based in San Francisco. Their simplistic goal: to create the world’s best cup of coffee. 

Dubbing themselves “coffee loving nerds” the team at Fellow led by founder Jake Miller found inspiration from across the globe and throughout history. They reviewed coffee pot designs from as far away as Scandinavia, as well as mid-century industrial designs.

Where 3D printing came into play was in the functionality
aspect.  In order to find that perfect
design that would brew and pour the coffee of their dreams, Fellow engineers
made hundreds of 3D prototypes, constantly changing, modifying and updating
their design to achieve the ideal result they wanted.

Using 3D printing not only provided a cost-saving measure with the ability to constantly change designs at a low cost, but it allowed them to see how their product would take up space in kitchens and countertops. By working in 3D, their designs could be reviewed both functionally and aesthetically in the real world. It became much easier to review a physical model because it was to scale, letting designers hold, manipulate and brew coffee using their 3D printed models.

Getting into the
Action

Valaverse’s action figure. Image source: Valvaverse

Turning to the toy category, Bobby Vale, a former designer at Hasbro, saw a hole in the consumer market for 6” highly articulated action figures that represented military soldiers and the different divisions of our service men and women.

Aiming to please the discriminating “adult collector” who looks for features such as sculpting detail, paint deco and above all a large amount of articulation points (for posing and display), Bobby was set up for success. He modeled his Valaverse military figures off of the successful Marvel super hero products he worked on in his previous position. 3D printing became the key tool to show off these features to potential funders on Kickstarter.

Both the durability and flexibility of 3D printing were important factors in creating the Valaverse 3D prototypes for Kickstarter. In order to show off the high level of articulation, each part needed to assemble and work just like a mass-produced action figure. The materials offered by 3D printing not only permitted his prototypes to articulate, but they could assemble and function exactly as finished products would. This permitted the most accurate and true-to-final prototype to illustrate his Kickstarter concept to potential backers.

All the Features You Need

3D printing is becoming more and more the go-to technology for prototyping visual models for crowd-funded campaigns.

At Shapeways, we offer 3D printing benefits that go above and beyond what consumers may find elsewhere. In addition to a vast selection of materials (over 75!) and the best quality checks by 3D printing engineers, printing with Shapeways requires no equipment to purchase or maintain. We handle all of the fast turnarounds and deliver exactly what you need to succeed for your campaign.

Whether you are looking for customization, to test out functionality, or demonstrate features that work like finished goods, 3D printing can be your best solution. The Shapeways team is here to provide all of your 3D prototyping needs in one place.

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LuminoGO: Comfortable and Sustainable 3D Printed Face Mask

LUMINO was founded by Bernhard Neuwirth, Michael Marcovici and Nadine Damblon to provide a new type of face mask that would be comfortable and reusable. The LuminoGo mask allows the wearer’s face to be fully visible and sterilizes breathing air with UVC light or with an integrated filter. Using Shapeways’ services to 3D print nearly all of the parts for the mask, the LUMINO team was able to prototype quickly and affordably with different material and color options.

We interviewed Bernhard Neuwirth, CTO of LUMINO, to understand how they utilized Shapeways’ 3D printing technology and services to develop their innovative face mask.

Can you take us through the start of LUMINO?

When the pandemic
started in China, my business partner Michael Marcovici and I, were in the
business of freeze dryer production. Our business slowed down immediately, as
we could not get many needed parts anymore. While we have been in lockdown in
Austria we started to look into the mask market and the various designs.

LuminoGO – UV-C based ventilated sterilizing mask. Image source: LUMINO

How has the pandemic influenced your business decisions?

The pandemic certainly was the reason for us to look into mask design and technology. But LUMINO was certainly not created just for the pandemic, we believe the design solves many problems of current masks on the market. The currently used masks in urgent care are one-way disposable. We want a product that is nice to wear and sustainable.

Who are LUMINO’s customers?

The LUMINO mask is
a very versatile product and has up to 16 different configurations, its use
ranges from hospitals to sales personnel, from bartenders to public services
and many more. LUMINO can be configured to sterilize in one or both ways (in
and exhale) it can be equipped with ventilators for fresh air and easy
breathing. It can be used with traditional filters as well as our own developed
UVC light module that kills germs with ultraviolet light.

Shapeways was helpful in every way from early on in the project. I especially liked the very fast production options, the choice of materials and the amazing quality of the product.

Bernhard Neuwirth, CTO of LUMINO

Which parts of LUMINO’s products are 3D printed? Why did you choose to 3D print them?

Almost all parts
are 3D printed. The main reasons for us have been fast prototyping, fast
production, choice of materials and colours, which is important for branding
and personalization. The big difference with competitors is that we have
already working prototypes.

LuminoGO in multiple colors. Image source: LUMINO

What is the benefit of using Shapeways over more traditional manufacturing methods?

Shapeways was
helpful in every way from early on in the project. I especially liked the very
fast production options, the choice of materials and the amazing quality of the
product. Traditional production methods would be injection moulding. We will
certainly do that in the future. Meanwhile we produce already, while optimising
the product. We use 3D-print as a production method.

What 3D printing materials do you use and why?

We mainly use Nylon in SLS (Versatile Plastic) as material. It is cost-effective, high resolution, heat and moisture resistant, and nearly unbreakable. Furthermore there is no allergic reaction with the human wearer (good biocompatibility).

How did you find Shapeways?

I’ve known
Shapeways for many years as one of the top addresses for 3D printing, so we did
not need to search actually.

How has Shapeways’ speed of manufacturing helped with your production process?

We had about 4
iterations of prototyping, most of the time we used the fastest production and
shipping option and have saved overall probably a month in development time.

What is the most important aspect of working with Shapeways for you?

We wanted a
partner that can deliver even in difficult times. We were amazed that all the
delivery was on time and that we could easily reach sales to get support.

What are some of LUMINO’s ambitions for the future?

The aim of the [Indiegogo] campaign is to get to the market, meet the minimum order quantity for many of the electronics parts of the product and get certification for the product in the main markets.

Prototype with Shapeways

Because 3D printing offers such a quick production turnaround, the LUMINO team was able to prototype and create their face mask in a very short amount of time. This allows them to very quickly circulate a new mask that maintains visibility, comfort and safety for anyone working in close contact with others.

Do you have your own innovative ideas? Upload your design and start printing with Shapeways now.

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Why 3D Printing Is Key For Mass Customizable Products

luxmea face mask variations
LuxMea’s customized face masks. Photo source: LuxMea Studio

Consumers in today’s market expect more and more for their products and experiences to be tailored to them, and to have more control over what they pay for. The challenge in meeting that demand for mass customization is having to switch from producing hundreds to millions of the same item to efficiently producing small batches of personalized items within a similarly short time frame without costs going up astronomically. Additive manufacturing helps maximize efficiency in making large-scale personalization more accessible.

Customer-Led Designs

Companies that use 3D printing for customization set up design interfaces to allow customers to make their own design choices in regards to color, texture, material or fit. For example, some automotive companies have given their customers the ability to choose their vehicle’s colors or include personalized lettering on the interiors. Any product can potentially be customized according to what suits the buyer: cars, furniture, fixtures, jewelry and more.

3D Scanning for a Perfect Fit

With 3D scanning software becoming more prominent and user-friendly, it is easier than ever for customers to contribute to the design process themselves. The footwear industry is making use of 3D printing technology, allowing customers to make aesthetic choices for their shoes and also to personalize their insoles based on their specific foot shape, weight or running style. Customization is also becoming a standard in the tabletop gaming industry, with more and more companies offering customizable game pieces.

A smart-phone app can take a scan of a person’s face or other body part and generate a 3D file that can be used to create a product that fits them perfectly. LuxMea has used this technology to produce face masks that are not only aesthetically customizable but also provide a perfect fit for the individual wearer, making them safer and more comfortable.

3D scans can be used to personalize earphones, shoe insoles, eyewear and many more products thanks to 3D printing technology. This ability to creatively participate in the design process boosts customer satisfaction, as the ability to have more say in what they spend money on makes the process more fun and efficient for the users.

Customization
to Improve Lives

Advances in 3D scanning technology contribute heavily to the medical industry, an area where personalization can be crucial. With the ability to scan specific parts of the body, more accurate and patient-specific improvements can be made to someone’s health and wellbeing. 3D printing allows for more affordable and personalized prosthetics, implants and other aids ensuring a higher level of comfort and support. This is an area where perfect fit as well as timely delivery can be of the utmost importance to the success of medical devices and equipment. 3D printing is able to surpass the limits of traditional processes because of its ability to produce highly complex parts quicker. Customization also improves the instruments and supplies that physicians use, making them more efficient and comfortable and improving surgical outcomes.

Understanding Preferences and Trends

By allowing customers to make more of their own choices, the process provides key insights into trends and consumer preferences. Customers’ tastes can be used to help companies evolve their products and make product developments to fit the needs of their customers.

On-Demand
Manufacturing

Another benefit of using 3D printing for customized products is a shift towards more on-demand production. By placing more emphasis on smaller personalized products instead of mass-produced products before orders are received, inventories can be reduced and a substantial amount of waste can be avoided. This can save money in material costs and create a more sustainable manufacturing process.

The 3D printing industry is growing at a very fast rate, and is making it easier to transition to using 3D printing over traditional mass production methods as time goes on. However, the transition can still be expensive and time consuming. 3D printing services like Shapeways can ease that transition by giving you access to high quality manufacturing as well as tailored e-commerce support. Let us know how we can help with your mass-customization needs.

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How 3D Printing Helped Atlas Games Achieve Kickstarter Success

For over three decades Atlas Games has been in the business of fun. As a game innovator, their focus has been on tabletop play, including traditional card games, board games and roleplaying games.

Their latest endeavor Dice Miner is a dice-based game that for the first time in the company’s history was pre-sold through a Kickstarter campaign. Because of the high expectations Kickstarter funders have, an early visual of the product was necessary to show off the new game to potential backers.

In order to create these visual components, Atlas Games sought out our 3D printing services to prototype the game pieces they needed, and were able to utilize 3D printing for fast and cost-effective solutions from early prototyping to final-stage designs.

Jeff Tidball, Chief Operating Officer of Atlas Games, has a deep passion for games. For a look behind the scenes at Atlas Games’ newest creation, we interviewed Jeff to find out how the advantages of 3D prototyping was critical for Dice Miner’s Kickstarter success.

Could you give us a quick summary about Atlas Games as well as your latest game, Dice Miner?

Atlas Games is a tabletop game publisher with a 30-year history and deep catalog of board, card, and roleplaying games. We’re best known for card games like Gloom and Once Upon a Time. Dice Miner is a dice drafting game with 60 custom dice and a unique mountain component that organizes the dice across each game’s three rounds, showing which dice are available to choose at any given time as the game unfolds.

Dice Miner’s Deluxe Edition mountain. Photo source: Atlas Games

What was the purpose of using Shapeways to make prototypes for Dice Miner?

Dice Miner’s Deluxe Edition will have a plastic PVC mountain, so we used Shapeways to prepare early prototypes of that component. We used Shapeways for two purposes. First, to playtest using components as close as possible to the final version, to make sure they performed as we expected at the table. Second, to evaluate their producibility while holding physical objects, as opposed to needing to evaluate them only on screen, or in our imaginations. 

How did you come to the decision to use 3D printing instead of other manufacturing methods?

Other manufacturing methods, to produce only one or two copies of a component like Dice Miner’s Deluxe Edition mountain, simply do not exist. (Maybe we could have hired someone to hand-sculpt one? I don’t even know.)

Did you already have technical knowledge in 3D printing? If not, was there a learning curve to getting into this technology?

Prior to Dice Miner, I had done very little 3D printing for a previous game’s miniatures prototype, also with Shapeways. However, we had the help of a consultant we had hired to create our plastic components, so we were able to use his model directly to produce the prototypes we used. So there was not much of a learning curve, but that’s because we had hired folks to help us already.

3D prototype of Dice Miner’s Deluxe Edition mountain. Photo source: Atlas Games

What material(s) do you print in and why?

We went with [Versatile Plastic, which are] cheap and fast for our game components. We were looking solely at form and function, rather than having any particular materials requirements.

How much time and/or cost were you able to save by prototyping with Shapeways versus using another method?

I don’t really have anything like that [to compare], since the other options don’t really exist. I suppose you could think about the complete disaster that would arise if a $3,500 mold was created wrong — having a physical prototype can help avoid that instance. Although it’s a small change, spending one or two hundred dollars to hedge against that downside seems pretty reasonable. Creating early prototypes also helped us get an advanced copy to an outside previewer, which helped illustrate to potential campaign backers how the game is played. Waiting for copies of the game from the production line would have simply been impossible. Without a preview of the game, I suspect fewer backers would have been comfortable joining the Kickstarter. Again, no hard-and-fast metrics, but I suspect we’d have left money on the table without being able to preview the game in that way.

Dice Miner box set. Photo source: Atlas Games

Not only was Atlas Games able to succeed on Kickstarter, but they surpassed their goal by almost $80,000. Our 3D prototyping solutions were instrumental in this process by providing a simple and cost-effective means to creating a visual preview of the game.

And more importantly, game fans would now be able to “draft the dice” in Dice Miner with the empowerment that they helped make the game happen by supporting it on Kickstarter!

Are you creating a new game or product for an upcoming Kickstarter campaign? Find out how Shapeways can help with your rapid prototyping needs today.

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BASF Forward AM Materials: Ultrasint & Ultracur3d Comparison Guide

Shapeways is pleased to have partnered with BASF to bring you access to four Forward AM materials: Ultrasint® PP nat 01, Ultracur3D® RG 35, Ultrasint® TPU01 and HP High Reusability PP enabled by BASF. These durable and versatile materials facilitate a high level of design complexity and accuracy, producing functional, resistant prototypes and end parts with first-rate surface quality. Common applications for these materials include automotive, industrial, aerospace and consumer goods.

Here are some details on each of these four material
options, and a comparison guide to help with your material selection process.

Ultrasint®
PP nat 01

Ultrasint® PP nat 01

Polypropylene (PP) is one of the most commonly used plastics materials printed using Selective Laser Sintering (SLS) technology. Highly flexible and durable, it has a low moisture absorption rate and is resistant to most acids and bases, which makes it a great choice for parts with water contact. Ultrasint® PP nat 01 suits a range of applications from healthcare and orthopedic products to electronic and automotive parts and allows for post-processing such as thermoforming and sealing. It is a sturdy material that is well suited to industrial parts and production.

IDEAL APPLICATIONS:
Pipes and Ducts
Water Manifolds and Reservoirs
Economic and Functional Prototypes
Multi-Purpose Industrial Goods
Durable Jigs and Fixtures

Ultracur3D®
RG 35

Ultracur3D® RG 35

This rigid, medium viscosity photopolymer is great for printing high-performance, functional and multi-purpose parts using Stereolithography (SLA), Digital Light Processing (DLP), or Liquid Crystal Display (LCD) machines. Parts produced with Ultracur3D® RG 35 are able to maintain extreme accuracy. It is a solid, tough material and is recommended for functional parts such as air ducts, electrical sockets and connectors.

IDEAL APPLICATIONS:
Snapper
Air Ducts
Electrical Sockets
Thermoforming Molds
Connectors
Jigs and Fixtures

Ultrasint®
TPU01

Ultrasint TPU01

Ultrasint® TPU01 is a multi-use thermoplastic
polyurethane that typically comes in white and printed using Multi Jet Fusion
technology. It is a highly flexible material with excellent shock absorption,
making it ideal for footwear and other elastomeric parts. It is capable of producing
a high level of structural detail and intricacy and is UV and hydrolysis
resistant. It has excellent surface quality, high process stability and
throughput and its flexibility opens it to a myriad of uses that include
sporting goods and protection as well as interior automotive components and
orthopedic models.

IDEAL APPLICATIONS:
Sporting Goods
Footwear
End Use Automotive Parts
Lattice Structures for Custom Performance

HP High Reusability PP enabled by BASF

HP High Reusability PP enabled by BASF

HP 3D HR PP is a highly versatile and durable
polypropylene material. It is chemically resistant and has a low water
absorption rate, which makes it a great choice for piping, fluid systems and
containers. It is the HP 3D material that costs the least and is very easy to
process, which increases productivity and reduces waste. Because it is both cost-effective
and functional, the material is well suited for prototypes as well as end parts.
It is a highly flexible material that is weldable to other PP parts, expanding
its range of applications from the automotive industry to the consumer goods
sector.

IDEAL APPLICATIONS:
Piping and Fluid Systems
Containers
Interior and Exterior Automotive Parts

Material Properties: Ultrasint® PP nat 01, Ultracur3D® RG 35, Ultrasint® TPU01 and HP High Reusability PP

Take a side-by-side look at each of these
materials’ properties below:

  Tensile Strength X Tensile Strength Z Heat Deflection Temp (0.45 MPa) Tensile Modulus X Tensile Modulus Z Elongation
at Break X
Elongation
at Break Z
Ultrasint® PP nat 01 28 MPa 28 MPa 102 °C 1400 MPa 1400 MPa 30 % 10 %
Ultracur3D® RG 35 49 MPa 49 MPa 84 °C 1990 MPa 1990 MPa 4 %  
Ultrasint® TPU01 9 MPa 7 MPa   75 MPa 85 MPa 220 % 120 %
HP High Reusability PP 30 MPa 30 MPa 100 °C 1600 MPa 1600 MPa 20 % 18 %

Ready to give these materials a try? Upload your model here to get an instant quote.

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10 Reasons Product Designers Prototype With 3D Printing

Prototyping is a necessary stage in product development that can be time consuming and expensive for product designers, sometimes taking weeks-long chunks out of the development process. But as 3D printing technology has entered the scene, rapid prototyping has become its most popular application in all areas of design whether it be in jewelry, architecture or engineering, and more, because it facilitates the product design process considerably. Using 3D printing for rapid prototyping, designs can be tested and improved at a higher rate, therefore increasing production efficiency and cutting costs. Realistic iterations can be printed quickly for any stage of the design process, from a concept model to a functional prototype, and allow the designer to explore a physical piece to improve and avoid problems early on.

Want to learn more? Here are 10 ways rapid prototyping with 3D printing streamlines the design process:

1. Optimize The Design Using 3D Software

By creating the blueprints for the prototypes
and final design in 3D software, any edits or improvements to that design are
reflected accurately and promptly. The design can be visualized enough at this
initial stage to reduce any errors of communication and to make early
improvements that will save substantial time during the prototyping and
production stages. If the product or part requires customization, this design
can be revisited and expanded upon at any time.

2. Take Advantage of Form Freedom

3D design allows for the creation of complex geometries
that might not be as attainable in other processes. This allows for expanded
freedom in the design and the final shape of the product can only be limited by
the designer’s imagination. This flexibility makes it possible to produce a
professional proof of concept of innovative and original pieces without
sacrificing additional time or costs in the development process.

3. Save Time in Prototype Production

In traditional prototyping, the product designer or engineer would use materials such as cardboard, styrofoam or wood to create initial prototypes, then move on to creating functional prototypes using manufacturing processes typically used for finished products. This is often a costly and time-consuming process, and often not a practical use of resources when the product is still in the developing stages. With 3D printing, a prototype at any stage of the design process can be printed quickly and provide the exact information needed in that stage whether it is a proof of concept or a functional prototype. When developing a part, being able to reiterate quickly and affordably is crucial, and 3D printing facilitates that need for all stages of prototyping.

4. Save on or Eliminate Tooling Costs

3D Printing acts as an all-in-one production method for low-volume production and for rapid prototyping. The technology eliminates the need to gather other manufacturing components or machines. Manufacturing methods like injection molding are much more costly to set up, especially for small quantities, and make creating custom prototypes very expensive and time consuming.

5. Create More Time for Designing and Customizing

Instead of having to wait weeks for a prototype
to be constructed by hand or for a mold to be made, prototypes can be 3D
printed in a matter of hours or days depending on its size. It allows for
mistakes to be fixed more quickly and for the design to evolve at a much higher
rate, leaving more time for further innovation, customization or moving on to
the next design.

6. Save Time Communicating Ideas and Information

When a product or part is being developed, it is extremely important to be able to communicate without misinterpretation and to leave as little to the imagination as possible when discussing with a client or any other involved parties. 3D printed prototypes look more professional and can communicate details better than a 2D drawing. This enables more viable and specific feedback for revisions to be made quickly and efficiently. The better the level of information in prototyping stages, the better the final product.

7. Choose from a Wide Range of Materials Depending on Each Iteration’s Purpose

Different materials can be used based on different prototyping stages to illustrate or explore the integrity of the design. Early iterations can be printed in more affordable plastics such as our Versatile Plastic, while later, more refined versions can be printed in different materials to fit the specific needs or testing requirements of the product. Many of our materials are end-use ready, saving you the need to look for a manufacturer once the product is market ready.

8. Minimize Material Usage Where Possible

In initial stages of prototyping different printing methods can be used to save on materials. If a version of a prototype is meant to show the shape alone, for example, it can be scaled down and hollowed out. Lattice or honeycomb designs can be used for surfaces to cut down on materials and costs while still communicating key information about the part or product. The on-demand nature of 3D printing eliminates material waste during the prototyping stages.

9. Use 3D Printing Services for Prototyping

You can save a lot of money on equipment start-up costs by working with 3D printing services like Shapeways. By printing with a specialized service you do not need to own any printers or materials, your model will be reviewed by engineers before they are printed, eliminating trials and errors encountered when using your own machine. You are guaranteed a high level of quality control, the use of industrial-grade printers and should you need technical assistance, your inquiries will be answered by experts in the 3D printing space.

10. Use Realistic Prototypes for Marketing and Sales Needs

Once the final design has been revised and refined to satisfaction, realistic prototypes can be used to get a head start on marketing and sales promotions. A visual model of the product can be used before money is spent on manufacturing to test with potential customers, for use on a sales floor or to send your products to beta testers to help validate the design.

3D printing is a crucial tool for designers to facilitate a more efficient prototyping process. It saves time and money and also generates a higher level of design freedom, and improves communication with clients and prospective customers. By making the prototyping process faster and without sacrificing on quality, this helps design innovation maintain a competitive edge.

Ready to start prototyping your next idea, part or product with Shapeways? Upload your design now or get in touch with our team to discuss your unique innovation.

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The post 10 Reasons Product Designers Prototype With 3D Printing appeared first on Shapeways Blog.

Customize Drones with 3D Printing to Suit Your Business

Drones, or UAVs (Unmanned Aerial Vehicles), are a growing technology used in many different sectors and their designs must suit their specific application. 3D printing facilitates drone innovation by enabling design freedom, as well as fast and affordable prototyping and printing of parts. It is possible to 3D print many of a drone’s parts including the frame, propellers, the landing gear, protective equipment and casings for the electronic components.

With the cost and time efficiency that 3D printing offers, each of these parts can be optimized, customized and upgraded to suit the exact needs of the business it is serving. If you are using or considering using drones for your business, 3D printing has the potential to substantially enhance your drone’s function.

Cut
Time and Costs By Turning to 3D Printing for Customized Drones

Commercial drones can be highly expensive and out of reach for smaller businesses that rely on the use of drones to grow their business. 3D printing cuts costs in many different areas including prototyping, customization and manufacturing and therefore makes specialty drones more accessible. It also speeds up the design and prototyping process so that changes can be implemented and the design can evolve more quickly. Kespry, a company that specializes in drones for mapping and surveying, were able to successfully grow their business thanks in part to the affordability of 3D printing their drone parts. Prototyping and printing the covers for their drones’ electronic components cost substantially less than traditional manufacturing methods like injection molding.

Design
a Drone that Suits Your Business Perfectly

Even with the wide range of drones already out there, why rely on a ready-made drone that only suits some of your needs? If you need drones to transport supplies and other cargo, to perform reconnaissance in tight spaces or remote areas, or to catch stunning video footage from the sky, 3D printing can allow you to upgrade drones to suit your business specifically.

Optimize Your Drone Based on its Function

A drone transporting cargo would need a much sturdier, reinforced frame, for example, whereas an FPV drone carrying a small camera might benefit from a more lightweight body. Perhaps your drone needs to be weather resistant and be able to continue flying in unpredictable conditions. No matter what your business’s unique set of needs is, 3D printing allows you to make specific design choices.

Take Advantage of a Higher Level of Geometric Complexity

3D printing technology allows designs to incorporate a higher complexity, allowing parts to be produced more efficiently. Using 3D Printing, companies like Quantum Systems are able to consolidate their drone parts by taking advantage of the ability to produce more complex designs that integrate multiple functions into one part. This not only saves time and materials but also gives them the opportunity to add any needed features to their designs without compromising on the drone’s weight.

Prototype
Your Drone Parts

Prototyping with 3D printing helps make customizing drones accessible even to smaller businesses. The process allows for unprecedented speed and cost reduction in making sure your drone is the best it can be. Instead of waiting months to test new iterations, changes can be made to 3D designs within hours, then printed and shipped to you in days. Implementing changes quickly allows for a faster evolution of a design and to find exactly what is right for your business.

Print
Your Parts with the Appropriate 3D Printing Method and Materials

Selecting the right 3D printing technology and materials will depend on the drone. SLA printing provides a high level of precision and a wide range of materials to choose from. The material should be tough and versatile and be able to handle stretching, bending and impact. Nylon is another option as it is strong, temperature resistant and is also good for printing drone fuselages that resist collision damages.

Partner
Up with a Service To Achieve the Highest Level of Quality

For the most efficient printing process, it is important to have dedicated support and access to the highest quality results. Our services at Shapeways enable businesses of all sizes to develop specialty drones without incurring high equipment startup costs and navigating the trial and error of adapting to a new technology. That way your focus can be on your needs and your unique drone design while the production of prototypes and parts is taken care of.

            Drones are used for such a wide range of projects and functions that having specific enhancements to suit its purpose are hugely beneficial. Traditional manufacturing methods would have made unique alterations inaccessible to many smaller businesses but thanks to 3D printing, updating a drone’s design has limitless opportunities. Whether your business uses or produces and sells drones, customization will become more and more important and 3D printing is the best suited technology to facilitate it.

See how Shapeways can help you produce the best drones to grow your business.

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The post Customize Drones with 3D Printing to Suit Your Business appeared first on Shapeways Blog.

What’s In A Technology Name?

The good news is that a technology by any other name might perform as sweet, to riff off of Juliet’s centuries-old question — but we still have to ask: what’s in a name?

This question comes up all the time when
talking about manufacturing processes used today, especially those newer to
shop floors like 3D printing. (Or is that additive manufacturing…or rapid
prototyping?)

Let’s start at the beginning. This technology suite traces its current roots back to the 1980s when processes like stereolithography (SLA) and fused deposition modeling (FDM) were being developed. These technologies found their initial usage in prototyping applications, achieving faster results than traditional processes. As these and other layer-by-layer approaches developed and matured over the last few decades, applications evolved as well, including into end-use production.

Throughout this briefly laid out history, we
see several stages of evolution in both process and usage. At each stage, a
different name has been appropriate, growing along with the fledgling industry
surrounding these technologies. Now that we’re in 2020, though, and have four
decades of experience in this maturing manufacturing area, we’re able to take a
step back and look at what the best terminology is to use today.

3D
Printing or Additive Manufacturing?

A question that comes up a lot is simple:
“What’s the difference between 3D printing and additive manufacturing?”

At the simplest level of response, these terms
are often used interchangeably. Use either phrasing and anyone in the industry
will understand what you mean. But of course, there are ways to be more
accurate in discussing these processes, and more precise in nomenclature.

3D printing is the process of actually
building up a part, as a step in the overall additive manufacturing workflow.
Additive manufacturing itself can be seen to encompass the total process: CAD
design to slicing to 3D printing to post-processing to finished product. Rapid
prototyping would then be an application, rather than referring to the process
itself.

That’s one way of looking at it, and
understanding what is meant when any of these terms are bandied about.

Another way is in terms of the user. Additive
manufacturing is recognized as a more industrial term, and tends to encompass
expensive professional machinery being used in applications from prototyping to
end-use product production. 3D printing can refer to the process of
layer-by-layer building of an object, or more generally to refer to any usage
of this technology, from hobbyists using inexpensive desktop systems to
professionals using industrial equipment. Rapid prototyping was one of the
first terms used for these technologies, which in the 1980s were geared toward
the rapid production of prototypes and for a few decades so dominated usage
that this application was synonymous with the tech itself.

These conversations are ongoing, and opinions among experts are still fairly varied. When, for example, in working to understand viewpoints on the terminology of technology, I turned to industry professionals, responses extended from ease of understanding to familiarity of phrasing.

That conversation was perhaps best summed up by industry veteran Rachel Park, long-time journalist and currently a principal at PYL Associates, who said of 3D printing (3DP) and additive manufacturing (AM):

“3DP versus AM will not be resolved any time
soon, and like many others here, I often use them interchangeably depending on
application, audience and process being used. On that – I have noticed that
process names (re the 7 categories identified by ASTM) are being used more
frequently, to differentiate capabilities and applications for manufacturing /
production.”

3D
Printing Technologies

That leads into an important conversation in
its own right, as the different 3D printing processes each have their own
terminology to take into account.

Industry expert Terry Wohlers, Founder of independent consulting firm Wohlers Associates, which puts out the annual Wohlers Report, recently discussed the importance of terminology through the lens of industry standard phrasing. He brings up several key points in this Wohlers Talk piece, chief among them the very availability of industry standards.

ASTM International, which defines standards in
a number of industries including additive manufacturing, has been publishing
terms for AM to serve as recognized standards. The first version, as Wohlers
points out, was published in 2009 as the ASTM F2792 Standard Terminology for
Additive Manufacturing Technologies defined 26 terms. That work was
foundational for the current ISO/ASTM 52900 Standard Terminology for Additive
Manufacturing.

As laid out from that standard in Wohlers
Talk, the presently recognized seven AM processes include:

  • Material extrusion—an additive manufacturing process in which material is selectively dispensed through a nozzle or orifice
  • Material jetting—an additive manufacturing process in which droplets of build material are selectively deposited
  • Binder jetting—an additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials
  • Sheet lamination—an additive manufacturing process in which sheets of material are bonded to form a part
  • Vat photopolymerization—an additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization
  • Powder bed fusion—an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed
  • Directed energy deposition—an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited

Different companies, of course, refer to
technologies that fall under these umbrellas by proprietary names. Think of the
ongoing conversation regarding FFF v. FDM (that is, the common term Fused
Filament Fabrication versus the trademarked Fused Deposition Modeling), both of
which effectively refer to the same process and are in fact classified as
material extrusion.

Seeking to differentiate may lead many a
company to brand copiously; why say the standard “material extrusion” when they
could tout FFF, which as an acronym may sound more intriguing — or, if that
branding is from Stratasys, why not further herald FDM, which is trademarked
and is one of the original 3D printing technologies invented decades ago.
There’s certainly something to be said for standing apart from the crowd by
owning a process name.

Still, it absolutely comes across clearly to
everyone what sort of process is up for discussion when the term is universal;
material extrusion will convey just what’s meant quite neatly, and without any
potential confusion.

Naturally we must include a disclaimer that
while these seven ISO/ASTM recognized processes cover most of what we see in 3D
printing, they do not cover every technology. Significant R&D is ongoing
around the world, with efforts to create wholly new 3D printing technologies
abounding. Most of even these new processes will still fall generally under one
of these categories, but some will be new unto themselves. This is why
standards creation is so important, as these experts regularly discuss and
evaluate new processes that may need to be added.

What’s
In A Name?

So ultimately, what is in a name?

Everything, when it comes to clarity,
legality, and precision. Certainly it never hurts to be precise when sharing
information about industrial technologies.

At the same time, if you say “additive manufacturing” to someone unfamiliar with today’s advanced production processes, it’s perfectly fine to clarify that you mean “3D printing”, which may be more easily understood. There’s a time and place for full accuracy, but as always the most important part of communication is establishing understanding.

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