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3D Printing News Briefs, June 28, 2020: Autodesk, Sinterit, BCN3D Technologies

In today’s 3D Printing News Briefs, we’re talking about software and hardware. First, Autodesk has added a new generative design extension. Sinterit has made some changes so its printers are ready for Industry 4.0. Finally, a BCN3D Technologies 3D printer has been recognized as one of Spain’s best industrial designs.

Autodesk Generative Design Extension

MJK Performance used generative design technology to create a set of lighter and stronger triple clamps for a drag bike

This week, Autodesk announced that it is allowing Fusion 360 users to take advantage of generative design capabilities more easily with the release of its new subscription offering – a generative design extension. This will give users complete access to Fusion 360 generative design for a separate subscription fee of $1,000 per month or $8,000 a year. Autodesk is now offering a special introductory price for a limited time only, so annual subscriptions to Fusion 360 and the new extension are available for 50% off the regular price through July 17th.

“We hear loud and clear that customers, especially these days, crave flexibility, and we’re more than happy to provide a solution at a price point that addresses their needs, especially for budget managers who require predictability. Most of all, we’re excited to see the momentum and incredible outcomes from casual users all the way up to major industry innovators or major brand innovators who are using generative design in the field,” said Stephen Hooper, vice president and general manager, Fusion 360.

Users can also access the generative design extension with their Autodesk Cloud Credits.

Sinterit 3D Printers Ready for Industry 4.0

SLS 3D printer manufacturer Sinterit released a new software update that makes its Lisa and Lisa Pro 3D printers compliant with the Industry 4.0 standard, which works to automate integration with factory logistics. The update provides a new function that allows the printers to generate communication output regarding print status, in addition to a more intuitive user interface and a better tool for object collision detection.

“We received questions from our clients about Industry 4.0 standards compatibility. For some of them, it was a must – a 3D printer without such compliance couldn’t be used,” explained Grzegorz Głowa, head of R&D department in Sinterit.

BCN3D Technologies Recognized for Epsilon 3D Printer

Barcelona company BCN3D Technologies announced that its advanced BCN3D Epsilon 3D printer has been recognized by the FAD Association of Industrial Design as one of the best-designed products of 2019 in Spain. The printer has been shortlisted for the 2020 Delta Awards, and an independent jury of industry experts will announce the winner during Barcelona Design Week this November.

“At BCN3D, we are design: we are meticulous, and our professional 3D printers are crafted after a long process of design and investigation to ensure that the end result is optimal. For us, this recognition is a reflection of the tremendous care we put in each product’s design and reflects on the work of every single member of the BCN3D team,” the company wrote in a blog post.

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3D Printing Webinar and Virtual Event Roundup, June 16, 2020

We’ve got the details on two webinars and one virtual event in today’s roundup. 3Ding is hosting a series of webinars about 3D printing, while Rize published one focused on generative design. Finally, an interesting online event is coming up near the end of the week.

3DIng “Let’s Talk 3D Printing” Webinar

Indian company 3DIng manufactures and supplies 3D printers and 3D scanners, offers prototyping and professional 3D printing services, and during this time of COVID-19, is also holding a weekly webinar about 3D printing. Every Wednesday, the company hosts a remote session called “Let’s Talk 3D Printing” that focuses on a different topic. The series began in late March with “Applications in Rapid Prototyping, Rapid Tooling & Agile Manufacturing,” and has continued every week since. Surendranath Reddy, the company’s founder, CEO and CTO, leads the webinar sessions, along with another trainer named Praveen.

Once you register for the webinar, you’ll receive related handouts. Topics have ranged from SketchUp and OpenSCAD, slicing and scanning, and even an open Q&A with Reddy. This Wednesday, June 17, the topic will be a hands-on SketchUp workshop, and the topic for the June 24th session has not yet been announced.

Rize Webinar on Generative Design & 3D Printing

Boston-based additive manufacturing company Rize, which specializes in Augmented Polymer Deposition (APD) technology that allows for the easy snap-off release of supports, has published a free webinar, which is available to view on-demand, about how to seamlessly use additive manufacturing and generative design to achieve process innovation. The webinar, which lasts about 20 minutes, features Rize Applications Engineer Neil Foley, who tells viewers how the combination of these two technologies can make it possible to automate and optimize important parameters, like weight distribution and strength, and how to speed up the adoption of new design methodologies in order to “streamline design and production and scale the technology across your company.”

“One of the main challenges of additive manufacturing is that it is not safe and easy for all users. This limits the adoption of next-generation design tools, like generative design, which need early validation that is only possible with 3D printing. Furthermore, design validation requires multiple iterations and the ability to have full digital traceability of 3D printed parts to the original designs.”

Makerbot’s “The Future is Now” Virtual Summit

This Thursday, June 18th, desktop 3D printing company Makerbot is hosting an online event, entitled “The Future is Now, A Virtual 3D Printing Summit.” Over 2,000 people have already signed up, and several big industry names, including JABIL, Stratasys, Forbes, and Makelab, will be participating. The event will kick off at 10 am with remarks from Makerbot CEO Nadav Goshen, and a total of seven sessions will take place, on topics ranging from 3D printing in automotive production and robotics to supply chain automation and product design. After a brief period of virtual networking, the summit will conclude at 4 pm.

“Living in an era characterized by innovation and the rapid implementation of technologies, 3D printing has long passed its tipping point and is now impacting almost every industry globally. With this additive manufacturing revolution well underway, we want to hear directly from the leaders and innovators that are shaping the world with 3D printing.”

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

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Additive Flow Goes Adds Additive Awareness to Generative Design

A new startup has emerged from stealth mode promising a software capable of aiding designers in enhancing their parts for additive manufacturing (AM) in ways that go beyond generative design and topology optimization. Additive Flow’s newly announced FormFlow software is meant to allow engineers to quickly modify their models for AM in ways that maximize their performance characteristics along a variety of criteria.

Founded in 2017 Alexander Pluke and Charles Fried, Additive Flow is made up of a team of artificial intelligence and architecture specialists. Its FormFlow software is meant to aid in the parametric design of parts for AM by allowing users to define multiple parameters to optimize a printed object in terms of geometry, process and material.

For instance, users can simultaneously simulate a model demonstrating physical properties equal in all directions (isotropic), as well as with physical properties maximized in the vertical and horizontal directions (orthotropic). This will then inform the direction in which a part is printed, sideways or standing upright.

The model can also be simulated as made from different materials. Other details the software can generate include productivity, cost, and performance outcomes based on design and process recommendations. As Additive Flow describes it, FormFlow “puts the right material, with the right properties, in the right place.”

A comparison of design optimizations depending on print orientation.

In the design of a bridge with Royal HaskoningDHV and DSM, Additive Flow generated designs that were isotropic and orthotropic, printed upright and sideways. The resulting design was seven times lighter than a solid object, with the orthotropic solvers improving performance by 20 percent compared to an isotropic model. Additive Flow also worked with Royal HaskoningDHV to establish a repeatable workflow for performing model optimization in a shorter period of time.

By including all of this information, FormFlow seems to go beyond typical generative design tools. Typical generative design software generates a number of design options based on such characteristics as weight and the ability to carry a certain load. However, these tools may not account for the anisotropic properties of 3D printing, in which the vertical axis is weaker than other axes. In turn, depending on the software, the printed geometries may not perform as simulated. Additive Flow describes the solvers within its software, however, as “additive aware.”

Multiple materials compared within a part.

Designing for additive is no easy task. Of course, this is coming from someone with absolutely no CAD experience, beyond some free and open source tools. However, even professional engineers don’t necessarily know what it takes to make a design right for 3D printing. In part, this is because manufacturing engineers have long been taught to ready their ideas for traditional production technologies.

This means keeping in mind certain constraints, such as limiting complexity in order to reduce the cost of molds and minimizing defects or integrating the gate location in injection molded products. In many ways, engineers have to unlearn a lot of design features they take for granted with traditionally made parts and replace them with a whole new set of design features.

While FormFlow doesn’t seem to address everything that someone would need to know in order to begin applying AM to their product design practice, it may make achieving high-performance, 3D printable designs easier. For instance, Evonik’s new software is able to determine if a host of parts would make good candidates for 3D printing in the first place. It would also be helpful to have a software that can automatically turn a multi-unit assembly into a single printable object. However, once those design decisions are made, FormFlow could further optimize their geometry for the best performance in the best material.

FormFlow certainly seems to have some benefits over existing generative design software, such as Netfabb from Autodesk and Siemens NX, which do not provide as much information as FormFlow seems to at the moment. However, those CAD developers are much, much, much larger, so there’s no telling when Netfabb or Siemens’ Frustum kernel will be able to offer the same capabilities. Who knows, maybe we’ll even see Additive Flow snatched up by some CAD giant in the coming years or even months.

At the moment, Additive Flow is taking FormFlow to market on a project consultancy basis, with the software customized depending on the customer’s needs. The company plans to deliver a license model for its software later this year.

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Next Chapter Manufacturing: Redesigning Injection Molding with 3D Printing

Additive manufacturing (AM) is already making strong inroads into the injection molding industry due to its ability to reduce the cost and improve the performance of molds used in the process. What we are now starting to see is an increasing number of companies and services aimed specifically at leveraging AM and computer aided engineering to disrupt the injection molding market. One such company is Next Chapter Manufacturing (NXCMFG).

Prior to founding NXCMFG, Jason Murphy worked in the mold making industry, using traditional processes like CNC machines, milling and drilling to craft tooling for injection molding. He eventually established a mold making company that he ran for about 10 years before selling it. Murphy then moved onto the plastics side of the industry, where he worked in plastics processing for another 10 years. He believes that the mold making industry has become somewhat set in its ways, forgetting to look for innovation in the space. For that reason, he established NXCMFG.

NXCMFG is a tooling company that uses AM to produce metal inserts and tooling for use in plastic injection molding and metal die casting, as well as jigs, fixtures and other tools. While it may not perform high volume production itself, NXCMFG makes the parts that make the parts made through high volume production technologies. Clients range from small businesses to Fortune 500 injection molding companies.

The hardware consists of Farsoon metal Direct Metal Laser Sintering (DMLS) systems, which have the performance, resolution and the cost necessary for a relatively small businesses like Murphy’s to produce entirely new molds or inserts for existing molds. And, while typical projects consist of one-off prints, the firm typically builds multiple parts for multiple projects at a single time. According to Murphy, his is in the only company in the U.S. that is able to print H13 tool steel and 420 stainless steel using a metal DMLS process.

A mold with conformal cooling. Image courtesy of NXCMFG.

However, probably the most interesting aspect of NXCMFG’s work is the use of conformal cooling and generative design to optimize injection molds and inserts. Unlike traditional CNC processes used to integrate cooling channels into molds, NXCMFG is able to include channels that conform to the shape of the mold, which reduces the time it takes for the mold to cool and a new injection molding job to begin. According to Murphy, his company is able to introduce a 20 to 80 percent improvement in cycle time.

While conformal cooling is becoming increasingly deployed by a number of additive companies in the space, NXCMFG is designing cooling vents for molds. Murphy explained, “Before you inject the plastic in, there is air inside of the mold so that, when you inject the plastic, that air has to go somewhere. You can’t have a hole in the mold because all of the plastic would come out. So, you have these thin slots that are about one-third of the width of a human hair that all of that gas has to escape out of.”

A mold with conformal cooling. Image courtesy of NXCMFG.

Using AM, Murphy’s company can incorporate slits that measure up to one-thousandth of an inch. Moreover, NXCMFG is working on new methods of design that actually change the density of the steel molds they are printing so that the areas in contact with the liquid plastic are porous like a sponge. This would result in quick and even gas displacement, as well as more rapid cooling for improved cycle times. The firm also uses generative design to reduce the weight of molds, resulting in organic-looking tooling with material only where it needs to be for proper strength and performance.

A generative design study. Image courtesy of NXCMFG.

NXCMFG isn’t only utilizing these unique design features in new molds, but also inserts that can be used to modify older tooling. Murphy’s team is able to incorporate cooling channels and venting into a single mold insert, placing a porous steel design alongside a cooling channel for maximum performance with legacy tooling. This saves customers the money that would be used for creating an entirely new mold

A 3D-printed insert. Image courtesy of NXCMFG.

All of these features end up being profitable for their customers in a variety of ways. By cutting cycle times, injection molders can make more parts more quickly, thus reducing machine hours and labor. The process also reduces plastic scrap because conformal cooling and venting reduces defects in plastic parts.

“We’re the only people in the industry 3D printing molds with a million shot guarantee. We offer a guarantee that says, ‘Look, our tooling is so robust that it’ll last a million cycles in production, which is industry standard for traditional tooling,” Murphy said.

What NXCMFG demonstrates is that the tooling sector is only beginning to feel the impact of AM. As one of the most innovative firms in the space, Murphy’s is ahead of the curve in terms of where molds are headed. By the time others follow suit, NXCMFG may be on to even newer and more unique methods for improving mass manufacturing practices.

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3D Printing News Briefs: January 11, 2020

We’ve got some business news to share with you in today’s 3D Printing News Briefs. For starters, Knust-Godwin has purchased a Sapphire 3D printer from VELO3D. The AMable project has issued another Open Call for 3D printing projects, and ASTM International launched an Additive Manufacturing Personnel Certificate Program. Finally, ABĒMIS LLC has announced new hyper-structure technologies for 3D printing.

Knust-Godwin Purchases Sapphire 3D Printer for Oil and Gas Industry

Precision-tool and components manufacturer Knust-Godwin has just purchased its first Sapphire metal 3D printer from VELO3D, which it will use to manufacture high-quality, SupportFree parts for the oil and gas industry, as well as aerospace applications, both of which require complex geometries, rapid delivery, and intense thermal management of extreme temperatures. The Sapphire, which comes with Flow advanced pre-print software and Assure quality management software, will be delivered to Knust-Godwin in the first quarter of 2020.

“We see so many parts that have been manufactured with traditional methods that could take advantage of the benefits from AM,” said Michael Corliss, the VP of Technology for Knust-Godwin. “Our new Sapphire system provides the accuracy and low-print-angle capabilities that enable recreation of those parts via AM without having to go through a complicated redesign process. We can finally print parts as-is, offering valuable cost-savings to our customers and improved turnaround time for delivery.”

AMable Project Launching Third Open Project Call

The AMable project, which works to provide funding opportunities at the EU level in order to develop AM projects from concept to complete product, recently launched a fourth Open Project Call (OC4). This call offers SMEs and small- to medium-sized enterprises the chance to submit a proposal in order to receive financial support, at their own companies, for innovative 3D printing ideas.

The submission deadline for OC4, which has an estimated budget of €450, is March 1st, 2020; available experimentation Types are Feasibility Studies and Best Practice Experiments. For more information, including templates, FAQ, and the rules, please visit the OC4 website.

ASTM International Announces Upcoming AM Certificate Program

The ASTM International Additive Manufacturing Center of Excellence (AM CoE) is launching one of the additive manufacturing industry’s first personnel certificate programs, which will cover all the basic concepts of the AM process chain and provide core technical knowledge, including standardized methodologies, that’s related to best practices. The comprehensive course, which will include specific modules such as design and simulation, feedstock, mechanical testing, post-processing, and safety, was developed after ASTM International completed a landscape analysis in order to determine where the gaps were located in current AM education and workforce development.

“With more and more industry sectors adopting additive manufacturing technologies, there is a growing demand for an educated workforce to support the expanding field. This is a groundbreaking first step in meeting that need,” said Dr. Nima Shamsaei, director of the National Center for Additive Manufacturing Excellence (NCAME) at Auburn University in Alabama, where the course will be held. “To fill the AM knowledge gap, we need world-class training from industry leaders who can equip the future workforce with highly valued technical knowledge.”

The course, held March 10-12, will be taught by academia, industry, and regulatory agency experts, and will require attendees to pass an exam in order to earn the “Basic AM Certificate” that is a prerequisite for specialized, role-based AM certificates that the AM CoE holds.

ABĒMIS Introduces Hyper-structure Technologies for 3D Printing

Cleveland, Ohio-based company ABĒMIS LLC has introduced new HGon technologies, which were developed in-house at ABĒMIS Research Labs and included advanced field-adaptive optimizing hyper-structures for the generative design and 3D printing of ultra-lightweight, vibration-controlling, high strength-to-weight ratio components. HGons just look like lattices when you first look at them, but they actually use controlled complex (directed) structures to push the concept of a lattice to multiple dimensions and “local-global isotropy.”

ABĒMIS can convert nearly any STL or CAD component into a shape-accurate, 3D printable HGon manifold structure, which can reduce a part’s weight by 50-80%. The image to the left shows several examples that the company has completed for current clients, such as Sandia National Labs, Marquette University, and ADDiTEC Inc. ABĒMIS is now offering free initial consultations and sample parts (contact techdemo@abemis.com), and is also requesting investor inquiries for a limited time. To learn more, download the company’s whitepaper, or check out the video below:

Discuss these stories and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the Facebook comments below.

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HRL, nTopology, and Morf3D explore advanced design and materials with 7A77 – the world’s strongest additive aluminum

Taking advantage of additive manufacturing requires exceptional design and production, but only if the materials used can meet the desired expectations during end use. Though metal 3D printing’s use in production has grown in recent years, there are still many applications where low strength AlSiMg dominates the market. With the launch of Aluminum 7A77.60L powder, […]

How Repeatable Workflows Allow Engineers to Automate and Optimize Designs

Advanced modeling platforms enable engineers to produce the highest-performing parts in the shortest amount of time

In the world of advanced manufacturing, a project’s path from beginning to end never follows a straight line. Parts need to be designed, tested, and redesigned, often requiring multiple iterations before they can finally hit the manufacturing floor. As a result, the process can slow innovation and require extensive low-value work.

Design engineers know all too well that many frustrating obstacles typically emerge when attempting to resolve more complex designs. Though some pose as more of a showstopper than others, the biggest frustrations can include:

Having to redesign an entire model after one small parameter has been modified
Needing to utilize multiple software suites in order to complete a single idea-to-manufacture process
Manually iterating input parameters for a desired output, such as changing the density of a lattice until a target volume reduction is achieved

Developers of advanced modeling platforms recognize that design-process issues such as these are quite commonplace when leveraging the power of new and evolving manufacturing systems such as additive manufacturing and precision CNC. By implementing the appropriate modeling platforms—and supplement legacy authoring software with the capability for intelligent, repeatable workflows–engineers can start eliminating productivity losses related to redundant and low-value tasks. The significance of repeatable workflows becomes even more evident as throughput of higher-performing parts increases in contrast to past projects of lesser scale.

Today’s reinvented modeling platforms enable engineers to leverage very complex geometries, quickly iterate on designs, and automate common but demanding operations. These sophisticated, new systems integrate with data from any existing CAD, simulation, or manufacturing software package, allowing engineers to efficiently streamline their workflows in a repeatable and reliable manner.

Engineers have long been in need of a way to capture and share knowledge that allows them to innovate more quickly and automate trivial modeling tasks. Design operations such as filleting the interface between a lattice and its adjacent shell often demand the full attention of the engineer to manually select every edge. With the repeatability and customization of a proven platform’s workflows, the process of blending these lattice beams to a structural solid can be developed once and leveraged endlessly.

A constant fillet radius of 0.5mm applied to each connection between the lattice and exterior shell

By utilizing a unique and easy-to-use block-based tree to perform complex modeling operations, connected workflows can be created, with broad design parameters that can be defined as controllable inputs. Not only does a nested system allow for configuration and packageability, it is automatically responsive to changes in upstream design parameters and external inputs.

The level of configurability the software provides enables the designer to create and distribute robust algorithms that are capable of automatically running numerous design iterations to converge on an objective-oriented result. Design exercises such as lightweighting through topology optimization or lattice propagation allows a user to define their solution upfront.

Topology-optimization workflow running through design iterations for a bracket and an updated model

The resultant complex geometry seen above can be exported as a classic surface mesh (STL) or sliced directly in the platform, avoiding the need for additional software before manufacturing. This, too, is an example of a type of common repeatable workflow that today is not streamlined in the stack of traditional engineering design tools. The most effective modeling platforms are architected to receive upstream changes and propagate them through the block system to produce a manufacture-ready model every time.

Optimized model ready to be 3D printed

A robust platform should include the ability to access prebuilt toolkits or configure repeatable workflows into toolkits that offer step-change advancements in the way engineers can collaborate across teams and organizations. The ability to lightweight components and generate complex geometries through rapid design iterations allows engineers to optimize part design faster than ever before.

By Sam Kratky, Application Engineer at nTopology.

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What is Metrology Part 20 – Processing

Processing

Hey everyone! So this series thus far has been a bunch of fun, and it gets more exciting with what we are doing today. Today I’ll be taking us through a basic tutorial in coding through the framework of the Processing API. I have had experience with this programming language and I believe it is an interesting medium for visualizations of various sorts. It can do awesome generative computerized art, and it can be the source of interesting projects when data and 3D environments are fused. I’ll give an informational overview of the platform as it pertains to 3D manipulation.

Processing is an interesting platform as it is a software sketchbook in a sense. It is a language used for coding and applying it specifically to the visual arts. Processing has done a lot of promotion for software literacy within the visual arts field. It has also done similar promotion for visual literacy within the technology sector. They have built a large global community of students, artists, researchers, and hobbyists who use the platform for educational and prototyping purposes.

Processing Tutorials

I personally started messing with Processing when I was in college. I had some skills in Python mostly through my physics courses, but I was working at my Center of Digital Media within my university. Being around digital media and artistic individuals got me curious as to see the combination of technical fields as well as the arts. When I was learning to code a bit more, I found the Processing platform and a large amount of YouTube tutorials.

Generative Processing Art

Something of interest to me with the platform is that it is a simple interface. It also is not as intimidating of an environment compared to other development spaces. For someone who is interested in things such as image processing, it is the ideal platform to learn quickly. Combining the arts and technology seems disparate for a lot of people. These two fields however are extremely similar and they should not live in vacuums away from each other.

Another great thing about Processing is the large portfolio of onsite tutorials that explain the basics to someone who has no experience with the platform. They did a great job of explaining what every command does within their environment. When learning to code, it is more of a learn as you go approach. When one needs a function, they will have to research online for the meaning of this function and how to execute it. Processing did a good job of centralizing their information through their website and online forum communities.

P3D Mode in Processing

Processing’s power lies within its five render modes. These render modes are the default renderer, P2D, P3D, PDF, and SVG. The default renderer is the backbone of a lot of the programs done by Processing users. It is used for 2D drawing. The usage rates vary based on whether the other renders lack the definition of the size() parameter. The P2D renderer is an alternative to the default renderer for 2D images. The difference between these renderers is that P2D has a quicker runtime, but it sacrifices some visual quality for speed. The P3D renderer is used for drawing in three dimensional space. The PDF renderer is used for writing PDF files from Processing. The files can be scaled to various sizes and output with high resolutions. This renderer can also flatten 3D data into a 2D vector file as well. The SVG renderer does similar tasks as the PDF renderer, but the file format is an SVG. A lot of the renderer power for 3D imaging comes from utilizing the software of OpenGL that is supported on multiple GPUs to help speed up the drawing process.

With this overview, I hope I have intrigued people for a couple of coding projects I will try to show off within the series.

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Autodesk releases generative design addons for 3D modelling software Fusion 360

Award-winning multinational software company Autodesk has released new add-ons for its entry-level 3D modeling software Fusion 360. Among the latest updates is a cost estimation tool combined with generative design. The add-on is powered by Massachusetts-based by aPriori Technologies, a cost management software maker. Stephanie Feraday, the president and CEO of aPriori Technologies, said, “This partnership with Autodesk […]

PTC highlights generative design at its 2019 LiveWorx Conference

PTC’s annual user conference in Boston’s Seaport District had one unifying message to attendees this year: Digital Transformation is coming. From augmented reality and industrial internet of things (IIOT) demonstrations, to a partner exhibition and interactive cybersecurity displays, this year focused on inbound technologies and their importance to our connected future. Select talks focused on […]