What Can SFF Be Used For?

1. What Can SFF Be Used For?

2. Use of 3D Hardcopy (+ Finishing) What is 3D Hardcopy good for? (cont.) • Consumer Electronics Design Prototypes==> touch and feel ! • Mathematical & Topoplogical Models==> visualization and understanding • Artistics Parts & Abstract Sculptures==> all-round visual inspection, including light and shadows. My goal is to inspire you to put these SFF technologies to new and intriguing uses. Comments on post-processing:  application dependent !

3. Consumer Electronics Prototypes Role of 3D Hardcopy – (Part 1): Modeling and Prototyping • Packaging of various electronics components. • Custom designed housing for other utility products. • Prototype demonstrations of novel mechanical gears or linkages.

4. Prototyping Consumer Products “Solarcator” and “Contact-Compact” Two student-designed “products” in ME221 http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/

5. More ME 221 Student Projects This device combines the functions of a GPS with an altimeter, and also tracks water use. “Dionysense”: a device to track fermentation by monitoring thePH value and acidity in a barrel of wine.

6. “Gameboy” Form-Factor Studies • Initial Shape Studies: 3D Print quick turn-around • Final Prototype Shape: FDM robustness

7. Watt-Meter: Concept Study (3D Print)

8. Watt-Meter: Rugged Prototype (FDM)

9. Button “Mote” and Casing (FDM)

10. Pico Radio Casing (FDM;  Mold) Custom-made Casing for Modular Research Kit

11. Injection Mold for Pico Radio • Very sophisticated and very expensive ! Slot done with Electro Discharge Machining

12. Model  Prototype  Mold Injection Molded Housing for ST TouchChip

13. Scientific / Engineering Applications SLA

14. Geometrical / Topoplogical Models Role of 3D Hardcopy – (Part 2): Visualization of objects, when 2D is not quite enough. • Self-intersecting surfaces. • Projections of 4-D polytopes. • Prototyping modular parts, before an injection mold is made.

15. Single-thread Figure-8 Klein Bottle Modelingwith SLIDE

16. Triply-Twisted Figure-8 Klein Bottle FDM, 9” diam. 6 days

17. The Projective Plane PROJECTIVE PLANE C -- Walk off to infinity -- and beyond … come back upside-down from opposite direction. Projective Plane is single-sided; has no edges.

18. Model of Boy Surface Computer graphics by John Sullivan

19. Boy Surface A model of the single-sided projective plane(with no rims and no singularities). FDM6” diam.6 days

20. Morin Surface This is the half-way point of a sphere eversion (without causing creases or tears). 3D-P6” diam 5 hrs.

21. Small 4D Polytopes • 24-cell (hyper-octahedron) • 4D simplex (five-cell) • 4D cross polytope

22. Two Ways to Make a Hypercube 3D Color Print Assembly of flat FDM parts ==>

23. Hypercube, Perspective Projections

24. Parallel Projection of the 4D 120-Cell • Zcorp, • 6” diam., • 6hrs.

25. 120 Cell -- Close-up

26. 120 Cell -- Perspective View • Zcorp, • 6” diam., • 6hrs.

27. Parallel Projection of the 4D 600-Cell • Zcorp, • 5” diam., • 5hrs.

28. Post-Processing for 3D-Printing Surface is porous, dusty. seal and strengthen the part: • Dip in wax: • Nice smooth finish • Needs separate waxing station • Infiltrate with “superglue”: • Tedious, dirty manual labor • Spray-paint with a sealant: • Polyurethane (yellowish, smelly) • Krylon (invisible)

29. Post-Processing for 3D-Printing • Spray-paint surface with Krylon

30. 6D Zonohedron • Sweep symmetrically in 6 directions (in 3D)

31. 4D Hypercube (= Zonohedron) • Tiles are based on PolymorfTM edge connectors.Prototypesmade byKiha Leeon FDM.

32. Modular Zonohedron Construction Injection-Molded Tiles: Kiha Lee, CS 285, Spring 2002

33. 6-Dimensional Zonohedron • 30 tiles intriacontra-hedral shell • 45 tiles forinternal subdivisions

34. Tiles to Assemble Smooth Surfaces Snap modular tiles together to form smooth surfaces. • Debugging of geometry using FDM

35. Evolution of T-Connector Tiles FDM

36. Injection-Mold for T-Connectors • Injection-mold geometryafter four versions of FDM prototypes. • Still not totally satisfactory: (materials properties!).

37. Boy Surface from T-Connectors KIHA LEE

38. Boy Surface

39. Artistics Parts, Abstract Sculptures Role of 3D Hardcopy – (Part 3): Maquettes for Visualization • All-round inspection, including light and shadows. • Parts to give tactile feedback. • Parts that could not be made in any other way …

40. Collin’s Conceptual Design SWEEP CURVE (FOR DOUBLE CYLINDER) IS COMPOSED OF 4 IDENTICAL SEGMENTS, FOLLOWS THE SURFACE OF A SPHERE.

41. Reconstruction / Analysis (v1) FROM THE FDM MACHINE AWKWARD ALIGNMENT

42. Sculpture Design / Optimization • “Galapagos 2” and “Galapagos 3” ( collaboration with Brent Collins )

43. Fine-tuned Final(?) Version (v5)

44. Exploring Minimal Surfaces … “Volution” elements, embedded in a circuit of 12 quarter circles in a cube.

45. More Minimal Surfaces Stack these modular elements.

46. Bronze Investment Casting • FDM original can be burnt to cinders in the plaster-of-Paris shell.

47. How to Get Multi-Colored Parts • Zcorporation: 3D color printer. • FDM: Make ABS pieces in different colors and assemble them; (use ABS solvent as glue). • Paint with different colors. Enamel works very well; (may have to use 2 coats of paint because of porosity of material).

48. Escher Spheres 1 Assemblies of individual FDM tiles (2.5” diam.)

49. Escher Spheres 2 Multi-colored Zcorp parts:no assembly needed!

50. Escher Spheres 3 Multi-colored Zcorp parts: No support removal needed!