3D Printing: An Entrepreneur's View
Steven Schain - Spectra3D Technologies - President
CD5192 Whether it’s being used in rapid prototyping and consumer products or small-run
manufacturing, 3D printing has become an important part of the workflows of many hobbyists, artists,
engineers, and fabrication companies. This course will look at the landscape of the 3D printing industry
in order to break through the hype that surrounds it. You will discover how 3D printing is being used in
the real world for both personal and professional uses. From creating art to engineering prototypes, this
course will also explore the expanding use of 3D printers and their place in an enhanced design
workflow. The course discusses the current state and the future implications of 3D printing in the real
world.
Learning Objectives
At the end of this class, you will be able to:
Learn the process of rapid prototyping and its applications.
Discover real-world applications of 3D printing and how you can make use of them.
Discover tools available that can be used to create and deploy 3D printable models.
Look at the future of 3D printing and its growing applications in the design industries.
About the Speaker
Steven attended R.I.T.'s film/animation in 1989 & A-B Tech's Entrepreneurship in 2011.
Opened Spectralight Images in 1989 to deliver 3D training and animation. Moved to Orlando,
FL in 1990. As VP of Computer Animators Plus (1995) began teaching 3D at Seminole State
College. With a love of art, opened Gallery 611 in 1997, and formed the Orlando Visual Artists
League in 2000, president until 2004. In 1998 he became an Autodesk® training specialist, and
has contributed to Autodesk's certified training material for 9 releases of 3ds Max®. He was a
co-developer of Autodesk's ACI Program, and Autodesk's 3ds Max® fundamental standards.
Now he develops 3ds Max / Maya training courseware for CAD Learning's online training.
Spectra3D Technologies provides 3ds Max, Maya & AutoCAD training. Steven teaches classes
for end users, companies, Autodesk University, & others. Past trainees: Disney, Guess, US
Army, and more. In 2014 Spectra3D Technologies expanded into 3D printer sales and support
offering an array of 3D printers, design services and 3D printing training.
steve@sli-3d.com
3D Printing: An Entrepreneur's View
3D Printing: An Entrepreneur's View
What is 3D Printing / Rapid Prototyping?
Rapid prototyping is a relatively new field in the design and manufacturing industries. By utilizing
rapid prototyping, companies can create models of 3D designs using a number of prototyping
techniques.
(3D Print courtesy of Rapid Prototyping Services, LLC)
There are several reasons a company would use rapid prototyping.
First, a company can quickly create an iteration of a new design, which allows them to test and
retest a complete finished part without the expense of manufacturing. Using this process, a
company or engineer can mock up a design, test features, evaluate form and function and
perform other tests, like conducting a focus group, in order to evaluate the design of a new
product. Having the ability to quickly alter the design and create a new version at a low cost
makes it easier for companies to create better designs.
The second application of rapid prototyping is the creation of parts that will be used in the field.
For many manufacturing companies, creating parts for a short run, say 25 to 200 pieces, can be
costly. If it is a standard part, such as a connecting tube with flanges that would normally be
molded from ABS plastic, rapid prototyping can save thousands of dollars. With materials
capable of withstanding high pressure that are also strong and flexible, parts can be made that
meet very rigorous standards.
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3D Printing: An Entrepreneur's View
A third application of rapid prototyping is the creation of fixtures that can be used during the
manufacturing process. Take, for example, an assembly line where people are installing
components into a small part. An engineer can spend the time to design a tool that holds the
part properly, but it still has to be made. This is where rapid prototyping can be used to deliver
low cost, reusable fixtures for the assembly line. If the design of the fixture were to change, the
fixture can be easily recreated and replaced with the new design.
Lastly, rapid prototyping is within the reach of nearly anyone with a computer and an idea. This
opens the door to a future where you can just print a replacement part for a broken toy, create
your own unique model, or even design your own custom chess set.
As a process, rapid prototyping has the ability to make the job of a designer a little easier by
allowing him or her to focus on the design. It also provides a way for companies to save on
manufacturing costs for low quantity items and can increase productivity in many areas of the
production industry.
Real-World Example
A common problem with a 3D solution
Once you have learned the basic tenets of 3D printing, opportunities for putting a 3D printer to
work are constantly popping up. Take, for example, a fairly common household issue: the loss
of a dishwasher wheel.
Without a 3D printer, you can shuffle through your paperwork to find the model number, contact
the manufacturer, pay for the replacement part, and wait patiently for the part to arrive. If you
happen to have a 3D printer, however, with some basic design skills, you can design your own
replacement and have your dishwasher back to fully-functional in a matter of hours.
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3D Printing: An Entrepreneur's View
Designing your replacement part
The first step when creating your dishwasher model is to make sure that you accurately recreate
the dimensions of the original. Use a digital caliper to take accurate measurements.
This information can be inputted into your software when creating your model. For this design, I
used Inventor.
The Results
After printing, I had a tangible model that was identical to my existing wheel.
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3D Printing: An Entrepreneur's View
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3D Printing: An Entrepreneur's View
3D Printing Businesses
Printing Services
One of the more obvious ideas when considering a 3D printing business is to offer the print
services themselves. As designers and the general public become more familiar with the
capabilities of 3D printing, there will be more demand for 3D prints. In the initial stages, there is
likely to be a large number of consumers interested in having a 3D part made without the ability
to do it themselves.
Printing services can come in many forms. You may consider opening a print shop. This service
would allow consumers to send you their designs and you return to them a printed part. You
may also consider offering design services for those who don’t have the expertise necessary to
create their own parts.
Peripheral Services
Peripheral services help make a 3D printed part more usable. In some cases, businesses in the
peripheral services will work to make the 3D part more durable by giving it a metallic finish, such
as chrome or silver. Other services, such as painting, simply work to make the piece more
aesthetically pleasing. Another example of a peripheral service is a company that takes a 3D
piece and uses it to make a mold or casting.
The Cost of Business
The Printer
One of the first costs encountered when starting a 3D printing business is the cost of the printer
itself. Many companies allow you to choose whether you would prefer to purchase the printer or
take on a monthly lease. There are benefits and disadvantages to both options. Be sure to
weigh the offers of each brand carefully before deciding which option is right for your business.
Miscellaneous
Other costs to consider before beginning your business are both the variable and fixed costs of
doing business. Fixed costs include your overhead and the cost of your lease or loan. A few
examples of the variable costs you will encounter include your necessary materials, the cost of
your power, and the value of your time spent.
Profit!!!
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3D Printing: An Entrepreneur's View
Even after costs are figured in, however, there is tons of room for profit in even the most
rudimentary printing business.
For a quick back of the napkin breakdown, say that your monthly lease on your printer costs you
$380 per month. Material costs tend to sit around $5 per cubic inch. A reasonable estimate for
how much you could charge for a printed part would start at about $75, with most parts selling
for an average of $150.
With these costs in mind, in order to break even printing parts at a price of $150 per piece, you
would only need to print approximately four parts per month. Now, let’s say that you were able
to sell 10 prints per month at the same rate. This would net a profit of $820 per month.
Whether you would like to add printing to the list of services that you already offer or embark on
a whole new venture, the potential for profits in a 3D printing business is significant.
What’s it all about?
The Process of 3D Printing
The principle of rapid prototyping involves the idea that you can take a 3D model and build it
using successive layers of a material. This is also known as 3D printing.
(3D Print courtesy of Rapid Prototyping Services, LLC)
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3D Printing: An Entrepreneur's View
First established in the early 1980's, neither the concept nor process of 3D printing has changed
much over the years. What has changed, however, is both the price and the technology used for
creating a 3D printed model.
The process begins with a designer, engineer or artist creating a 3D model in one of the many
design programs on the market today. That model is then saved out to a format that will be used
by the 3D printer, generally an STL file.
The printing process uses software specific to each printer, though they all do basically the
same thing. The printing software takes the STL file data and slices it into layers that the printer
is able to print.
Different printers use one of a handful of 3D printing processes. A majority of the 3D printers
used in rapid manufacturing use a plastic filament that is laid down one layer at a time using a
heated print head; others use ultraviolet light to cure layers of plastic resin; and some lay down
a layer of fine material and an inkjet-like process that sprays a polymer to create the layer of the
model. No matter which method you use, the process is generally the same.
What can you do with your model?
Printed parts can be used in a number of different applications. If you would like to test a
concept or evaluate a design, a printed part is a great place to start. By creating a printed
prototype, you can analyze many elements of the design and modify the part as necessary
without the expense of traditional prototyping. A 3D printed part is also a great way to help you
establish a new process.
With the high-quality of available materials and the high-degree of precision that many printers
are capable of producing, printed parts can also be functional components. Using printed
alternatives for pieces is particularly useful when you are designing a small-run of a part. Using
a printer to create small parts can save design and engineering firms tons of money.
A function of a 3D print that shouldn’t be ignored is that it is simply fun to create. When 3D
printing, if you can think of an idea for an invention, a piece of art, or anything else that you can
dream up, you can bring it to life.
The Old Way. . .
Traditional Process
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3D Printing: An Entrepreneur's View
In the past, when you worked in design or product development, you went through a multi-stage
process. After part development, you would have to create a part mold. The mold would then be
used to create your finished product. If the part wasn’t produced accurately the first time, there
was often a considerable amount of cost involved in both material and time to rework the
concept.
The New Way. . .
Rapid Prototype Process
Now, after creating a CAD model design, you can perform a quick model analysis and, from
there, order the 3D print. If it is not correct the first time, it will take far less time and money to
correct the part the second time around.
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3D Printing: An Entrepreneur's View
Process
With the 3D Printing workflow, there are six basic steps that you should go through before
completing your design.
Plan
Although this stage is all-too-often overlooked, it is quite possibly the most important step.
Taking the time to really think through your model, including how you want it to look and
function, will help make the remaining five steps go much more smoothly.
Design
During this stage, you will transform your plan from a concept or a napkin sketch into a fully
realized design. This will be done in the CAD software of your choice.
Print
Once you have designed your part and run any preliminary tests on your design, it is time to
print. One of the most important things to keep in mind during this stage is that every printer is
unique. In order to get the exact quality of print that you want, you will likely have to spend a fair
amount of time becoming familiar with your system’s software and tweaking the settings to your
specifications.
Test
Once your printed part or prototype is complete, it is time to begin the testing phase. Whether
you are using focus groups, torture tests, or some other method, you should feel comfortable
that the design you have is the design that you want.
Develop
Now that your design has gone through these carefully-orchestrated steps, it is time to put your
design into development.
Uses and Applications
Commercial
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3D Printing: An Entrepreneur's View
Turn your concept into something more concrete that you can feel, hold, and interact with in
order to get a better idea of how your design will work.
End-user products from a 3D printer can range from parts, to models, and everything else in-
between.
Fashion
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3D Printing: An Entrepreneur's View
The fashion industry has eagerly embraced the technology of 3D printing. You can find
everything from small pieces of jewelry to full outfits created by a 3D printer.
Hobby and Fun
If you really want to check out the creativity that 3D printing has inspired, you needn’t go any
further than a quick search on a hobbyist site. With prints available for download for free or for a
fee, these sites are packed with innovative design concepts.
Artistic
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3D Printing: An Entrepreneur's View
There are a number of amazing artists currently using 3D printing as a medium to produce
works that would be difficult, if not impossible, to create before the invention of this technology.
Printer Types
Extrusion
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3D Printing: An Entrepreneur's View
Extrusion printers utilize basic Fused Deposition Modeling (FDM) technology in a 3D printer
application. Quite simply, FDM is the additive manufacturing process that occurs through an
additive principle, with each piece being constructed layer by layer.
Extrusion printers can print a few different materials, primarily ABS plastic and polycarbonate.
These printers are a good option for professional use.
Granular
Granular printing is typically found in heavily industrial environments. This process requires an
extremely controlled environment. During this process, a powdered material is fused together
with the help of a heat source. After each layer is complete, the tray holding the materials sinks,
slowly, exposing the part.
Direct Metal Laser Sintering (DMLS)
DMLS uses a high-power laser to create a solid structure out of powdered metals.
Selective Laser Sintering (SLS)
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3D Printing: An Entrepreneur's View
Similar to DMLS, SLS also creates solid forms out of powdered materials, including metals and
ceramics. DMLS and SLS differ primarily in technical details.
Powder Bed / Inkjet (PP)
In this type of granular printing system, instead of using a laser or heat source to bind the
powder together, an inkjet printhead moves across the bed of powder and adds a binding liquid
to create the part.
Other
Plastic Jet Printing
Another term for Fused Deposition Modeling, Plastic Jet Printing utilizes the same techniques
as an extrusion printer.
Stereolithography
This type of printer creates layers by curing a resin that is photo-reactive with a UV laser.
Laminated Object Manufacturing
Starting with materials, including paper, plastic, and metal, which are coated with an adhesive,
the layers are glued together and a knife or laser is used to cut the desired shape.
The Printers
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3D Printing: An Entrepreneur's View
Professional / Production
Like any other technology, the advancement in process and equipment has steadily brought the
cost of 3D printing down all the way to the consumer level. Companies that make 3D printers
have developed a variety of printers that range in price from $500 up to more than $200,000 for
industrial applications.
On the high end, Stratasys (http://www.stratasys.com) builds several lines of printers that can
be used by small business providing low cost 3D printing services with prices starting at $6,000
(Image courtesy of Stratasys, Inc.)
The Mojo and uPrint SE Plus (pictured above) are two options in this category.
For more industrial applications, Stratasys’ Fortus Series, which starts around $50,000, use the
production-grade thermoplastics that are typically found in injection molding, CNC machining,
and traditional manufacturing processes.
3D Systems (www.3dsystems.com) is another well known 3D printer company. The ProJet 1500
and 160 are nice mid-range options with good build speeds and resolutions. 3D Systems also
offers professional models, such as the ProJet 5000, which can be left to print unattended for 80
hours and features a build volume of more than 21x15x11 inches.
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3D Printing: An Entrepreneur's View
Consumer / Hobby
The consumer can now get into the 3D printing market using one of several low end 3D printers.
Two that compete head to head are the Replicator 5th Generation by Makerbot
(http://www.get3dp.com) costing about $2,900, and the Cube Pro by Cubify 3D Systems
(http://cubify.com), which is at approximately the same price point.
(Image courtesy of Makerbot)
Formlabs www.formlabs.com) is one of spate of relative newcomers who are offering upgraded
features like multiple materials. The Form 1+, for example, puts the power of stereolithography
on your desktop and can even print castable resin.
With so many options and costs coming down to acceptable prices, 3D printing is bound to be in
your future in one way or another. Whether you are an engineer or designer, or just having fun,
3D printing opens the door to infinite possibilities.
Tools for 3D Printing
Modeling for Rapid Prototyping
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3D Printing: An Entrepreneur's View
Basic AutoCAD Modeling
The process of creating a model that can be used for rapid prototyping can be as simple or as
complex as your part requires. Here we use AutoCAD
1. Begin with the basic curves that make up each element of the design.
The curves represent the main body portion of the nose cone, the material to be added to the
body and the material to be removed from the body.
2. Using the 3D solid modeling tools available in AutoCAD you can begin to create the solids
you will need to construct the final part.
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3D Printing: An Entrepreneur's View
Using the Revolve tool allows you to create a solid model that represents the shape of the main
body of the nose cone.
3. Creating the additional elements, then using the Boolean functions allows you to create more
complex solids.
The final version of the nose cone uses boolean operations to union and subtract elements from
the main body. Fillets complete the creation of the final part.
You are now ready to send the part to get 3D Printed.
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3D Printing: An Entrepreneur's View
AutoCAD quick rendering of the part
Other Autodesk programs that can be used to create 3D models include Inventor, Fusion 360, Revit, 3ds
Max Design, InfraWorks, and Sketchbook Pro. For a free program that is great for beginners who are
learning to model in 3D, Autodesk now provides a suite of apps, located at www.123dapp. These apps
give you tools to help you create your STL file, build a 3D model out of foam board, or transform
photographs into a printable model.
3D Printer Software
Once you have your model designed, your printer needs to be able to read it. A slicer program, such as
Slic3r (www.slic3r.org) or KISSlicer (www.kisslicer.com) can take your existing model, slices it into
horizontal slices, and creates the necessary toolpaths. The program will then calculate the material that it
needs to extrude.
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3D Printing: An Entrepreneur's View
The Future. . .
The future of 3D parts is one in which pieces can be modeled on demand. Finding replacement
parts will be as simple as sending the file to your printer and snapping the part into place when it
is complete. This will lead to a significant reduction in inventory and a much more streamlined
workflow.
Although we have already seen some medical advancement through 3D printing, as
technologies continue to become more refined, there could be some major breakthroughs
thanks to 3D printing.
Finally, as demand increases for items that are customized for the user, there are tons of
possible markets that 3D printing could fulfill, including custom fit items and mass customization.
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