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Analogue Processes, Additive Manufacturing and RepRap Adrian Bowyer 9 March 2012

Analog Processes

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Page 1: Analog Processes

Analogue Processes,Additive Manufacturing

andRepRap

Adrian Bowyer

9 March 2012

Page 2: Analog Processes

5 ways to make things

1. Cut

Page 3: Analog Processes

5 ways to make things

2. Bend

Page 4: Analog Processes

5 ways to make things

3. Mould

Page 5: Analog Processes

5 ways to make things

4. Add

Page 6: Analog Processes

5 ways to make things

5. Grow

Page 7: Analog Processes

Additive Manufacturing Example

Fused Filament Fabrication(Fused Deposition ModellingTM)

Page 8: Analog Processes

SomeAdvantages

SomeDisadvantages

Control

CutQuite fast,

Quick shape change

Complicated shapes difficult

Difficult

Bend No waste Limited shapes Difficult

Mould Very fast, no waste

No shape change

Not needed

AddAny shape,

quick change, no waste

Slow Easy

GrowFree(ish),et fast

Materials, not products

Not well understood

Comparison

Page 9: Analog Processes

Control - why is cutting hard and adding easy?

Types of geometric complexity

Page 10: Analog Processes

Control - why is cutting hard and adding easy?

5-D Path Planning 2-D Path Planning

Page 11: Analog Processes

Additive techniques

Stereolithography

Page 12: Analog Processes

Additive techniques

Laminated object manufacturing

Page 13: Analog Processes

Additive techniques

Selective Laser sintering

Page 14: Analog Processes

Additive techniques

Powder printing

Page 15: Analog Processes

Additive techniques

Inkjet 3D printing

Page 16: Analog Processes

Additive techniques

Microscopic stereolithography

Page 17: Analog Processes

Competitive subtractive techniques

Meso machining

HSS + ion beam

Machined featuresSome things never change

Page 18: Analog Processes

STL Formatsolid my_am_object facet normal 0.000000 0.000000 1.000000 outer loop vertex 2.394684 0.987658 1.491202 vertex 2.492724 0.705324 1.491200 vertex 13.910414 3.727284 1.491202 endloop endfacet facet normal 0.000000 0.000000 1.000000 outer loop vertex 2.319906 1.151621 1.491200 vertex 13.910414 3.727284 1.491202 vertex 12.471736 7.200560 1.491202 endloop endfacet...

1. Established at the start of the industry2. Ubiquitous3. Poorly designed

Much improved version:

Hod Lipson et al.:Additive Manufacturing File (AMF)

Page 19: Analog Processes

Slicing at height Z1. Compute line segments from Z plane and STL triangles2. Join segments to make polygons (!)3. Offset polygons4. Infill polygons with cross- hatch5. Record results in file

Tiresome (but not hard) with STL, easy with bitmap or CSG

Page 20: Analog Processes

Support calculation1. Slice top down2. Support at layer N for stuff above:

SN = (S

N+1 U L

N+1) – L

N

3. Reverse layers → bottom up at the end.

Easy if model and layer are: CSG/Boolean Bitmap

Hard if they are B-rep:PolyhedraPolygons

Page 21: Analog Processes

Strengths and weaknesses

Fused Filament Fabrication

Easy to implement

Multiple materials

Needs support

Coarse

Page 22: Analog Processes

Strengths and weaknesses

Stereolithography

Quite easy to implement

Fine

Expensive resin

Single material

May need support

Page 23: Analog Processes

Strengths and weaknesses

Layered object

Cheap raw materials

Warping

Single material

Needs support

Page 24: Analog Processes

Strengths and weaknesses

Selective Laser Sintering

Polymers and metals

No support

Intrinsically expensive

Single material

Page 25: Analog Processes

Strengths and weaknesses

Powder printing

Easy to implement

No support

Colour

Weak products

Single material

Page 26: Analog Processes

Strengths and weaknesses

Inkjet 3D printing

Quite easy to implement

Multiple materials

Colour

Very slow

Needs support

Page 27: Analog Processes

Strengths and weaknesses

Microscopic stereolithography

Only one that works at this scale

Conceptually simple

No support

Needs exceptional precision

Single material

Page 28: Analog Processes

Additive Manufacturing

The most versatile manufacturing technology we have.

Can make shapes impossible with any other technique.

Only been going 30 years.

Computationally simple.

Some AM machines very cheap.

Basis of RepRap – the first replicating production machine in the World.

Page 29: Analog Processes

RepRap is a self-replicating 3D printer

RepRap

Page 30: Analog Processes

RepRap Facts

● RepRap can copy about half its own parts.● The other half: hardware shops and on-line.● Cost of all the materials $500.● Working volume: 200 x 200 x 140 mm3.● Material: most plastics.● Print rate: 19 ml/hour (one day to replicate).● Licence: GPL.

Page 31: Analog Processes

RepRap Makes

http://thingiverse.com

Page 32: Analog Processes

RepRap Makes

http://thingiverse.com

4

Page 33: Analog Processes

The biggest difference

Page 34: Analog Processes

Biology – mutualist symbiosis

RepRap = flowersPeople = insectsGoods = nectar

Page 35: Analog Processes

Anyone with a RepRap can make another RepRap for a friend

29 May 2008

Page 36: Analog Processes

It's like MP3 music sharing, but for real solid stuff...

...ultimately any stuff

Page 37: Analog Processes

Personal manufacturing: destroyer of industry

London 1943

Page 38: Analog Processes

Destroying Things

London 2012

That way never works

Page 39: Analog Processes

The Arrow of Time

Alwaysworks

Page 40: Analog Processes

The Arrow of Time

Page 41: Analog Processes

The Arrow of Time

Page 42: Analog Processes

The Future?Everyone in the developed world runs their own

CD pressing plant

Page 43: Analog Processes

The Future?Everyone in the developed world runs their own

CD pressing plant

Photographic Lab

Page 44: Analog Processes

The Future?Everyone in the developed world runs their own

CD pressing plant

Photographic Lab

And printing press

Page 45: Analog Processes

The Future?

Why not their own factory...

Page 46: Analog Processes

The Future?

...that makes more factories?