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The John A. Swanson Center for Product Innovation (SCPI) is housed within the SSOE and has been assisting industry and education since 1999. Clients connect with a high quality, one-stop job shop that provides efficient turnaround for product analysis and design, process design and development, rapid prototyping and reverse engineering, small-lot product manufacturing, and additive manufacturing. Our mission is to give students, researchers, industry, and entrepreneurs access to state-of-the-art product development technology through its technical services.
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Swanson Center for Product Innovation (SCPI)
Schohn Shannon Howard Kuhn Andy Holmes
Swanson Center Mission
The John A. Swanson Center for Product Innovation (SCPI) is housed within the SSOE and has been assisting industry and education since 1999.
Clients connect with a high quality, one-stop job shop that provides efficient turnaround for product analysis and design, process design and development, rapid prototyping and reverse engineering, small-lot product manufacturing, and additive manufacturing.
Our mission is to give students, researchers, industry, and entrepreneurs access to state-of-the-art product development technology through its technical services.
Our True Mission…
“…is to help you get your stuff done...” – Andy Holmes
Swanson Center Facilities
SCPI is comprised of four facilities:
• W.M. Keck Rapid Prototyping and Reverse Engineering Laboratory
• Kresge Rapid Manufacturing Laboratory• SSOE Machine Shop• SSOE Electronics Shop
Swanson Center Administration
David Vorp –Assoc. Dean for Research
SCPI Rapid Prototyping & RapidManufacturing Facilities
Andy Holmes – Project Coordinator, Machinist, and SCPI Manager
Thorin Tobiassen – Engineer and Machinist
SSOE Machine ShopDan Lewis – Machinist
Scott Macpherson -- Machinist
Schohn Shannon –SCPI Director
SSOE Electronics ShopKeith Devine – Electronics Technician
Swanson Center Best Parts…Direct Student Involvement
Swanson Center Best Parts…Student Workers
Swanson Center Best Parts…Safety Training
Swanson Center Best Parts…On-Line Job Submission and Approval
http://scpi.engr.pitt.edu
• Users Create a New Account or Login to Existing Account
• Job Submitted On-line with Valid Account Number or Course Designation
• Job Quote Dispatched via E-mail• Job Approved by Faculty or
Responsible Staff Person• Job is Entered into Queue
Swanson Center Best Parts…On-Line Job Submission and Approval
• $50/hr for research projects including design time, set-up, machining, and clean-up.
• Users supply all major materials and off-the-shelf components.
• Additional charges for major consumable materials, e.g. resins for SLA.
• Users may pay for specialty tooling or high- wear of tooling.
• No charge for class-based student projects.• No charge for student use of the equipment.
Swanson Center Best Parts…Charges
• Senior Design Projects• BioE 1160 Senior Design• ME 1043 Senior Design• ENGR 1050 Product Realization
Swanson Center Course Support
Swanson Center Course and Research Student-Use Tracking
2010-11 2011-12 2012-13 Proj0
200
400
600
800
1000
1200
1400
1600
1800
SCPI STUDENT USAGE by DEPARTMENT
MEMSIEHS/UPMCECECIVCHEMBIO
YEAR
#
OF LOGINS
2010-11 2011-12 2012-13 Proj0
100
200
300
400
500
600
700
800
900
SCPI HOURS of BILLABLE RESEARCH WORK
MEMSIEHS/UPMCECECIVCHEMBIO
YEAR
HOURS
Current Location – G13 BEH
Swing Location – SB10 BEHJuly 2013 – Dec. 2013
New SCPI Coming Back to the Ground Floor – Jan. 2014!
Selective transformation of material having no form (liquid, powder, wire)
AdditiveManufacturing
Machine
Solid form prescribed by a CAD solid model
into a
ASTM F-42 committee definition: a process of joining materials to make objects from three-dimensional (3D) model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies.
Additive Manufacturing (3DPrinting, Direct Digital Manufacturing)
Powder Bed Fusion Laser Processes
Selective Laser Melting (SLM)Selective Laser Sintering (SLS)Selective Mask Sintering (SMS)
Electron Beam Melting (EBM)Binder Jetting
3DPrintingDirected Energy Deposition
Powder Feed (LENS)Wire Feed (Sciaky)
PolymerizationStereolithography (SLA)Flash CuringFilm Transfer Imaging (FTI)
ExtrusionFused Deposition Modeling (FDM)
Material JettingDrop-on-Demand (DoD)Multijet Modeling
LaminationSolidicaUltrasonic Consolidation (UC)
ASTM F-42 Classification of AM Processes
Metal Powder
Polymer
Powder Bed
Powder Bed Fusion Laser Processes
Selective Laser Melting (SLM)**Selective Laser Sintering (SLS)Selective Mask Sintering (SMS)
Electron Beam Melting (EBM)Binder Jetting
3DPrinting*(2)Directed Energy Deposition
Powder Feed (LENS)Wire Feed (Sciaky)
PolymerizationStereolithography (SLA)*Flash CuringFilm Transfer Imaging (FTI)
ExtrusionFused Deposition Modeling (FDM)*(2)
Material JettingDrop-on-Demand (DoD)Multijet Modeling
LaminationSolidicaUltrasonic Consolidation (UC)
ASTM F-42 Classification of AM Processes
Metal Powder
Polymer
Powder Bed
* at SCPI** proposed
Student use of SLA
SLA prototype of a new bus shelter designproduced on Viper SLA
Pitt CL model via MakerBot FDM
Mg scaffold prototypes
Fe-Mn scaffold prototypes
ERC-RMB Applications
Mg bone plates
Knotted GearOskar van Deventer
Mathematical Puzzle
3DP Metal
Collaboration withBathsheba Grossman
Expanding the Limits of Artistic CreativityBathsheba Grossman
3DP Metal
3DP Glass
Geometry Stress Analysis Fluid Flow Analysis
Digital Casting Production: No Patterns, No Core MoldsIntegration of process simulation and 3DPrinting of molds
Part concept Mold Design Mold Package
t = 0 t = 2 days t = 4 days
t = 6 days
Process Simulation 3DPrint
Finished Part
Pour
New design approachcombining AM and FEA/ topological optimization
Machined 0.8 kg
SLM lattice structure 0.31 kg
SLM optimized structure 0.37 kg
ChocALM(chocolate additive layered manufacturing)
Contour Crafting
Lunar Base via Contour Crafting
Swanson Center Rapid Prototyping & Reverse
Engineering Laboratory(Resources)
CAD - COMPUTER AIDED DESIGN (NEED THIS TO DO THAT)AM - ADDITIVE MANUFACTURINGSLA - STEREO LITHOGRAPHY APPARATUS (VIPER)FDM - FUSED DEPOSITION MODELING (DIMENSION 1200EX) (BFB)3DP - 3 DIMENSIONAL PRINTING (ZCORP 310) (EXONE)CAM – COMPUTER AIDED MANUFACTURINGCNC – COMPUTER NUMERICAL CONTROLRE – REVERSE ENGINEERNGDLM – DIRECT LASER MELTDDM – DIRECT DIGITAL MANUFACTURING
WHAT’S IN AN ACRONYM?
PDQ OR A.S.A.P. - HOW FAST EVERYONE WANTS THEIR “STUFF”!
Objective:• Lab Equipment and Processes• Overview of Rapid Prototyping Methods• Overview of Reverse Engineering Methods• In-house fabrication capabilities• Swanson Center Work Request• Questions/Answers maybe…
Manufacturing conventionsTHREE MAIN CATEGORIES
Subtractive manufacturing
Additive manufacturing
Forming
Swanson Center Lab CapabilitiesHaas TL-1 CNC lathe
Hardinge English/Metric Toolroom LatheHaas TM1-P 4 Axis CNC Machining Center
2 axis Bridgeport milling machineKern HSE 25 Metal Cutting Laser
Brown and Sharpe CMMFaro Arm
Minolta scanning cameraRenishaw Clylone Scanner
Viper SLAStratasys Dimension 1200 EX FDM
BFB3000 FDMZcorp 3D printers
MCP vacuum casting system15 ton Morgan injection molding machine
What is Rapid Prototyping?
• A term used to describe the technologies that produce models or prototypes with less effort and time as related to traditional methods.
• Additive process or…• If additive then - builds in layers• Variety of materials• *new technology every month!
Current A.M. Offerings
• (Swanson) Stereolithography - VIPER• (Swanson) Fused Deposition Modeling -
Stratasys Dimension1200ex, BFB3000• (Swanson) 3D Printing or Multi Jet Modeling
Zcorp Z310 and Z510 color• (Service Bureau “FineLine Prototyping) Direct
Laser Melting Metal
Stereolithography (VIPER) by 3D Systems, Inc.
• System that creates physical prototypes by curing thin layers of a liquid epoxy photopolymer with an ultraviolet laser beam
Specs of the VIPER• High accuracy• Excellent surface finish• Multiple Materials (SOMOS 11122 XC)• Build volume – 10” x 10” x 10”• Prototypes good for form, fit, and
functionality testing as well as masters for secondary tooling
FDM – FUSED DEPOSITION MODELLING
BFB 3000
DIMEMSION 1200EX
3DP 3 DIMENSIONAL PRINTING
Zcorp 310
Service Bureau Example
316 SS
1-3 days!!
$200.00!!!
Cost to CNC Machine 1 ?
$$$$$$$And LOTS of time
DLM – Direct Laser Melt
Top 10 Common Mistakes in Designing Parts for Rapid Prototyping
1. Part design having thin-features less than .030” for Std. SLA and .015”-.020” for High Res SLA.
Solution: Make sure that there are features no less than .030” for Standard SLA and .015”-.020” for High-Res SLA to ensure features build correctly.
2. Saving the CAD model to STL file in low-resolution setting resulting in too much faceting in the model.
Solution: Typically, there should be an Edge-to-Edge distance between faces less than .020” for a smoother finish. For more information on STL and how to save to a higher resolution file in the most commonly used CAD packages, please visit this link.
3. STL file conversion error resulting from the CAD data having numerous unstitched surfaces rather than solids.
Solution: Make sure that the surfaces in the original CAD model are “water-tight” in that only solids are modeled.
4. Part design having knife edge design where the edge thins down to zero thickness.
Solution: Thicken any thinning/ knife edge features, which a lot of time are found in thread designs, in the model that are less than .030” in thickness for Std. SLA and .015”-.020” for High-Res SLA.
5. Part design with enclosed hollow space where support materials can’t be removed.
Solution: Add a hole for the internal voids in the model to allow the removal of the support materials.
6. Curvier sections of the part, such as in bottles or lids, with thickness less than the minimal feature size.
Solution: Thicken any features in the model with curvy sections that are less than .035” in thickness for Std. SLA and .025” for High-Res SLA. For curvier sections that are at or near the minimum, even thicker dimensions from the standard tolerance will increase the probability of the part building properly.
7. Parts, assemblies, and threads with improper clearances and mating features.
Solution: Typically, there should be a .015”-.020” clearance b/w prototype parts, which will differ when it comes to the full production stage.
8. Having small text and logos features in the part model.
Solution: Make sure that the logo and text features are no less than .030” for Standard SLA and .015”-.020” for High-Res SLA in length, width, or thickness.
9. Designing living hinge to function for Rapid Prototypes.
Solution: Living hinge design doesn’t typically function as intended in the rapid prototyping process (with an exception of the NEW SLA High-Strength). A simple fix would be using a normal Scotch tape to act as the hinge.
10. Saving in the wrong units for the STL file.
OUR AWESOME WORKSPACE!
Traditional Machining….sort of.
CNC MACHINE TOOLS
4 AXIS CNCMACHINING CENTER
2 AXIS CNC LATHE
MANUAL MACHINE TOOLS
MANUAL MILL
PERCISION TOOL ROOM LATHE
Kern HSE 25 Metal Cutting Laser
Specs:• Non Metallics: up to ¾” • Steel .125”• Stainless .093”• Ti .040” • *No Al.• *No Brass
Reverse Engineering
What is Reverse Engineering?
• The process of taking an existing part and accurately reproducing the surface geometry in a three-dimensional data file
• Contact and non-contact methods
Contact Scanning (Cyclone) by Renishaw, Inc.
• An semi-automated contact system that utilizes a touch probe to continuously acquires data along a scanning path
Scan Density: .002”Accuracy: .0005
Coordinate Measurement (Gage 2000) by Brown & Sharpe
• A manually operated machine that utilizes a touch probe to capture single analytic feature measurements (sphere, cylinder,
bore, etc.)
Scan Density: N/AAccuracy: .00005
Minolta VIVID 910 laser camera
• Speed - scans in less than one second (Fast Mode)
• Precision - over 300,000 points with range resolution to 0.002" (Fine Mode)
• Simplicity - point and shoot simplicity • Interchangeable lenses for variable scanning
volumes • Color Scanning - great for scanning people
Scan Density: .020”Accuracy: .002
Laser Scanning (FARO ARM)
• A manual contact/non-contact system that utilizes an adaptive laser scanning and probing process
Scan Density: .004”Accuracy: .003”
REVERSE ENGINEERING
NON-CONTACT LASER SCANNING
CONTACT PROBE SCANNINGMEASURING MACHINE COORDINATE
SURFACE CREATION
POINT CLOUD FROM SCANNER
FACETED OR “TRIANGULATED” SURFACE
FEATURE RECOGNITION
SURFACE PATCH CREATION
MANUFACTURABLE CAD DATAFINAL NURB SURFACE
SURFACE GRIDS
You Don’t know what you don’t know!
• Collet your thoughts and come up with a plan.• Identify challenges that don’t appear to have a simple solution.• Solve a “subsystem challenge” first. • Prototype prototype prototype.• Integrate solved “subsystem challenge” into the main design. • Don’t forget the HARDWARE!!
How to interface with the Swanson Center for Product
Innovation
http://scpi.engr.pitt.edu
G13 or G20 on the GR LevelSOON TO BE SB10 in the Sub
Basement
Create a new account
http://scpi.engr.pitt.edu
If you use a gmail account for email, you may use that as your email address
Create account using CSSD user name?
What’s that??
Your Initials and two numbers
Why?To filter anyone without a
UNIVERSITY username from the system
Add Association- dept. or person
Questions and Answers
Don’t Miss the Next Lunch & Learn!
July 11, 2013The Notebook – (NOTE that this is the SECOND Thursday of the month due to the July 4th holiday conflict with the first Thursday) Presenters: Julie Myers-Irvin Topics to be covered: The importance of keeping a laboratory notebook (including legal ramifications, protection of IP, etc.), and what should be recorded.
