Introducing ULTEM 9085 in Black!

All the things you like about ULTEM, but in black!

ULTEM 9085 from SABIC Innovative Plastics has superior strength, is light weight, and has other desirable characteristics, including FST rating. The FST (flame, smoke and toxicity) rating is a safety standard that ensures a material won't promote a fire, release harmful smoke, or emit toxic fumes, and it is particularly valued in the transportation industries.

"The majority of our tan ULTEM users have requested the material also be available in black, because it gives a uniform look to product assemblies," said Fred Fischer, business development director at Stratasys. "It also helps mask dirt or grease found in mechanical systems or under the hood, in the fuselage, or on the manufacturing floor. For many users, the black color will eliminate the need for non-value-added post-processing step of painting or coating."

Truck fender and accessory manufacturer, Minimizer, uses ULTEM when creating both fender and mounting component prototypes. Mounting brackets are commonly made from glass fiber and tough, rigid plastics, which can be a challenge to prototype, according to Minimizer mechanical engineer, Martin Larsen.
"When we make an FDM part and mount it on a truck there's a lot of drilling, using fasteners and even mating parts together," he says. "We found that (because) the ULTEM has high tensile strength and is rigid, it's a good alternative for us to prototype with. Having the black material is a big bonus for us. We don't have to spend the time to finish the part, and we get the same material properties we look for in the (standard) ULTEM material."




Like standard ULTEM 9085, the black color material has a V-0 flammability rating. The material is heat resistant up to 320° F (160° C) and is inherently flame-retardant, offering full FST compliance including OSU heat release of less than 55/55, or 55 kw min/m2 for heat release and 55 kw/m2 for peak heat release.
The material's impact strength also makes it appealing to the aerospace industry, where high-strength, lightweight parts are extremely valuable.

In addition to the automotive and aerospace industries, Stratasys anticipates that black ULTEM 9085 will be useful for construction, agriculture and industrial equipment manufacturers.

Tan and Black ULTEM 9085 are now available at RedEye Australasia.

Call 1300 559 454 or email enquiries@redeyerpm.com.au for more information or competitive quote on your next project. 

The Future of Additive Manufacturing

Ask Jeff Hanson, business development manager at RedEye On Demand, and he’ll tell you the factory of the future is headquartered in Eden Prairie, Minn. Hanson helped launch the digital manufacturing company in 2005 after working for parent company, Stratasys, for more than 10 years and explains how RedEye is leading the future of manufacturing.

Read the full article by Marta Jiménez-Lutterat Manufacturing Today, click here.

NASA's New Rover uses FDM printed parts

NASA Trusts 3D Printing in Space

When you're developing highly customized space vehicles that must sustain human life, stock parts and traditional machining simply won't fly. So NASA engineers put around 70 3D printed FDM parts on their new rover. A new video shows the rover enduring desert tests with ABS and polycarbonate parts built using FDM technology and materials.


The rover, about the size of a Hummer uses about 70 3D-printed parts made from thermoplastic materials including ABS, PC/ABS and PC using FDM technology and materials created by Stratasys, parent company to RedEye On Demand Australasia. The printed parts include flame-retardant vents, pod doors and many custom fixtures. One ear-shaped exterior housing is deep and contorted, and would be nearly impossible to build without 3D printing.

Watch the video below to see how NASA harnessed the design flexibility and durable materials of Redeye On Demand's FDM technology.

FDM printed Magic Arms change a little girl's life

The moment Megan Lavelle saw the device, she knew it would change her daughter’s life. Lavelle is an energetic, unstoppable mom whose youngest daughter, Emma, was born with arthrogryposis multiplex congenita (AMC). At a Philadelphia conference for AMC families, Lavelle learned about the Wilmington Robotic Exoskeleton (WREX), an assistive device made of hinged metal bars and resistance bands. It enables kids with underdeveloped arms to play, feed themselves and hug.
AMC is a non-progressive condition that causes stiff joints and very underdeveloped muscles. Emma was born with her legs folded up by her ears, her shoulders turned in. “She could only move her thumb,” says Lavelle. Doctors immediately performed surgery and casted Emma’s legs. The baby girl went home with parents determined to provide the best care.
Medical experts warned that AMC would prevent Emma from ever experiencing any sort of normalcy. She developed more slowly than an average child and spent much of her first two years in casts or undergoing surgery. Unable to see Emma play and interact with her environment in ways her older daughter had, Lavelle privately wondered whether Emma’s cognitive ability would be hampered as well.

Determined to Grow
But Emma progressed, slow and steady. As she grew and became able to move about with the help of a walker, it became clear that her mind was sharp and her determination on par with her mom’s. At two years old, she still couldn’t lift her arms, and the smart little girl wanted more. “She would get really frustrated when she couldn’t play with things like blocks,” Lavelle says. And so the mom would be Emma’s arms for her; playing with blocks, eating, brushing teeth.
Then came the WREX, demonstrated at the conference by an 8-year-old AMC patient lifting his arms and moving them in all directions. Lavelle met with the presenters, Tariq Rahman, Ph.D, head of pediatric engineering and research, and Whitney Sample, research designer, both from Nemours/Alfred I. duPont Hospital for Children in Wilmington, Delaware. Rahman and Sample had worked for years to make the device progressively smaller, serving younger and younger patients. Attached to a wheelchair,
the WREX worked for kids as young as six. But Emma was two, small for her age, and free to walk.
In Sample’s tool-and-toy filled workshop, the team strapped Emma’s little arms into a small but awkward trial WREX attached to a stationary support. “She just started throwing her hands around and playing,” Sample says. Megan brought Emma candy and toys and watched her lift her arms toward her mouth for the first time.

Tiny Rewards
For Emma to wear the WREX outside the workshop, Rahman and Sample needed to scale it down in size and weight. The parts would be too small and detailed for the workshop’s CNC system to fabricate. But just perfect for printing using FDM technology. So a 3D printed prototype WREX was created in ABS plastic.
The difference in weight allowed Sample to attach the Emma-sized WREX to a little plastic vest.
The 3D-printed WREX turned out to be durable enough for everyday use. Emma wears it at home, at preschool, and during occupational therapy. And the design flexibility of 3D printing lets Sample continually improve upon the assistive device, working out ideas in CAD and building them the same day.
Fifteen kids now use custom 3D-printed WREX devices. For these littlest patients, Rahman explains, the benefits may extend beyond the obvious. Prolonged disuse of the arms can sometimes condition children to limited development, affecting cognitive and emotional growth. Doctors and therapists are watching Emma closely for the benefits of earlier arm use.
Emma quickly grew to love the abilities WREX unlocked in her. “When she started to express herself, we would go upstairs [to Sample’s workshop] and we would say, ‘Emma, you know we’re going to put the WREX on.’ And she called them her magic arms,” Lavelle says.
The little girl’s approval is a fitting reward for her determined mom and dedicated researchers. Sample says: “To be a part of that little special moment for someone else, can’t help but tug at your heart strings.” 

To watch the movie, click here

Introducing RedEye Australasia's Corporate Advantage Network

Calling Existing FDM machine owners!

Do you have a Dimension, U-Print, Mojo or 400MC machine and can’t keep up with your printing requirements? 

Supplement your existing capabilities by utilising the facilities at Redeye Australasia (the bureau service for Stratasys and Fortus).

RedEye Australasia offers corporate rates to existing machine owners allowing them access to a full suite of machines (including 400MC and 900MC), as well as the complete range of FDM materials including Ultem, PC, PC-ISO, ABS-M30i, and ABS in a wide variety of colours. 

Whether you need diversity in materials, a larger build platform or simply more machines to meet your short term requirements, take advantage of the RedEye Corporate rate and allow RedEye Australasia to supplement your existing FDM capabilities.

You already know the benefits of FDM for accurate repeatable models, prototypes and parts, and now you can gain a corporate discount for any projects that are built in the RedEye Australasia facilities because of your previous machine purchase.  

To receive the corporate discount, send your existing Stratasys or Fortus serial number along with your files, and upgrade your capabilities without the capital expenditure by becoming a member of the RedEye Australasia Corporate Advantage network. 

RedEye Australasia, www.redeyeondemand.com.au, 1300 559 454, enquiries@redeyeondemand.com.au.

FDM end use parts break land speed record

Not sure of the end use applications of FDM? Read about how durable parts can be in the following article where FDM parts were used on a custom built motorcycle to break the land speed record.

When the Discovery Channel set the task of building a custom bike in 10 days for viewing by die-hard cyclists at the annual Sturgis Motorcycle Rally for their Biker Build-Off, no-one expected that bike to be able to break the AMA Land speed record.

Klock Werks Kustom Cycles, South Dakota, took on the Biker Build off challenge and won with 'Best bike at the show'. They followed up their win by setting an AMA Land Speed Record (147 mph) at the Bonneville salt flats.

“Direct Digital Manufacturing gave us a major edge in the competition,” says Jesse Hanssen, Klock Werks mechanical engineer. With only a five-day filming schedule, one-of-a-kind components with complex geometries and strict functional requirements were created with direct digital manufacturing using polycarbonate. “FDM enabled us to build anything we could imagine. FDM put no limits on our imagination,” says Hanssen.

“Many of the parts on this bike could not have been produced by any other method in the time-frame required. FDM saved us a considerable amount of money and made a major contribution to our winning the Biker Build-Off,” says Klock Werks partner Todd Snedeker.

 

In building a custom bike for the competition, Klock Werks called upon their own line of bagger parts, purchased some components, and others were one-of-a-kind creations that could not be purchased off the shelf. Most of these unique parts had complex geometries and many also needed to also meet strict functional requirements such as a gauge pod which had to withstand cyclical vibrations without breaking.

“Normally, these parts would be produced from injection molded plastic or machined aluminum,” says Hanssen. “But it takes three to four weeks to build parts using either of these methods because they require tooling. Klock Werks had to fabricate all of the components during a five-day filming segment.” In addition, the cost of building the parts needed for the competition would have been between $15,000 and $20,000, which would have been far too expensive.

Klock Werks engineers designed the gauge pod, fork tube covers, headlight bezel, floorboard mounts, floorboard undercovers, and wheel spacer cover in SolidWorks. “FDM put no limits on our imagination,” says Hanssen. “We built all of these parts in a quarter of the cost to injection mold or cast them."

"The finished parts met all of our requirements for both geometric accuracy and mechanical strength," says Klock Werks partner Todd Snedeker. "The ability to produce fully functional parts using direct digital manufacturing methods was instrumental to our success. Many of the parts on this bike could not have been produced by any other method in the time-frame required. FDM saved us a considerable amount of money and made a major contribution to our winning the Biker Build-Off at Sturgis Week."

After winning the competition, the Klock Werks team raced the bike at the Bonneville salt flats, where they set an AMA Land Speed Record. "The WFB (World’s Fastest Bagger) proves the durability of FDM polycarbonate parts at 147 mph.," says partner Brian Klock.

FDM creates prototypes for the Smithsonian

The possibilities are endless with rapid prototyping technologies. Aside from functional tools, injection moulds, blow moulds and highly accurate parts, FDM is also suitable for building lifesize replicas, like the model of Thomas Jefferson recently created for the Smithsonian. The possibilities are endless with rapid prototyping technologies. Aside from functional tools, injection moulds, blow moulds and highly accurate parts, FDM is also suitable for building lifesize replicas, like the model of Thomas Jefferson recently created for the Smithsonian.

The Smithsonian was putting together an exhibition for the National Museum of African American History called Slavery at Jefferson’s Monticello: Paradox of Liberty. They would obvioulsy have loved to use the statue on permanent display at Monticello, the Thomas Jefferson Museum in Virginia, but that was not practical or possible.

Instead of using traditional modelling techniques, such as rubber molding and casting, the statue was instead scanned and built in three sections (four parts) using FDM technology and materials. The full scale replica was then finished and painted to look like the original bronze statue.

Not only is this an excellent example of rapid prototyping technology and the possibilities of this growing industry, it also opens up a whole new way for people to experience some amazing objects in a museum or gallery which they may otherwise never have the opportunity to see.

FDM parts and prototypes are durable and accurate, minimising the risk of damage during transport.

Already popular with medical models, architectural models and teaching aids, a new era of model making has arrived, and with it, new opportunities!

Well Done Redeye On Demand and the Smithsonian.

Streamline Manufacturing with Fused Deposition Modeling (FDM)

All traditional manufacturing processes involve substantial investment of labor, time and money for toolpath creation, fixtures, tooling, molds and machinery. For example, a single injection mold can cost $75,000 or more and take anywhere from 8 to 16 weeks to manufacture. FDM has no tooling costs and the waiting period for the first production parts may amount to only a few hours.

This not only minimizes new-product startup investment, but can translate to better cash flow, improved profit and decreased debt for a company. Lowering the initial investment also opens the door to more product introductions.

To read the whole White Paper, click here.

FDM prints an entire coffee table in one piece

In a recent article on imaterialise, a FDM printed modular coffee table was featured.

The Module, designed by celebrated designers WertelOberfell–Platform is printed in one piece on a Stratasys FDM (Fused Deposition Modeling) Maxum machine.

The coffee table is based on fractal growth patterns in trees and designed specifically to minimize waste. Individual Module coffee tables can be intertwined in order to get just the size of table you need.

To watch the build click on the link below.



The machine used in the video is the Stratasys FDM Maxum, one of the largest 3D printers in existence with a build volume of 600 x 500 x 600 mm. Redeye Australasia has a Maxum on the premises and can make large scale prototypes in a single piece within Australia, reducing waiting time for parts to a maximum of a few days.

The Stratasys 900MC in RedEye's American Build Centre is capable of building prototypes as large as 914 x 610 x 914 mm and can supply them direct to Australia through the Australasian Build Centre. See it in action below.



Producing prototypes with a high degree of dimensional accuracy, FDM is becoming increasingly popular for aerospace, automotive as well as art and other creative prototyping. For an instant quote visit http://www.redeyeondemand.com.au/.

Helping Hand for NASA

Mockup Helps Prepare Astronauts to Use Dexterous Robot on International Space Station

“The mockup has made it much easier for the crew to
train and prepare to utilize
R2.”
— Gina Young, Project Manager, Wyle

Wyle is a leading provider of high-tech science, aerospace engineering and information technology services to the federal government on long-term outsourcing contracts. Wyle’s Integrated Science and Engineering Group in Houston helped the National Aeronautics and Space Administration (NASA) prepare the Robonaut 2 (R2) dexterous (pictured right).

While most current space robotic systems, such as robotic arms and exploration rovers, are designed to move large objects, R2’s tasks require more dexterity. Its mission is to work alongside astronauts, taking over repetitive and dangerous tasks. Its form factor and dexterity are designed such that R2 can use the same space tools and work in environments suited to astronauts.

One of Wyle’s responsibilities under this contract was building a one-to-one scale high-fidelity mockup of R2 (pictured right) for use in the simulation of potential missions. The exterior of the mockup had to duplicate the geometry and appearance of the actual R2. The limbs of the mockup had to be easily moved into the same positions as the real robot. And, the mockup had to withstand rough handling that it might receive during simulation and training

“The geometry is very complex and we were under time constraints to produce the mockup,” said Robert Stevenson, mechanical designer for Wyle. The parts have so many compound contours that it would have been very difficult to hold them during finish machining. One consequence is that they would have had to be thicker than on the real R2 which would have added to the weight of the mockup. The estimated delivery time for conventional machining for the mockup was 8 months and the cost was $180,000.

“RedEye On Demand was a good fit for Wyle because of FDM’s ability to create complex geometries,” said Jeffrey Gangel, RedEye On Demand Account Manager. “FDM also provides the high level of accuracy needed to ensure that the many pieces required to build the mockup fit together during assembly. Finally, with the largest installed base of FDM machines and the largest inventory of FDM materials in the world, RedEye On Demand was able to meet the tight timeline for the project.”

“Our manufacturing lead had used RedEye On Demand digital manufacturing services in a previous job and had good results,” Stevenson said. “I sent CAD models to RedEye for quotation and evaluated the mechanical properties of the Fused Deposition Modeling (FDM) materials on their web site. The ABS material met our strength and durability requirements. RedEye was also very helpful in educating me in what I needed to do to get our CAD models ready for digital manufacturing.” Fused Deposition Modeling is an additive manufacturing process that builds plastic parts layer by layer, using data from CAD files.

It took only two weeks and cost $36,000 for RedEye to make all of the parts required for the mockup. The interior of the mockup is made from square tubing to provide strength. The mockup is positioned by tension in its joints like a mannequin.

“NASA was very happy with the mockup,” said Gina Young, Project Manager for Wyle. “They liked the fact that it was produced on schedule, is light compared to the original and is strong enough to withstand the large amount of handling it has received. The feedback we received is that the mockup has made it much easier for the crew to train and prepare to utilize the R2.”

The R2 flew to the ISS in February on the Space Shuttle Discovery’s last flight. Initially, R2 will be deployed on a fixed pedestal inside the ISS for operational testing. Next steps include adding a leg for climbing through the corridors of the ISS and further upgrades to go outside in the vacuum of space.

Free Webinar: Additive Manufacturing

Thermoplastics: A Solid Choice For 3D Printing

When designing a new product, engineers can best predict its end performance by prototyping with a material as similar to it as possible. Fused Deposition Modeling (FDM) thermoplastics use the same types of raw materials found in injection molding - and that’s why 3D printing is a wise choice. You’ll learn the unique properties of each thermoplastic and find out how these aspects can help you choose the right material. Join us as we introduce nine FDM materials and the characteristics that make them ideal for everything from rapid prototyping to low-volume manufacturing.

Presented By: Fred Fisher, Director Business Development, Stratasys, Inc.

What you will learn:
• What thermoplastic is the best choice for your application
• How additive manufacturing technology works
• What makes each FDM thermoplastic unique

Who should attend:
• Design Engineers
• Product Designers
• Manufacturing Engineers
• Inventors/Entrepreneurs
• Technology Educators

About Additive Manufacturing Technologies:
Additive manufacturing technologies are also commonly known as "Rapid Prototyping" or "3D Printing" as well as other names. And, although they are still being used by design engineers for concept modeling and prototyping, that’s not all. Manufacturing engineers are now employing these technologies for various applications such as jigs, fixtures, check gauges, and even as a bridge-to-tooling and low-volume end-use parts.

To view the free 30 minute Webinar click here.

Digital Manufacturing of Vacuum Forming Tools

Vacuum forming tools are a perfect application for Fused Deposition Modeling (FDM) technology. FDM has the unique capability of creating sparse fills that allow for a vacuum to be pulled through the part. Because of this built in porosity, the benefit for vacuum forming is that it eliminates the need for vacuum holes; the small vents in the tool that are normally created as secondary operation.

The other added benefit of sparse fills is build speed. And since thermoform tools are simpler in shape, not requiring any support, we can often turn these around in a day; Build on the day of the order, and ready to ship the next day.

Read on to find out how one RedEye customer was able to make the statement; "High quality prototype molds for custom thermoform packaging made 60% faster."

Prototyping Vacuum Forming Tools Quickly

Thermoforming is a collection of manufacturing methods that heat and form sheets of extruded plastic. Thermoforming processes include: drape, vacuum and pressure forming. Today, packaging is the leading application for vacuum forming. Excitingly, consumers see it everywhere from the plastic coffee lid on their morning cup of java to the clear plastic box their sandwich at lunch was delivered in. And, although thermoforming is most often used when manufacturing packaging items, the cost and time saving advantages are realized in a broad spectrum of products in an equally diverse range of industries.

Founded in 1993, the LINDAR Corporation stands on principles of innovation and resourcefulness. This plastics thermoforming company proudly serves customers in food packaging, paint sundry, medical and custom OEM markets. They offer a broad range of services including: product/tool design, high capacity product manufacturing, secondary operations, fabricating and assembly.

Upon recommendation by one of their best customers, LINDAR turned to RedEye On Demand to create quick, cost effective thermoform packaging prototypes. Find out how the team at RedEye saved them time and cut costs while delivering a high quality tool.

The Challenge

Doing more in a shorter period of time is something many businesses are faced with today. In order to keep their competitive edge and satisfy customers, LINDAR needed to reduce turnaround time of their thermoform prototypes. Additionally, they were neither satisfied with the end product or the level of service other agencies had provided.

LINDAR was excited to try RedEye's fused deposition modeling (FDM) technology for creating new packaging thermoform prototypes because the LINDAR team had tried Selective Laser Sintering (SLS) prototypes in the past, but they were brittle. "Ninety percent of our packaging projects require the use of hinges. RedEye's FDM technology allows us to create functional thermoform molds where other technologies fail," says the LINDAR team.

Another advantage of using RedEye's technology is the tools created are inherently porous, which is beneficial when vacuum forming because it can eliminate the need for vacuum holes (small vents in the tool). This unique property, a result of modified build parameters, is essential to thermoform a prototype part with good detail because all air must be removed during the forming cycle. If air becomes trapped (in corners for example), between the sheet stock and the tool surface the part is not formed correctly. The quantity and placement of the vents directly affect the quality of the formed part. Vent placement also affects the cycle time of the forming process. At RedEye, this porosity is designed into the rapid prototype, eliminating the need to locate and drill vent holes completely. RedEye tools offer excellent feature detail and fast vacuum cycles while eliminating the labor and time related to drilling vents.

In addition to producing a quality thermoforming tool, service providers need to complete design revisions and form parts in just a few days. Ultimately, they needed a service provider that could react in timeframes that are continually compressed. The LINDAR team says, "Our customers want to have concepts designed and thermoformed for review as fast as possible."

So, when one of their best customers requested RedEye service they agreed to give it a try.

The Solution

The LINDAR Corporation was able to offer their customer an innovative solution that was appropriate for their company and its objectives. "By using dEye, we have reduced our thermoform prototyping time by 60%," stated the LINDAR team.

Applying the technology at RedEye to the creation of vacuum forming tools offers many advantages: eliminating the time and labor required of machined tools - CAM programming, set-up and operation, as well as eliminating vacuum hole drilling. RedEye expedites the vacuum forming process while decreasing costs and time constraints.

The technology offered at RedEye has streamlined LINDAR's rapid tooling process. Combining the advantages of the 3D CAD and FDM technology, vacuum forming can be completed quickly, efficiently and cost effectively.

"RedEye On Demand exceeded our expectations without exception. We are happy to have chosen RedEye as our digital manufacturer of thermoform prototypes," says the LINDAR team. As a result, LINDAR will continue to use RedEye for quality thermoform prototypes.

When you need prototype thermoform molds quickly, turn to RedEye On Demand.

Read more RedEye Case Studies

3D printing critical in MINI World Rally Championship

Stratasys recently announced that its Dimension 3D printers and Fortus Production 3D Printers played a critical role in the development of the new MINI John Cooper Works World Rally Car (WRC).

The MINI Cooper WRC Team used the additive manufacturing machines to create a full-scale mock-up of the vehicle directly from the CAD (computer aided design) files, and it used the technology extensively on other assemblies and components of the vehicle.

The MINI WRC Team relied heavily on 3D printing throughout the car’s two-year development cycle. To design the test car, engineers used Stratasys FDM 3D Printing technology to create large parts of the engine bay, gearbox, steering assembly, vehicle interior and even engine components, such as intake valves. In addition to prototyping parts for the test track, the MINI WRC Team even produced some end-use parts for the finished car. One of the most visible of these is the ergonomically styled gearshift display and control panel, which is mounted on the steering column.

The development of the car, which will be featured in this year’s World Rally Championship, has impressed upon MINI WRC Team the importance of 3D printing in saving time, reducing tooling costs and enabling more design freedom of complex geometric parts.

“We would find it nearly impossible to build another car without using FDM technology,” said Paul Doe, chief design engineer. “We would never have dreamt of building the parts we did without the Stratasys machines. Using composite parts would have cost up to three to five times more.”

“MINI WRC Team’s use of FDM technology to develop a race-worthy car for WRC demonstrates that it’s both efficient and cost effective,” said Tim Heller, managing director of Stratasys Europe. “It’s nice to be considered an indispensable part of the prestigious team’s operation.”

MINI WRC Team used Stratasys Dimension 1200es 3D Printers and Fortus 400mc Production 3D Printers with polycarbonate and ABS materials.

MINI WRC Team Details

The MINI WRC Team made its debut in the FIA World Rally Championship in Rally Italy, Sardinia in May and for 2011 will be competing in just six European rallies with two MINI John Cooper Works WRCS. This is ahead of a full assault taking in all rounds of the championship in 2012.

MINI has a great rallying heritage and so for its two cars the team has chosen the numbers 37 and 52, which were carried by the cars winning the Monte Carlo Rally in the sixties.

Driving number 37 is Spain’s Dani Sordi with his co-driver being fellow Spaniard Carlos del Barrio.

Kris Meeke from Northern Ireland is driving number 52, and his co-driver is Paul Nagle from Southern Ireland.

This programme was initially announced last July, but even before then a lot of development had been done by MINI’s partner in this project Prodrive, one of the most experienced and respected operations in rallying. This UK based company from Banbury has no less than six World Rally Championship titles to its name. It was founded by team principal David Richards, who was himself a very successful rally co-driver.

“MINI powered by BMW Motorsport”: The heart of the MINI John Cooper Works WRC is the 1.6-litre, four-cylinder Di turbo engine, which is also available in the MINI production models.

The production engine was further developed by BMW Motorsport for the use in various categories according to FIA Super 2000 regulations. The power transmission takes place via an Xtrac 6-speed, sequential gearbox.

For its outings on the rally stages, the MINI Countryman chassis has been fitted with a roll cage developed by Prodrive, which exceeds the strict safety requirements of the International Automobile Federation (FIA).

Stratasys Inc. is a maker of additive manufacturing machines for prototyping and producing plastic parts. The company markets under the brands Fortus 3D Production Systems and Dimension 3D Printers. The company also operates RedEye On Demand, a digital manufacturing service for prototypes and production parts. According to Wohlers Report 2010, Stratasys supplied more additive manufacturing systems in 2009 than any other manufacturer, making it the unit market leader for the eighth consecutive year. Stratasys patented and owns the process known as FDM.® The process creates functional prototypes and manufactured goods directly from any 3D CAD program, using high-performance industrial thermoplastics. The company holds more than 285 granted or pending additive manufacturing patents globally. Stratasys products are used in the aerospace, defense, automotive, medical, business & industrial equipment, education, architecture, and consumer-product industries. Online at: http://www.stratasys.com/

FDM Technology is a trademark, and FDM, Stratasys, Fortus, Dimension and RedEye are registered trademarks of Stratasys Inc.

The FDM Tooling Alternative

The following events, although fictional, are very real problems in companies with low volume product needs.

Design Engineer (DE): " I just spoke with our tooling vendor and they are quoting us $15,000 just for the tool and the lead time is 4 weeks."

Engineering Manager (EM): Gets out his calculator. "We only need 50 parts, that's $300 per part not including their molding costs. We need these out in the field next week if possible. What's with the long lead time?"

DE: "Remember we designed in some complex features because it needs to fit with other components. Redesigning this will take another week minimum and we might have to create multiple parts to make this work, costing more to get it tooled."

EM: "What about those FDM rapid prototype parts we had built in a couple of days and tested last month? They withstood our testing requirements and as I recall they had some fairly complex features as well. Do you think using FDM would work for these parts in the field?"

DE: "You know what, this might be the perfect application for this part, I'll go find out what 3D printing service she used for those prototypes."

Sometime in the near future .......

The design engineer gave it shot and had a first article part delivered overnight for validation. The part worked great, so the rest of the 50 parts were ordered. The 3D printing service provider was able to build the parts over the weekend and had them delivered and on the doorstep by Tuesday, ready for assembly.

The engineers were treated like heroes for their ingenuity in getting the products into the field faster than ever before.

EM: "Using FDM as an alternative to tooling is our best secret weapon yet!"

Lesson Learned: Always have an alternative manufacturing method like FDM that can fit your budget and time. FDM IS an alternative to tooling and outsourcing can provide yet another vehicle to getting parts in your hands fast. For more details, visit RedEyeOnDemand.

Written by Tim Thellin from Stratasys Inc

Make Fiber Molds 80% Faster with a 3D Printer

Molded fiber packaging is an ideal choice because it's eco-friendly and sustainable. It's produced from old newsprint, corrugated boxes and a variety of other plant fibers making it 100% recyclable and biodegradable. Unfortunately, waiting three to four weeks for a machined mold might be a deal breaker.

With RedEye Australasia's FDM technology, you can produce a fiber mold in just a few hours. FDM technology automates and accelerates mold production by replacing the design, machining and screening processes of traditional mold building.

Download the application guide to find out how you can make paper pulp molds 80% faster with a 3d printer.

Urbee - an additive fabricated car!

"FDM technology made it easy and efficient to make design changes along the way."
- Jim Kor, President and Senior Designer, KOR EcoLogic

Caring for the environment

"We should want to own and drive a clean, energy-efficient car," said Jim Kor, president and senior designer for the Winnipeg-based engineering group of KOR EcoLogic. His passion for the environment led him to design the principles of sustainability into a new car code-named Urbee and created with the 3D printing capabilities of Stratasys. The two-passenger Urbee, which stands for Urban electric with ethanol as backup, was designed to use the least energy possible. It is capable of reaching more than 200 mpg on the highway and 100 mpg in the city. And now, it is the first prototype car ever to have its entire body printed with an additive process.

When KOR leaders decided to create the world's most fuel-efficient and environmentally friendly vehicle, their goal was "to design a practical, roadworthy car that runs solely on renewable energy, is environmentally responsible and has universal appeal," Kor said. He hopes it will find a global market some day. Kor wanted to make Urbee aerodynamic and as "green" as possible throughout the design and manufacturing processes.

Initially, Kor and his team made half of a model of the car out of clay at 60 percent scale. By holding a mirror to the half, they could see what a whole model would look like without having to make the entire car. "A clay model has a reality that can't be denied," he said. "We can add and remove material and live with it on a daily basis. The downside is that it takes up to three months to make."

Next, the team had the model scanned into a computer to test its aerodynamic properties. They wanted to achieve certain goals or their computer simulations would be off, and the whole car would "unravel," said Kor. One very important statistic was the coefficient of drag (Cd), which they wanted to be 0.15 or less. By comparison, the Prius is 0.26. The computer model showed the Urbee's Cd to be 0.149. "This was amazing," said Kor. "It gave us the confidence to go ahead."

There was just one little problem. "We had everything in the computer but no way out," said Kor. He and his team knew traditional manufacturing methods would not provide the results they were looking for, so they explored other options.

One option was building the prototype body panels using fiber-reinforced polymer (FRP) or fiberglass. This would involve building a 1:1 scale plug for each of the body panels, first creating a strong framework of wood or MDF and covering it with dense foam that could be hand-carved into shape. Alternatively, the plug could be carved using a CNC milling machine to produce a more precise surface.

Then a mold would have to be made and layers of fiberglass and resin placed onto the surface until it maintained its shape. Once the part was cured, the component would be separated from the mold. "This is a long, labor-intensive process," said Blaine McFarlane, one of KOR's engineers. He estimated building all of the body panels from FRP would have taken 8 to 10 months of steady work for two people. Using CNC machines would have cut the time, but still taken three months.

"A fiberglass body would have taken a long time," agreed Kor. "In addition, we would have had to deal with draft, or the ability of the part to come out of the mold."

The solution: Printing a car

About the same time, one of KOR's industrial designers, Terry Halajko, sent Jim Kor an e-mail with a link to Stratasys. "Look at the size of the parts they can make!" he wrote. It seemed the team had found its solution. Conversations with Stratasys executives led Kor to believe that all exterior components could be created using Dimension 3D Printers and Fortus 3D Production Systems at RedEye on Demand.

Kor and his colleagues transformed the scanned computer model of the car into 10 logical body panels, first creating a 1/6th scale model to verify the exact fit of all the individual parts. This gave the team the confidence that the large panels would be trouble-free.

Together with Stratasys, the team selected ABS as the material of choice and began to build the car. Several major body panels were built within weeks of receiving the go-ahead. The full-scale door and side panels were completed first. "These were big panels," said Kor. "The parts fit together perfectly." The remaining body panels are currently being built by Stratasys.

"Just to make the first car was quite an achievement," said Kor. "With our second prototype, we will design to the Stratasys printer capabilities. We want to exploit the full capacity of the machines." That means designing both the inside and outside of the car. It also means putting plastic only where it is needed.

Kor likes to compare the fender of a future Urbee with a bird bone. "If you look at a cross section of a bird bone, you'll see that there is bone only where the bird needs strength," he said. "The bone looks like chaotic webbing. FDM is the only process that can replicate a bird bone." This will be important when building extremely light, yet strong, pieces, such as the Urbee's fender.

Currently, fenders are made to be a constant thickness, but much of the material is unnecessary, according to Kor. It only adds to the car's inefficiency and environmental waste. "Stratasys can build a fender and place the plastic exactly where it is needed," he said. "That is just so powerful, it's unbelievable. It is good for the environment, it reduces cost, and it doesn’t sacrifice safety. We simply don't need to put material where we don’t need it."

"FDM technology made it easy and efficient to make design changes in the Urbee along the way," said Kor. "It also helped us meet our environmental goals by eliminating tooling, machining and handwork. If you can get to a pilot run without any tooling, you have advantages." Currently, the Urbee is largely self-funded, but KOR's team hopes to raise money to build a second prototype. Once the money has been raised, Kor estimates it will take one year to build the next Urbee.

Kor marveled at the speed of 3D printing. "To have body parts that take days or weeks to make is pretty fast," he said. "Other methods are months away."

Kor said he feels a responsibility to initiate positive change by creating a vehicle that uses the least energy possible. "If we have the car model in the computer anyway, then from the designer's perspective, the 3D printed body is quite effortless," he said. "One just sends files, waits a bit, and…POOF…there are the body panels. No other process can really compare with that."

How Did FDM Compare to Traditional Prototyping Methods for KOR EcoLogic?

With FDM
Cost Affordable
Design Easy to make design adjustments
Time A few weeks

Using FRP or fiberglass
Cost Expensive labor
Design Each new design would require a new mold
Time Up to 10 months for two people

Stratasys prints a Car!

Stratasys, the pioneers of Fused Deposition Modelling (FDM) technology, are a proud Development Partner on the Urbee Hybrid - the first car to have it's entire body 3D Printed.

Read the article here.

Watch the CNN video here.

Congratulations Stratasys and RedEye On Demand.

Gearheads Boycott Scrap Yards and Swap Meets

It's a problem that's all too familiar for custom automobile enthusiasts - finding replacement parts. Featured in this month’s edition of Street Thunder magazine, Eric Anderson reveals how FDM (Fused Deposition Modeling) gives you the power to print your own parts and put the fun back in restoring vintage and muscle cars.

Depending on size and complexity, most parts can be produced with FDM in less than 24hours. Because FDM uses real thermoplastics, you can create strong parts that hold up under high pressure and temperatures - perfect for automobile components. Ultimately, it means you can design a part today and have a real part shipped to you the next morning.

If you like restoring cars, but hate chasing down replacement parts - read the entire article. It'll give you the inside scoop on how you can use direct digital manufacturing services (sometimes called 3D printing services) to get parts fast.

Throw Your Design for Manufacturability Guide Out the Window

Starting any new product design with a traditional Design for Manufacturability (DFM) checklist can stifle innovation. Why limit your creativity? One of the key benefits of additive manufacturing is true freedom of design. Find out how you can use additive manufacturing technology to put the fun back into product development.

If you design plastic parts you probably have a Design for Manufacturability (DFM) guide sitting on your desk. A typical list of things to consider when designing for plastic injection molding include:
•Radii
•Wall Uniformity
•Ribs
•Bosses
•Draft
•Snap-fits
•Screws
•Molded-in Threads
•Picture Framing
•Warpage

For each of the above bullets, you must alter your design to accommodate the limitations of injection molding tooling, (which is what “design for manufacturability” is all about). By the time the DFM rules are met, your original design may end up needing numerous adjustments, taking away from its intended use.

Talk about sucking the wind out of your creativity. Of course when you’re designing a product to be produced from plastic in the tens of thousands or more, your only choice for this volume is injection molding. But how many of you design products that will only be produced in the hundreds to a couple of thousand?

Using an additive manufacturing technology such as Fused Deposition Modeling (FDM) allows you to produce parts directly from digital CAD files. Because plastic parts are built in layers, you’re no longer confined to the constraints of DFM.

Take for example this electrical connector cover. The designers knew they were only going to produce a couple of hundred covers. Functionality required some internal channels that would normally require a multiple piece component. When the designers found out they were going to use their FDM system for the final production parts, they threw DFM constraints out the window. Instead of multiple components, they designed the internal channels into a single component. They also minimized their design time by not worrying about radii, fillets or draft angles. Straight walls and 90 degree angles were perfectly acceptable.

Using direct digital manufacturing allows you the design freedom your product deserves. Imagine being able to optimize your design and product for its true end-use and not have to worry about how it's going to be manufactured.

Direct digital manufacturing with FDM could be the next industrial revolution because it offers companies an unprecedented freedom to innovate their products, processes and businesses.

The Evolution of Additive Manufacturing Materials

Deciding what material to use for your project is probably the most important decision you make. The testing or usability considerations undoubtedly determine the mechanical properties of the material, whether it is heat resistance, durability, elasticity or fine feature detail. Today's availability of multiple materials to match nearly any project is a testament to the expeditious evolution of material development.
More than 15 years ago, Stratasys started out using wax with its FDM technology because it was easiest to develop due to its low temperature resistance. It is also commonly used in investment casting so it seemed like the perfect segue from traditional manufacturing processes to rapid prototyping. As rapid prototyping gained momentum in the industry, the need for more functional prototypes rose demanding more durable materials.

ABS was developed to provide a more structurally sound prototype that enhanced testing for fit, function, durability and temperature resistance. ABS is a highly functional material that can be used to create prototypes, jigs and fixtures and production parts. It is widely used in applications where impact-resistance and structural strength are necessary.

Additionally, its dimensional stability positions it as an ideal material for pre-production rapid prototypes that can accurately predict performance of injection molded parts.

More than 10 years after the introduction of ABS, Stratasys introduced a material that is even stronger and more functional that ABS – ABS-M30. ABS- M30 is approximately 50 percent stronger than traditional ABS. The increase in strength provides more functional prototyping and digital manufacturing options for designers and engineers today.

Within the last 5 years, FDM technology has expanded the number of materials to include Polycarbonate (PC) and Polyphenylsulfone (PPSF) in addition to a variety of ABS and PC blends. There are even some that meet ISO 10993-1 and USP Class VI classification 1 for medical applications.

The most recent addition to FDM materials is Ultem 9085. If you're in the automotive, aerospace, or military industries you've probably heard of it. At a tensile strength of 10,390 psi1 and flexural stress of 16,700 psi, it's the strongest FDM thermoplastic available today. It is also inherently flame-retardant, offering full flame/smoke/toxicity (FST) compliance including OSU heat release of less than 55/55.

The constant evolution of better, stronger, more functional materials has created a real alternative for designers to choose FDM over injection molding.