SCPI Lunch Learn

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 DavidRapid SCPI SSOE Schohn Vorp Machine Electronics Prototyping Shop ShopDavid & Rapid Vorp – Assoc. Dean for Research

Schohn Shannon – SCPI Director

SCPI Rapid Prototyping & Rapid Manufacturing Facilities Andy Holmes – Project Coordinator, Machinist, and SCPI Manager Thorin Tobiassen – Engineer and Machinist

SSOE Electronics Shop Keith Devine – Electronics Technician

SSOE Machine Shop Dan Lewis – Machinist Scott Macpherson -- Machinist

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

Swanson Center Best Parts…

On-Line Job Submission and Approval • 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…

Charges • $50/hr for research projects including design time, set-up, machining, and clean-up.

• Users supply all major materials and off-theshelf components.

• Additional charges for major consumable materials, e.g. resins for SLA. • Users may pay for specialty tooling or highwear of tooling.

• No charge for class-based student projects.

• No charge for student use of the equipment.

Swanson Center Course Support

• Senior Design Projects • BioE 1160 Senior Design • ME 1043 Senior Design • ENGR 1050 Product Realization

Swanson Center Course and Research Student-Use Tracking

SCPI STUDENT USAGE by DEPARTMENT 1800

1600

1400

1200

MEMS IE HS/UPMC ECE CIV CHEM BIO

# O F L O G I N S

1000

800

600

400

200

0 2010-11

2011-12 YEAR

2012-13 Proj

SCPI HOURS of BILLABLE RESEARCH WORK 900

800

700

600

H O U R S

MEMS IE HS/UPMC ECE CIV CHEM BIO

500

400

300

200

100

0 2010-11

2011-12 YEAR

2012-13 Proj

Current Location – G13 BEH

Swing Location – SB10 BEH July 2013 – Dec. 2013

New SCPI Coming Back to the Ground Floor – Jan. 2014!

Additive Manufacturing (3DPrinting, Direct Digital Manufacturing) 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 Machine

Selective transformation of material having no form (liquid, powder, wire)

into a

Solid form prescribed by a CAD solid model

ASTM F-42 Classification of AM Processes Powder Bed Fusion

Metal Powder

Laser Processes Selective Laser Melting (SLM) Selective Laser Sintering (SLS) Selective Mask Sintering (SMS) Electron Beam Melting (EBM)

Binder Jetting 3DPrinting

Directed Energy Deposition Powder Feed (LENS) Wire Feed (Sciaky)

Polymerization Stereolithography (SLA) Flash Curing Film Transfer Imaging (FTI)

Polymer

Extrusion Fused Deposition Modeling (FDM)

Material Jetting Drop-on-Demand (DoD) Multijet Modeling

Lamination Solidica Ultrasonic Consolidation (UC)

Powder Bed

ASTM F-42 Classification of AM Processes Powder Bed Fusion

Metal Powder

Laser Processes Selective Laser Melting (SLM)** Selective Laser Sintering (SLS) Selective Mask Sintering (SMS) Electron Beam Melting (EBM)

Powder Bed

Binder Jetting 3DPrinting*(2)

Directed Energy Deposition Powder Feed (LENS) Wire Feed (Sciaky)

Polymerization Stereolithography (SLA)* Flash Curing Film Transfer Imaging (FTI)

Polymer

Extrusion Fused Deposition Modeling (FDM)*(2)

Material Jetting Drop-on-Demand (DoD) Multijet Modeling

Lamination Solidica Ultrasonic Consolidation (UC)

* at SCPI ** proposed

Student use of SLA

SLA prototype of a new bus shelter design produced on Viper SLA

Pitt CL model via MakerBot FDM

ERC-RMB Applications

Mg scaffold prototypes

Mg bone plates Fe-Mn scaffold prototypes

Mathematical Puzzle

Click to edit Master text styles – Second level – Third level • Fourth level – Fifth level

• Click to edit Master text styles – Second level – Third level • Fourth level – Fifth level

Knotted Gear Oskar van Deventer

3DP Metal

Collaboration with Bathsheba Grossman

Expanding 3DP Glass

3DP Metal

the Limits of Artistic Creativity

Bathsheba Grossman

• Click to edit Master text styles – Second level – Third level • Fourth level – Fifth level

Geometry

Stress Analysis

Fluid Flow Analysis

Digital Casting Production: No Patterns, No Core Molds Integration of process simulation and 3DPrinting of molds

Part concept

Mold Design

t = 2 days t =Process 0 Simulation

Mold Package 3DPrint

t = 4 days Pour t = 6 days

Finished Part

New design approach combining 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)

Andy Holmes jholmes@pitt.edu 412-624-8878 Thorin Tobiassen ttobiassen@gmail.com Benedum Hall

What’s IN AN acronym?

CAD - Computer aided design (Need this to do that) Am - ADDITIVE MANUFACTURING sLA - Stereo LITHOGRAPHY APPARATUS (viper) fdM - fused deposition modeling (dimension 1200ex) (bfb) 3dp - 3 dimensional printing (zcorp 310) (ExOne) Cam – computer aided manufacturing CNC – Computer Numerical Control RE – Reverse engineerng Dlm – direct laser melt DDM – direct digital manufacturing

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 conventions THREE MAIN CATEGORIES

Subtractive manufacturing

Additive manufacturing

Forming

Swanson Center Lab Capabilities Haas TL-1 CNC lathe Hardinge English/Metric Toolroom Lathe Haas TM1-P 4 Axis CNC Machining Center 2 axis Bridgeport milling machine Kern HSE 25 Metal Cutting Laser Brown and Sharpe CMM Faro Arm Minolta scanning camera Renishaw Clylone Scanner Viper SLA Stratasys Dimension 1200 EX FDM BFB3000 FDM Zcorp 3D printers MCP vacuum casting system 15 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

•

Click to edit Master text styles

– Second level – Third level • Fourth level – Fifth level

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

DLM – Direct Laser Melt

Service Bureau Example • Click to edit Master text styles 316 SS 1-3 days!! $200.00!!!

– Second level – Third level • Fourth level – Fifth level

Cost to CNC Machine 1 ?

$$$$$$$ And LOTS of time

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 CNC MACHINING 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.

Scan Density: .002�

Accuracy: .0005

• An semi-automated contact system that utilizes a touch probe to continuously acquires data along a scanning path

Coordinate Measurement (Gage 2000) by Brown & Sharpe

Scan Density: N/A Accuracy: .00005 • A manually operated machine that utilizes a touch probe to capture single analytic feature measurements (sphere, cylinder, bore, etc.)

Minolta VIVID 910 laser camera • Speed - scans in less than one second (Fast Mode)

• Click to edit Master text style

• 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

– Second level – Third level • Fourth level – Fifth level

Scan Density: .020” Accuracy: .002

Laser Scanning (FARO ARM)

Scan Density: .004” Accuracy: .003”

• A manual contact/non-contact system that utilizes an adaptive laser scanning and probing process

REVERSE ENGINEERING

NON-CONTACT LASER SCANNING

CONTACT PROBE SCANNING

MEASURING MACHINE COORDINATE

SURFACE CREATION

POINT CLOUD FROM SCANNER FEATURE RECOGNITION FACETED OR “TRIANGULATED” SURFACE

SURFACE GRIDS SURFACE PATCH CREATION

FINAL NURB SURFACE

MANUFACTURABLE CAD DATA

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 G13 or G20 on the GR Level SOON TO BE SB10 in the Sub Basement

http://scpi.engr.pitt.edu

http://scpi.engr.pitt.edu Create a new account

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, 2013 The 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.