Inkjet Printing 3-D Prototypes

This three dimensional architectural model by ABC imaging was printed using their 3-D ProJet printer. Photo courtesy ABC Imaging)

If you think digital “printing” is all about putting ink to paper, or other media, you’ve missed the emergence of an alternate “print” technology that could one day redefine production of many manufactured goods.

Called 3-D printing, rapid prototyping, solid imaging, or additive manufacturing, it combines some of the core technologies driving digital graphics production with advances in CAD software to empower printers that can render solid three-dimensional objects from 3-D designs or scans. That’s right. These systems can “print” conceptual designs, working prototypes, sales samples, scale models of architectural designs—whatever the client needs.

NO LIMITS

“The only limits to 3-D printing are your own imagination and access to CAD files or 3-D CAD scanning systems,” says Cathy Lewis, vice president of global marketing for 3-D Systems, Rock Hill, S.C., “It’s truly a blank canvas.” What’s printed can be a concept model, functioning prototype, a real end-use part or a tool.” The company offers a full line of 3-D print systems, ranging from the V-Flash Personal 3-D Printer, less than $10,000, to the ProJet 5000 production printer for rapid manufacturing.

At rival Objet Geometries, Billerica, Mass., director of marketing Bruce Bradshaw reports the technology has already been embraced to varying degrees by the consumer goods, education, military, medical, dental, architectural and entertainment industries. “People use these systems because they can closely match their desired end product,” says Bradshaw. “They are also being used in limited quantities today for direct manufacturing of some products, like medical devices, in limited quantities.”

Two examples of color prototypes printed with the ZPrinter 650. (Photo courtesy of Z Corp.)

As these tools evolve, so do their applications. “This technology started years ago as a tool for engineers,” notes Scott Harmon, vice president of business development for Z Corp., Burlington, Mass., maker of the ZPrinter line of 3-D printers, including four-color models. “It’s now becoming a tool for the marketing and product development departments, as well, as they discover all they can do.” He says they are tapping these systems to test product concepts, perfect the design, and produce scaled up or scaled down sales samples before tooling up for full production.

PRINTING IN LAYERS

Additive manufacturing may best encapsulate how these systems work, and their capabilities. Although the end result is the same—a physical rendering of an object designed with CAD software—manufacturers take different approaches, and use different materials to achieve those results. Simply stated, the 3-D systems “print” in the conventional sense by laying down a layer of “ink”—glue, resin, plastic or metal powders—much as any print system applies ink to paper or other media. In fact, several systems use the same printheads as some inkjet printers.

But there the comparison ends. Whereas in graphics production, the printing is done once ink or inks are applied to the media, additive manufacturing is actually a layering process. The 3-D model is built of stacked slices, applied thin layer by layer as the print head moves back and forth. As those layers add up, an object slowly takes shape.

Its finished size depends on the system’s “build” space. Price for service is based on the cubic dimensions of that finished piece and material consumed, as well as the time involved for file preparation, system operation and finishing the piece. Depending on the system, the finished piece may need to be trimmed, support material removed, and hardener or paint applied after production.

This model was produced from two dimensional elevation and site drawings of a proposed school campus. It was printed using a 3-D printer for a construction company using the four-color ZPrinter 650. (Photo courtesy ABC Imaging)

With the Z-print system, a powder bonds to a special glue shot through standard HP 57 inkjet print cartridges in layers 4/1000 inch thick to create the object. Objet’s approach, on the other hand, sprays liquid photopolymer resin through commercial inkjet cartridges in layers 16 microns thick to build a plastic rendering. These are then cured by UV light to build the object. With Dimension’s line of 3-D systems, the models are built of production-grade plastic called ABSplus. Depending on the desired end result, 3-D has systems that can produce objects composed of wax, a variety of plastics, even powdered metals, depending on the desired end use.

“These systems allow a lot more flexibility when trying to arrive at the right design for a product,” notes Lewis. “They also make it possible to build a prototype in just hours or days, and actual end use products in quantities as few as one.”

A full-color Z-Printed topography model done in several tile pieces. On the screen in the background is the aerial image used in the file preparation. (Photo courtesy ABC Imaging)

PRODUCTS AND PROTOTYPES

In fact, consumers may have already encountered the fruits of 3-D printing without realizing it. Lewis reports 3-D systems are already used to produce and conceptualize models and working prototypes and tools of all types of finished products from custom-built duct systems for helicopters to specialized medical devices.

“We’re helping revolutionize the design and production of things like hearing aids,” adds Bradshaw. His company’s printers have also been used to test new designs in snowboards, bicycle handlebars and pedals. “In the new Iron Man movie, 90 percent of the parts for his outfit were produced with one of our printers,” he adds.

“Most of our customers are companies making physical goods, everything from toothbrushes to tennis shoes,” notes Harmon. “Clearly, these systems are also the best way to produce architectural models in a way that’s much faster, and less expensive, than anything available before.”

Three years ago, ABC Imaging became one of the graphics industry’s early adopters of 3-D imaging services, installing both the ZPrinter 650 and Stratasys Dimension 1200es systems at its Washington D.C. headquarters. “Our 3-D services keep us at the leading edge in adopting new technologies for our clients in architecture, engineering and construction,” says John Lee, 3-D Printing Specialist.

“It lets us offer a full suite of reprographic services. We can host a project’s construction drawings on BluePrintOnline and then output any type of print, including a 3-D-printed model, from those same two dimensional drawings.” Lee says the systems give clients the option of easily producing multiple models from the same file, each an exact replica, as well as several versions of the same design at different scales.

Another of ABC Imaging’s plastic architectural models, this one printed with its Dimension 1200es printer. (Photo courtesy ABC Imaging)

The ZPrinter 650 from Z Corp., uses inkjet technology to build full color three dimensional (10” x 15” x 8”) objects at a resolution of 600 x 540 dpi. With a vertical build speed of 1.1” per hour, it’s not fast by typical graphic printing standards. (Photo courtesy of Z Corp.)

“They appreciate this as a way to produce a model from their designs that’s both faster and less expensive than what was available to them before.”

AEC OPPORTUNITIES

That could translate into new opportunities for companies with a strategic interest in becoming that full line supplier of all types of output.

“Clearly, any reprographics house with a significant number of architectural clients could look at 3-D as a new service, a beneficial offering that most architects still don’t know about,” says Harmon.

Lewis notes many graphics services providers, “have been through the digital printing revolution while continually servicing the needs of architects, construction companies and engineers since the days of the plotter. When you provide a way to demonstrate the physical power of their designs, with faster turnaround than before, you bring them new value.”

This may not be a venture for all digital services providers, however.

“The big issue any service bureau is up against is that the prices on these systems are reaching a point where large commercial companies can now bring these capabilities in house,” cautions Bradshaw. “You also need special expertise in how to create and handle the STL files used by these systems.”

There’s much more to 3-D than adding a new printer, advises Lee. To succeed, providers must become masters of a new category of sophisticated design software, the systems themselves, and what can be labor intensive post-processing of models.

With several technologies competing in the same space, Lee advises anyone considering expanding into this area to evaluate the different systems based on what you intend to produce.

“Awareness is definitely growing but there are several competing technologies,” he says. “Some technologies are definitely better than others for producing different types of 3-D models, depending on the application.

“You really want to do your research before jumping into this.”

Sign & Digital Graphics

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