Guest Post - How The Cube Has Changed My Daily Workflow

Editor's Note:  I met Chris Crowley because he and his Cube had a rocky first  meeting.  His Cube had been damaged in shipment and he asked for some  advice.   I quickly became an admirer of his analytical skills and the  more we interacted the more I wanted others to hear from him.  Obviously, those initial problems were resolved and, as you can see,  Chris is clearly a Cube fan!

So, here is Chris' first guest post.  And, he is right.  You will be hearing from him in the future and I hope you will be hearing from him many times.

Hi Everyone -

I’m Chris Crowley, and I’ll be your guest blogger for today! I own Table Mountain Innovation, Inc.... a Mechanical Engineering consultancy specializing in medical equipment design.

Tom Meeks and I met through “Cube” activities, and Tom asked me to describe how the Cube has changed my daily workflow.

“Wow” is the best description!

All of my clients are extremely impressed by the fact that they get “free access” to a 3D printer when they hire me for mechanical engineering. You see... I don’t charge any additional fees to 3D print parts from my Cube. I am not acting as a “service bureau” for my clients. Just as I might make a prototype with a rough cardboard cutout, with my milling machine, or with my silicone casting process.... I can now simply print prototype designs on my Cube and test them with my clients.

I offer this service because the material cost is so low. Of course, I charge professional hourly fees for the concept, design, and CAD work, but now the printing comes “free”.

The results are simple.... my product designs are better. My design cycle is much shorter. The costs to the client are lower. We do more prototyping in less time.

I’ve used Cube parts in FDA “Final Verification” tests. I’ve used Cube parts as a 3D “master” to make a soft silicone mold, and then cast several silicone or rubber prototype parts from that tool. I’ve used Cube parts to repair existing machinery. The ABS is MUCH stronger than the epoxy-based stereolith parts that people sometimes purchase - this is critical for durability testing. The possibilities are endless.

The Cube has been great throughout. Perfect? No. There were some early technical issues quickly solved by 3D Systems’ top notch Customer Service. The surface finish isn’t as good as the $50K Objet Eden machine at my usual service bureau. I wish the accuracy was higher. I have some tricky geometry-related shrink issues. But... SO WHAT?!

In-house 3D printing capability has literally changed my business. I am 100% certain that the Cube has paid for itself in repeat customers, just in the last few months.

Here are some great examples:

Example #1: Replacement Spindle for Vinyl Printer

A client needed a “thumb-sized” spindle to replace a worn part on a very expensive production vinyl printer. The OEM spindle was so worn that it would occasionally DROP a 100+ pound spool of vinyl on the floor during a print job. They wrapped it in masking tape and rubber cement. When that didn’t work, the client used an old piece of sprinkler pipe, which caused the spool to jam. HP wants $900 for this part - it is only purchasable with a larger assembly. I reverse engineered the spindle and printed 3 replacements all in an afternoon. Client VERY happy!

Example #1a: Vinyl Printer Needing Replacement Part

Example #1b: Part Location

Example #1c: Cube Printed Part next to old

Example #1d: Cube Printed Part in Place

Example #1e: Old Part for Comparison

Example #1f: New Cube Part for Comparison

Example #2: Using a Cube Printed Part to Create a Mold

In this case, a Cube printed part was used as the "positive" for a wrist strap for a medical device being prepared for silicone molding. I’m pouring the second half of the mold, and the black “master” part is soaked in oily mold release. The strap was printed in the Cube, and the resulting molded parts will be “rubber” versus the rigid Cube ABS.

Example 2: Using a Cube Printed Part to Create Mold

Example #3: Snap-Fit Speaker Mount

I designed a production test fixture for a client, but they needed a quick solution to hold a speaker that wasn’t part of the original design. I quickly printed a snap-fit speaker mount, and we were back in business that afternoon. You can see the Cube “lime green” part near the lime green arrow. :-)

Example 3: Snap Fit Speaker Mount

Example #4:  A Clip to Hold Surgical Dressing

well... I’m not at liberty to disclose just yet. It is “clip” to hold a surgical dressing to the body in a certain fashion. As you know, human skin a full of sensitive nerves and tiny changes in the clip design really affect the comfort. The client and I have been working on many different designs... sometimes we print 2-3 per day. It is a magic and wonderful machine that makes this a design and prototyping process possible.


That’s all for now! I’m sure Tom will have me back sometime, and I’m sure that I’ll have more photographs for you!

Thanks for listening. If you want to find out more about me and my company:

Protomold Case Studies

http://tablemountaininnovation.com
http://www.linkedin.com/in/tablemountaininnovation
http://www.gokittygolitterbox.com

CubeX a finalist in Best of Show

Some congratulations are in order for 3D Systems.  The new CubeX, the big sibling to the Cube, has been nominated as a finalist for the Best of CES Peoples Voice awards.

CubeX

You can read about it on the Cubify blog and there is a link for you to vote for your own favorite among the finalists. The voting is only active for this evening, so take a look at it early.

Here is a link to the CES page announcing all the finalists.  The CubeX is the only 3D printer in the finalist list.  And, it beat out some heavy competition, going up against the new Makerbot Replicator 2X.

Frankly, I LOVE the aesthetics of this new printer, just as I loved the Cube's aesthetics.  But, as beautiful as they are, they would not earn my respect without more than matching their looks with solid performance to match.   And, since the Cube has NOT disappointed me in that regard, I expect the CubeX to be just as impressive.

I've decided, for clarity, to keep the focus of this blog dedicated to the Cube and the consumer centered aspects of Cubify.com.  The CubeX, clearly is a light industrial 3D printer and I'll be focusing on that category of 3D printers on my companion blog, 3DPrinterUsers.blogspot.com

But, I will point you to a wonderful collection of images of the CubeX and it's output from TheVerge.com.   There is one piece that seems to have warping issues and there are some minor issues with the globe.  But, the other results are simply spectacular!  The Cathedral blows me away.  Remember, just as were the Cubes shown last year at CES, these CubeX machines are probably development models so I wouldn't read much into the little glitches.  This printer is going to be AWESOME!

And, the judges at CES seem to agree!  Congratulations Cubify Team!

New Cube 3D Printer - 2nd Generation

The Cubify blog has a brief description of the new Cube 3D printer that also includes this photo.

ICube 3D Printer - 2nd Generation

Here is the description...

Meet the new Cube – the second generation at-home printer that can make anything you can imagine up to 5.5 inches cubed. Keeping all the features that are loved from the original Cube like the easy touchscreen UI, the new Cube printer now prints at 2X better accuracy and 1.5X faster speed with more material choices, and more colors and print modes available.
Along with more options, the new Cube has added safety features such as a glass plate that can hold a 3D printed object without heating up, making it even safer for your home and your children. Cube is the only 3D printer officially certified for home use with IEC regulations.
Another great feature about the new Cube is the user will be able to choose to print in both ABS and PLA plastics without adjusting any settings. The print head detects which materials are in the cartridge automatically. The Cube sells for $1299 or you can purchase a special print pack that comes with 4 cartridges, 25 files and cubify invent for $1399.

 First Analysis...

The specs are spars on the Cubify site.  But, the vertical (layer) resolution has been refined from .25mm to ,20mm.  This should make for nicer looking curved surfaces.  I have no idea if the horizontal accuracy has been improved.  But, this is something I will be testing the first chance that I get.  It's worth a trip to 3D Systems to find out for you, after they get back from CES.

The second thing to note is that we will not be limited to just ABS plastic.  The Next-Generation Cube, as they are calling it, is also able to print PLA.  This probably means that the print jet temperature can now be varied to match the different characteristics of the material.

But, there is also something else hidden in the above description and image that is a bit puzzling.  And, that is the phrase, " the new Cube has added safety features such as a glass plate that can hold a 3D printed object without heating up..."   For all practical purposes, the image of the new version and the original version appear to be identical except for the GLASS bed that is clearly seen in the image.  The glass appears to be frosted.  And, the description says that it no longer needs to be heated.  

This is something that I definitely plan to follow up on as soon as possible.  If they have found a way to print ABS without a heated bed, this is BIG news.  I will try to get to see one as soon as I can to run some tests on the new bed.  I love the toughness of ABS.  But, it needs to be able to be printed without lifting up.  

MORE TO COME....

Note:  If anyone should have any false ideas about my connection with 3D Systems, the fact that they posted their notice about the new version on January 3 and I didn't even know about it until today should set the record straight!  LOL!   I am typically woefully late hearing about new developments because I am concentrating on how to use the Cube more effectively than waiting for press releases!  :)

CubeX!! BIGGER and FASTER!

Knowing that this was CES week, I decided to check out the Cubify site early this morning.

The first sign that my instincts might be right about something special on the horizon was that the site was initially down.  But, a few minutes later I found out why.

I was shocked!!!  AND VERY PLEASED.

Not only was there an announcement of a 2nd generation Cube that is faster and more accurate than the first.  There was also an announcement that the the Cube has a big sibling!

It's called the CubeX and it's not just a little update.  It's a whole new printer capable of printing both PLA and ABS in up to THREE colors!

I don't have time to do it justice this morning.  But, go to www.Cubify.com

Be ready to be VERY happy!

UPDATE:  Pictures 

As you can see, it seems to be using cartridges similar to that of the Cube.   A puzzling thing for me is that it is apparent that the bed is NOT heated.  As you know, one of the things I love about the Cube has been the heated bed which reduces warping of ABS.  As the new Next-Generation Cube seems to have dropped the heated bed in favor of a special glass bed, I'm hoping that they have found a way to control ABS warping WITHOUT having to have a heated bed. 

 I can't imagine a scenario where 3D Systems would go backwards in this regard.  So, I am REALLY anxious to see the new beds in action and to test them for myself.

The goal is NOT to simply have a heated bed.  The goal is to be able to print ABS without warping.  I don't care how that is accomplished as long as it is accomplished.  :)

Designing to Reduce Warping #1

One of the great things about the Cube is that it comes with a heated build platform.  Until recently, most 3D printer owners had to concoct their own heated build platform or do without and be content to limit their printing the using PLA instead of ABS plastic.

That is because ABS melts at a higher temperature than PLA and has a tendency to warp as it cools.  A heated bed helps prevent too rapid cooling.

Recently, I was contacted by a Cube owner, in the Netherlands, that was experiencing warping of a downloaded object they were using to test their Cube printer.  They were wondering if the problem was the build platform temperature or some other issue with their Cube.  In particular, they noticed that their Cube build platform seemed to settle in at 115C which is slightly above the nominal temperature in the specifications.

STEP 1: Try to duplicate the problem

Having experienced warp with a non-Cube 3D printer, and not with the Cube, the first thing I wanted to do was check to see how my own Cube printer did with the object they were trying to print.  They sent me to the link to the object, a slanted stacking bin, on Thingiverse.
 

Slanted Stacking Bin by Cymon

Once I saw the design, which is generally very elegant, I felt that we would find that both of us would have issues with warping due to the way the plastic was so unevenly distributed on the upright areas of the part.  But, the only way to know was to print one in the same environment as the user which was a 68F room.

Sure enough, mine print warped in the same place described by the user.  So, the next step was to analyze the print process to see if we could determine why it warped.


STEP 2:  Tracking Heat Distribution

I had to admit that I had no idea what the temperature of the build platform of my own Cube was.  So, when in doubt, I did as I always seem to do and spent money on the tools to check it out for myself... and other Cube owners.  I picked up a digital infrared thermometer with laser pointer from Harbor Freight.

Infrared Thermometer

I wanted to test not only the bed temperature, to see if mine matches that of the user; but, also to test the temperature of the piece as it was built.

Starting Build Platform Temperature - 114.4C

Just as I'd hoped, our build platform temperatures were essentially the same.  This meant that there was nothing amiss with the user's Cube so they would not have to return it for a repair.  That was good news.

The interesting thing to note is that the print jet is a much higher temperature than the build platform.  This means that the ABS, for a while is well above the temperature of the build platform.  Early on, the temperature was recorded at 119.4C with an average of 118.6C.

Early ABS Temperature High of 119.4C

The highest ABS temperature that was recorded during the print was 123.4C.  This was actually at the top of the wall, late in the build.

Highest ABS Temperature Recorded - 123.4C Top of Wall.

But, between the bottom layers of the build and the top layers of upright wall, late in the print process,, things got interesting.  In the middle of the upright wall, the temperature was recorded as low as 77.4C.

Low Reading of 77.4C along the upright wall.

That is a HUGE differential in temperature.  But, to make matters more interesting, scanning the upright wall returned a variety of uneven temperatures.

Temperature Differential along Upright wall

If might be hard for you to see.  But, the highest temperatures along the upright wall were where the wall was thickest..  This probably resulted in the thinner parts of the wall contracting more than the thicker part of the wall which pulled the corner of the wall inward and the bottom up.

So, as elegant and beautiful as the design is, it contributes to it's own warping.

CONCLUSION

The uneven depth of the wall is probably the principle reason why both of us experienced the same warping of the object as it printed.  In addition, the flat side resting on the build platform probably also contributes to the behavior due to its thickness and mass.

So, what we need to do now is to see if we can accomplish the same goals as this design that will work well with the Cube without warping.  So, look for an update in part 2.

A SPECIAL THANKS

While I have not mentioned the name of the user, since I have not had a chance to get permission to do so, I am very grateful that this was brought to my attention.  It is the perfect example of how Cube owners can help other Cube owners by spotting issues and exploring solutions!

Cubify - A World of Designers and Manufacturers

This blog is almost a year old.  The first entry is dated January 11, 2012, shortly after the Cube 3D printer was announced.

I knew from the start that the Cube was the 3D printer that was going to open up 3D printing to a whole new group of people.  It was, and continues to be, the first real consumer 3D printer on the market.  But, a consumer 3D printer WITHOUT a community is not nearly as powerful as a driver for good as a 3D printer WITH a community.  And, it was clear, with the release of the Cubify web site, that 3D Systems also understood this.

If you will notice, this blog is called "CubifyFans" and not "CubeFans".  That is not to demean the Cube.  I pride myself on being one of its greatest fans.  It's what makes Cubify possible.  But, the Cube printer is just the first of what I hope will be a long line of ever more powerful 3D printers aimed at the consumer marketplace.  At some point in the future it will be seen as archaic and quaint as the first 1970's Pong game.

1970's Era Super Pong Game System

Few remember the very first 1976 Apple computer was, like many RepRap 3D printers, a 'bare bones' kit meant for hobbyists...

1976 Apple 'Kit' Computer

It wasn't until the release of the Apple II, a true consumer model, that the Apple really made it's mark on our culture.

Apple II -The First Consumer Apple

At the time of its introduction it was heralded as a major technological breakthrough. But, even that is crude by today's standards.  And, so it will be for the Cube in 40 years.

What will remain and grow is the 3D community as represented by Cubify.com.

Each of you reading this blog, when you come to own a 3D printer or begin creating a 3D design that can be printed, are founding members of that community.  You are on the ground floor of an inevitable explosion of personal 3D manufacturing that will ultimately cover every corner of the globe.

I have said it before.  But, it remains worthy of repeating...

Through distributed design and manufacturing via Cubify (and other peer-to-peer sites), every Cube (or other 3D printer) owner has the potential for being a manufacturing site having a worldwide stable of designers. And, every 3D designer has the potential for feeding a world-wide network of manufacturing facilities.

The minute you buy a Cube and begin to explore Cubify, YOU are a part of that world-wide dynamic.

On January 26, 2012, I talked about the tremendous potential of being a part of a world-wide network of geniuses. (See: Surrounded by Geniuses ) If you have purchased, for yourself or another member of your family, a 3D printer, then I assume you are among those astute enough to recognize the potential for 3D printing for creative people.

In that article, I mentioned a gentleman in Goa, India named Sid Naique.  At the time, he only had a handful of designs in the Cubify store.  But, even so, it was clear that he was a skillful 3D designer.  I'm happy to say that he is now a featured artist on the Cubify Store where he has specialized in scale model furniture.  As of now, he has at least 47 designs on the Cubify store!

Sid Naique - Kitchen

But, that was just the beginning.  From those first days, just one year ago, Sid Naique has created his own web site to showcase his wondeful creations and wide ranging design skills.

So, thanks to the community that is Cubify, a Cube owner in Kensington, Maryland is not only able to enjoy the work of a young artist in Goa, India; but, 'manufacture' it as well on my own 3D printer!

This is what Cubify is all about!  And, THAT is why I am a Cubify Fan!
 

Creativity Run Amuck! Photo Pop by BitBox

Blogging is a mind expanding pursuit.  And, that is especially true when blogging on a subject that attracts creative people.  This morning, I got a "Friends" message from Facebook from Ana Vaz Ferreira, a name I did not recognize.  I am certain that the request came about because of this blog.

I am VERY cautious about answering Facebook "Friend" requests.  I always go out of my way to research the person before deciding what to do.  In this case, my search lead me to a site called BitBox that makes apps for the iPhone and Android.  And, THAT lead me to an app that is loads of fun.

The nice thing about iPhone and iPad apps is that they are generally free or inexpensive.  Noticing that it had to do with photos and art, I decided to give their app, called Photo Pop, a try. And, THAT, was the beginning of a few minutes of hilarious fun with my grandchildren.  We had a ball.

It's definitely an app that draws out the insanity in us.

The idea is to take a picture and then add POP to the photo to create the REAL you.  Here's our first sample.

Greta Pop

Now, if a 13 year old can make herself beautiful, then surely a 69 year old can do one better.  So, here is my try,  Ain't I a beauty?

Pop with POP!

It seems to be a new app for the iPad and there are a few kinks to iron out.  One hint,  If you take a picture and it does not immediately show up in the edit window, leave the app and come back in,  The photo will be there.

Other than rhat, it's a LOT of fun and in just a few minutes my granddaughters and a friend created these Photo Pop results.

Roughing it!

And, of course, the others felt my YOUTHFUL view of myself was completely out of character and decided to create their view of me.

Old 3D Guy

Hmmm.... maybe Photo Pop is more dangerous than fun!

Thank you Ana!   We had a great time:)