3D printing is about to change the world forever

http://www.forbes.com/sites/ricksmith/2015/06/15/3d-printing-is-about-to-change-the-world-forever/

3D Printing Is About To Change The World Forever

I believe, along with a growing number of leaders around the world, that 3D printing will change the way things are produced more in this century than the industrial revolution did over the last 300 years.

Consider these two recent events:

A little over a year ago, a young Indonesian man named Arie Kurniawan participated in an open innovation challenge hosted by the global industrial company GE. The goal was to redesign the bracket that attaches a jet engine to an airplane wing. Arie’s design beat out over 1,000 other submissions, which was surprising to almost everyone. For one, Arie had absolutely no experience whatsoever with industrial manufacturing. None. Secondly, he had used a completely new design technique enabled by industrial 3D printing technology. But Aries’s bracket worked perfectly. It passed every one of the rigorous end use industrial tests for durability, stress and reliability.

And it weighed 83% less than the part it replaced.

At about the same time, halfway around the world, GE’s radical new fuel injection system for a jet engine first emerged from a industrial 3D metal printer. The previous system had 21 separate parts, which needed to be produced, shipped to the same location, and then assembled. The new 3D printed system had only one. It was five times stronger, and contributed to an increase in fuel efficiency of an astonishing 15%! That a savings of over $1 million dollars per year on fuel. On every single airplane that uses the new system.

Reports of these two startling events quickly spread throughout GE and beyond. While certainly no one expected these single parts to have an immediate impact on the company’s overall financial performance, the implications of these two events were disarmingly clear.

  • If 3D printing enabled individual parts to be redesigned with such massive improvements in efficiency, what possibilities existed for the companies’ other millions of parts?
  • If someone with no training in industrial production could so impact a company stocked with top engineers, what were the implications for the current global workforce?
  • If the new technology could reduce 21 component parts to one, what did this mean for the future of GE’s longstanding parts producers?
  • If these parts could now be cost effectively produced in the United States, what did this mean for the global supply chain?

Even bigger, what if these new technologies could be used to redesign not only a few parts, but an entire airplane?  Could we envision reducing the entire weight of a plane by 5%, 10%, even 20%?  An outcome like this would not simply result in a financial uplift for companies like GE—it would change the economics of an entire industry!

In fact, it would change every industry.

forbes.com

by Rick Smith | JUN 15, 2015 @ 2:05 PM

 

3D printed estate set

http://edition.cnn.com/2015/06/03/americas/architect-3d-prints-luxury-estate/

An artists rendering of a 3D-printed estate which is set to be built by architect Adam Kushner in conjunction with 3D-printing firm D-Shape.

The luxury 3D printed estate set to be made from sand, dust and gravel

(CNN)There’s already a 3D-printed house being built in the Netherlands. In China, 3D-printed mansions are reportedly on the rise.

Now, a 3D printed estate featuring a swimming pool, jacuzzi, car port and 2,400 square foot house could be coming to a sleepy plot of land in upstate New York.

The ambitious project is being undertaken by New York City architect Adam Kushner, alongside partners including 3D-printing pioneer Enrico Dini and his D-Shape firm.

Kushner told CNN that surveying has already begun with excavation work also set to commence soon.

The swimming pool and jacuzzi are penciled in to be completed by December 2015 while construction of the house is expected to continue until the end of 2017, he says.

An artists rendering of the pool house which will be 3D printed by D-Shape.

But the project hinges on getting the giant 3D printer, which will be used to produce the digitally designed building blocks of the estate on-site, into the country.

The device is currently in Italy after it was originally being built for a project partly funded by the Italian defense agencies. Military clearance is now required before the green light is given to export the printer to the United States, Dini says.

The delay in receiving this clearance is part of the reason the project has been held up since it was first announced back in August 2014.

“We are now waiting (for) permission to borrow the printer (from the military),” Dini says. “If I had another printer I’d send it there tomorrow, but unfortunately we don’t have and must wait.”

The litmus test

Whatever the import-export issues, Kushner says he sees the estate project as a test of D-Shape’s printer technology and its distinctive method.

This practice entails collecting sand, dust and gravel on site and mixing them with a magnesium-based binding agent to produce the 3D-printed building blocks required to piece the estate together. According to literature on the D-Shape website, the material produced by the printer is “similar to marble” in its constitution.

This technique is vastly different from other 3D-printing methods, Kushner says, and enables the production of many more “sculptural forms” that simply aren’t possible with other systems.

If D-Shape can prove its technology works and is efficient for a project of this size, Kushner believes it could lead to all manner of possibilities in architecture and construction. Not only could it be faster and safer than existing construction methods, he says, it could also end up being cheaper, more streamlined and of higher quality.

A Dini 3D printer like this one will be used to construct Adam Kushner's 3D printed estate in upstate New York.

And although the 3D-printed estate is something only the very wealthiest would be able to replicate, Kushner sees D-Shape’s construction methods benefiting the less fortunate as well.

“This will serve as a way of using our project to … pave the way for more humanitarian purposes that we see as the highest and best use for our technology,” he says.

“If we can build a simple pool house, I can print thousands of refugee housings. If I can build a pool, I can print underwater reefs (which he says D-Shape has already done before) to repair bridges, piers and infrastructures.”

A technology on the rise?

Integrating progressively more advanced 3D-printing methods into the construction industry has been a topic that has generated many eye-catching headlines in recent years.

The process of contour crafting — where large 3D printers are assembled on a building site (much like what will happen on Kushner’s estate) and programmed to construct pre-designed concrete structures and their relevant sub-components — was put forward by Dr. Behrokh Khoshnevis of the University of Southern California as far back as 2009.

Khoshnevis told industry website 3DPrint.com earlier this year that the first printers large enough for his version of contour crafting should become available within the next two years. He added that the method could even be used to build high-rise structures within ten years.

Chinese firm WinSun seemed to take inspiration from Khoshnevis’ methods when they claimed to have 3D printed a mansion and six-story tower block in the city of Suzhou, eastern China earlier this year.

Meanwhile, in the Netherlands, DUS Architects continue to piece together a 3D-printed house using its “KamerMaker” machine. Company co-founder Katherine De Wit described the DUS technique as being a potentially valuable tool that could be added to those already used to build homes.

An artists impression of the DUS Architects 3D printed house.

Other experts, however are more cautious about the immediate potential of 3D-printing technology in the construction industry.

In an interview with CNN in 2014, Dr. Phil Reeves, managing director of UK-based 3D-printing consultancy and research firm Econolyst, described 3D-printing a house on site like that planned by DUS as counter to existing building techniques which are already relatively efficient.

Then there are other fast-developing building methods like prefabricated construction which entails manufacturing components in a factory before transporting and rapidly piecing them together on a building site.

Chinese firm Broad Sustainable Building claimed to have used this method to piece together a 57-story skyscraper in just 19 days earlier this year.

For Kushner, however, the benefits of large-scale 3D-printing are many and will likely increase as the technology becomes more advanced.

“This is not superfluous, nor a lazy architects idyll,” he says. “I think it’s as important as the automobile was in changing the design of cities or how the printing press altered communication.”

“Why? Because it democratizes construction and architecture and puts it into everyone’s hands, just like the camera phone made everyone a photographer. Not everyone is good at it but everyone can become one.”

edition.cnn.com

3D printed prosthetics for Ugandan schoolchildren

http://www.3ders.org/articles/20150603-3d-printed-prosthetics-get-ugandan-amputees-back-on-their-feet.html

3D printed prosthetics get Ugandan schoolchildren back on their feet

Although we’ve heard numerous stories about how 3D printing has helped enable hundreds of those in need of prosthetic limbs, a majority of the cases have been located in the United States or the United Kingdom where 3D printers or 3D printing providers are becoming increasingly common and access to a 3D printer is getting easier than ever before.  While this is excellent news, there are still many world locations where affordable prosthetic devices – and even 3d printers in general – are needed and could be used perhaps even more than those located in more developed Western countries.

In the meantime – thankfully – various organizations and 3D printing providers have been picking up 3D printing jobs as needed to ensure that those who need the prosthetic devices the most are getting the proper care that they need.  More recently, the University of Toronto and charity Christian Blind Mission took it upon themselves to produce prostheses for a Ugandan schoolboy who had been in need of a prosthetic device for years.

The schoolboy, Jesse Ayebazibwe of Kisubi, Uganda, tragically had his right leg amputated after he was hit by a truck after walking home from school three years ago.  Since then, the nine-year-old has been maneuvering with the aid of crutches – however they have since made it difficult to play or move around.  “I liked playing like a normal kid before the accident,” he said.

Thanks to the support of a local orthopaedic technologist, Moses Kaweesa of the Comprehensive Rehabilitation Services (CoRSU) in Uganda, Ayebazibwe was able to use an infrared scanner and some 3D modeling software to create a prosthetic solution for the young boy before shipping the files to Canada to be 3D printed.

“The process is quite short, that’s the beauty of the 3D printers,” said Kaweesa.  “Jesse was here yesterday, today he’s being fitted.”

While Ayebazibwe previously wore a traditional-style prosthesis last year, his new 3D printed prosthesis is among the first in a trial that could see more 3D printed prosthetic device across Uganda for others in need – thanks in no small part to the efforts of Kaweesa.

Currently, the entire country of Uganda has just 12 trained prosthetic technicians for over 250,000 children who have lost limbs, which are often due to fires or congenital diseases.  At $12,000, a portable solution consisting of a laptop, a 3d scanner and a 3d printer is not cheap – however when considering the impact that a portable prosthetic device system could have on over 200,000 children in need – in northern Uganda alone, many people have lost limbs due to decades of war where chopping off limbs was a common reality.

“There’s no support from the government for disabled people … we have a disability department and a minister for disabled people, but they don’t do anything,” said Kaweesa.  “You can travel with your laptop and scanner.”

Upon receiving his 3D printed prosthetic, Ayebazibwe was clearly ecstatic.  “(It) felt good, like my normal leg,” he said. “I can do anything now — run and play football.”

The boy’s 53-year old grandmother, Florence Akoth, looks after him, even carrying him the two kilometers to school after his leg was crushed and his life shattered. She too is thrilled.

“Now he’s liked at school, plays, does work, collects firewood and water,” said Akoth.

3ders.org

by Simon | Jun 3, 2015

http://www.3ders.org/articles/20150603-3d-printed-prosthetics-get-ugandan-amputees-back-on-their-feet.html

19 year old creator of cheap robotic arm controlled by brainwaves

https://www.yahoo.com/tech/19-year-old-uses-3d-printing-to-create-cheap-120454888024.html

19-Year-Old Uses 3D Printing to Create Cheap Robotic Arm Controlled by Brainwaves

For Easton LaChappelle, a 19-year-old from Colorado in the United States (U.S.), the difficulty with robotics has never been the technology itself – something he says he managed to master in a matter of months from his bedroom in his parent’s house – but the cost.

The technology used by most robotic arms and hands on the market – and many more of those in development – typically comes with large overheads.

In the last five years, though, learning almost exclusively online in forums and emails, LaChappelle has managed to synthesize a series of robotic hands that could change industries and lives – and most of which cost just a few hundred dollars.

While other developments in countries like Austria and Argentina have pushed the boundaries of prosthetic offerings, helping those missing limbs to start to regain use of them with robotics, LaChappelle has done so using 3D printing.

And he’s made one that he says can read your mind. It’s called Anthromod.

“This reads right about 10 channels of the brain, so it kind of works kind of like a muscle sensor in that it picks up small electric discharges and turns that into something you can actually read within software, and then we actually track patterns and try and convert that into movement. So with this I’m actually able to change grips, grip patterns, based on facial gestures, and then use the raw actual brainwaves and focus to actually close the hand or open the clamp or hand,” he told Reuters Television.

One of the most important aspects of the Anthromod design is the way in which it’s controlled by the software, which LaChappelle says is different from the types of control that exist in other robotic platforms.

While it’s the hand itself that moves, as more advanced controls are created it’s the software that’s doing the heavy lifting, using algorithms that make the arm easier to use.

“A good example is we actually had an amputee use the wireless brainwave headset to control a hand, and he was able to fluently control the robotic hand in right around about 10 minutes, so the learning curve is hardly a learning curve any more,” he said.

The arms themselves might not look polished and ready for the shop floor – but LaChappelle sees them as cutting edge.

His robotic arms are all prototypes, each fulfilling a different need according to their design, with some using a wireless brainwave headset, designed more for prosthetic use. Another of his tele-robotic controlled hands was created with dangerous environments in mind, where human-like robots could be sent to allow people to monitor situations and intervene from afar.

“I really tried to make this as human-like as possible – this is probably about my fifth generation of the full robotic arm, and this is controlled using a full tele-robotic system, so there’s actually a glove that you wear that tracks your hand movements, accelerometers to track your wrist and elbow, and then an IMU sensor as well to track your bicep rotation as well as your shoulder movement, and that gets all translated wirelessly to the robotic arm where it will copy what you do,” he said.

One of the most impressive aspects of the arm is not the hardware itself, or even the software that controls it – but the fact that it can be 3D printed for a fraction of the cost of modern prosthetics.

This allows him to make complex internal structures to the designs which would otherwise be impossible, using not just any 3D printer, but precisely the kind many expect people to have at home in the near future.

“So 3D printing allows you to create something that’s human-like, something that’s extremely customized, again for a very low cost, which for certain applications such as prosthetics, is a really big part of it,” he told Reuters.

“The full robotic arm is actually open source, and so people are now actually able to take this, reproduce it, and adapt it for different situations, applications, and really see what you can do with it,” he added.

The Anthromod itself cost only about 600 dollars to make, LaChappelle said.

His work is documented in the videos he made at home, showing his handiwork – all part of his effort at making the invention open source – which means anyone can take his technology and customize and build on it.

The idea, he said, is not to create something that can solve problems for those with prostheses and other needs for robotic arms like the ones he’s invented – but rather to create a platform that people around the world can use to customize their own versions of to suit their needs.

“A big reason we designed this on the consumer level is because we made this open source, we want someone that has a 3D printer, or very little printing experience, to be able to replicate this, to be able to use this for new applications, to be able to adapt it into new situations, so it’s really exciting to see what people will start doing with something like this,” he said.

“For the actual arm, we designed everything to be modular, meaning all the joints can actually interchange, and there’s a universal bolt pattern. So you can now create something human-like, or you can create a big 20 degree freedom arm for complex filming or even low cost automations. So we really want to make a robotics platform, not so much just a robotics hand from this,” he added.

LaChappelle hopes his efforts will contribute to developments in bomb defusal robots, heavy equipment and heavy industrial automation robotic arms, as well as exoskeletons.

yahoo.com