Star Trek Tech Today: 3D Printing

[Daniel Leuck]

I recently had the chance to spend some time at RAPID Technology's offices in the Executive Center. Prior to my visit I knew very little about the world of 3D printing. I'd heard of it, but assumed 3D printers were still in laboratories at MIT. I was amazed to learn 3D printing is being used today by businesses for everything from product prototypes and prosthetics to costume armor for movies. It can even be used to print working mechanical devices with moving parts. The model above was printed as one piece with moving gears. No assembly required!


The material used to print the models can be infused with infiltrants that give the objects radically different properties and appearances. Some feel like rubber while others look and feel like solid metal. Today's 3D printers are capable of producing very intricate models with a painted appearance. The vase below sports delicate flowers on its exterior and Chinese characters on the interior.


Many thanks to RAPID COO Russ Ogi for providing us with a tour of the RAPID facility and educating us about the world of 3D printing. If you want to learn more, give Russ a call at [phone].

Company Profile
RAPID Technology LLC (RAPID) is a Honolulu-based, Minority, Service-Disabled, Veteran-Owned Small Business specializing in the use of technology to reduce cost and increase efficiency. Our specialized solutions include 3D Printing equipment sales, 3D design and on demand production services. 3D Printing is a technology that converts 3D computer data layer by layer into a physical model you can hold in your hand. RAPID focuses on process and system based solutions. We analyze the overall client needs and goals to streamline project communication, reduce delivery time and create more efficient business processes.

Our solutions have included product prototypes, 3D models for design analysis, virtual walkthroughs for client presentations, educational lesson plans for learning 3D applications, and consultation on automated digital processes to streamline and replace traditional practices.

RAPID currently services industries from engineering and architecture to entertainment, forensics and education. We are listed on the Central Contractor Register (CCR) and are a registered vendor with SuperQuote and the Hawaii State Department of Education (DOE). As Hawaii's certified Z Corporation dealer for 3D Printing and scanning solutions, RAPID provides all technical support and training locally.

Description of Images
Braingears: The braingears are an interlocking set of gears that rotate together when any one of the gears are turned. The most interesting aspect of this model is that it is not assembled and despite the moving parts it actually prints out in one piece.

HWC_inside: This is a model of the proposed Hawaii Wildlife Center created by former Kealakehe High School Senior, Jonny Hasselmann. Hasselmann created the CAD model that generated this 3D print originally as a student project. This model was used by the Hawaii Wildlife Center organization to secure funding and receive final approval for its construction.

Samurai: This Samurai helmet is an original artwork created by RAPID's Chief Operating Officer, Russ Ogi. The inspiration behind the piece is the question, "If the Samurai had continued into modern times, what would their armor have evolved into?"

Vase: This model is an example of the color capability of the 3D printer. The design and the vase itself are created at the same time, layer by layer in the 3D printer. This unique process allows for the design to even be printed on the inside of the vase.

Ikayzo - Design • Build • Localize | Web • Desktop • Mobile

[Ken Berkun]

I think we all wish we had time, but let me know when I can move into one of your homes!

[Daniel Leuck]

Nice work Christopher! Thank you for sharing.

[Christopher Jetton]

Hi Ken,

Thanks for sharing the links about that project. It will be interesting to see the final project. I am wondering if they do windows. In other words, the contour build does not use support material, so a strategy will have to be created similar to the roof. They came up with supporting the roof with corrugated or ribbed material to support the roof build. Maybe the tool path would do a stop and flatten motion and then start again. This would leave flat gaps for the windows, and then at some point, a support will be placed to hold the top of the window. The roof, ceiling, and tops of the windows will be flat. I guess that is why he is aiming for the affordable housing market.
The cost of my design would not be greater, and could be used for affordable and luxury homes. In my design, sand is used as the support material. This not only allows for windows, it allows for dome shaped buildings, fancy vaulted ceilings and a multitude of roof designs with built-in tile patterns. Color can also be added so that the building will be completely maintenance free. A brick pattern with the look of mortar can also be done and the color would be in the mix as it is being shot. The sand would be removed with a vacuum and loaded on trucks ready for the next job. Do not get me wrong, there are drawbacks to my design as well such as the ratio of space to building will be greater. His design allows for the building to come right up the rails. I have not looked at my design in over ten years, but this has renewed my interest. If only I had time to pursue all of my projects.

[Ken Berkun]

Home page for contour crafting: http://www.contourcrafting.org/

[Ken Berkun]

Speaking of building houses, did you see this?

http://www.technovelgy.com/ct/Science-Fiction-News.asp?NewsNum=57
Contour Crafting: 3D House Printer

And an update:
http://www.technovelgy.com/ct/Science-Fiction-News.asp?NewsNum=900

[Christopher Jetton]

There seems to be a lot of 3d printers on the market today. The price is decreasing as popularity increases. As a consultant for this technology (CAD and CAM), I have a lot of experience with different Printers. I have attached a battleship that was printed on a 3D printer. Printing is usually referred to as “Grown” since the process is a layer by layer process. The battleship was, or still is, sold at Maui Divers Jewelry located at Pearl Harbor along with some other military designs of mine.
I have some architectural models grown on color printers as well. These will have the roof tiles and color in the code and when the printer grows the file, it will include the different colors in the model.

Do not forget the viable subtractive prototyping that has been around for a much longer time. I have a little of this information and more pictures on my CAD/CAM site, www.cadfilestogo.com.
I have often wondered about this… If it takes a milling machine to mill out the parts for a milling machine… Well, you do see the dilemma, do you not?

One last thing... I have invented a rapid prototype machine that will grow a house. Cement and water are mixed and sprayed layer by layer. The build material, or support material is sand. The machine rides back and forth on temporary railroad ties during the build. Sintering technology is used for the wiring and another pvc material for the plumbing. Once the house is built, the sand will be removed and the shell of the cement house will be left and ready for the windows and doors. It would be so cool if money fell from Heaven to build one. ;-)

[Collin Kobayashi]

I use 3D Printing as well. It works out well with the educational training program I have with students. They get to design objects in CAD and I have it printed out for them. They love it!

[Alyssa Murphy]

Check it out! http://www.youtube.com/watch?v=_P3ijLiqOKo
These guys made a 3D printer that prints sugar (sugar cubes, sugar spheres)

[Kurt Sussman]

You know you can build your own, right? Check out the RepRap project. I don't think it can build a system with working gears in one pass, but it'd be fun to try!

[Truman Leung]

Interesting, Mitchel! Do you have pictures of ship models that you printed out?