nScrypt and NovaCentrix hybrid 3D printer named winner of 2016 Innovations Auditions

Nearly two years ago, micro-dispensing and 3D printing company nScrypt partnered with electronics company NovaCentrix to create an unrivalled, all-in-one system for 3D printing electronics. Together, and with a significant investment from FlexTech Organization, the companies were able to combine nScrypt’s top-of-the-line 3Dn 500 3D printer with NovaCentrix’s PulseForge to create the currently named 3DnPulseForge, a system which was recently named the winner of the 2016 Innovations Auditions competition hosted by the annual SME RAPID conference on 3D printing.

At the 2016 Innovations Auditions hosted by RAPID, nScrypt and seven other innovative additive manufacturing companies and entrepreneurs were invited to showcase their ideas and technologies to a panel of judges and investors. Keeping in line with the Auditions format of the event, each company was given five minutes to pitch its 3D printing innovation and explain how it could impact the additive manufacturing industry in a big way. Among those in attendance for the event were Trilion Quality Systems, talking about their 3D Digital Image Correlation for holistic measurement of material strength technology, Laser Design with their CyberGage360 3D scanning system, and a number of other candidates.

In the end, Orlando, Florida-based nScypt was selected as the winner of the competition. The 3D printing system developed by them in collaboration with NovaCentrix has offered a versatile multi-head 3D printer capable of printing in an impressively wide range of materials. Primarily, the 3DnPulseForge has applications in the 3D printing of complex electronics and hybrid circuit boards. The easy-to-use system can even print an entire working electronic circuit at the push of a single button, without any necessary post-processing.

Kenneth Church, CEO of nScypt said of the achievement, “Working with NovaCentrix has been rewarding on many fronts. Great collaborators can do great things together, and together we have created a new level of possibility for 3D printed electronics. We really appreciate being recognized by RAPID for our joint effort.”

Church hopes that the continued advancement of 3D printing technologies, like nScrypt’s own, will help to resurge the American manufacturing industry. He explained, “We used to be so good at machining here in the U.S. We can regain that position, but we can also do much more. Rather than just milling big bulk parts, we can 3D print and polish where it’s possible and then mill where we need to mill.”

nScrypt’s technology, by offering both precise and fast 3D printing capabilities, is undoubtedly contributing to additive manufacturing’s viability as a large-scale manufacturing option. Additionally, the technology also offers an unprecedented level of customization, which will impact a number of industries. As Church continued to explain, “Personalization in medicine will continue to be really important, but there will also be a bigger demand for it in consumer goods, as well. With 3D printing and the technology it enables, someday people will want more than just comfortable shoes. They’ll want shoes that can give them feedback and data, shoes that can talk to them.”

While nScrypt and NovaCentrix’s advanced 3D printing system has not been put on the market yet, the attention it has been receiving, along with having won top prize at the 2016 Innovations Auditions competition, indicate that the technology will be a disruptive force, not only in the additive manufacturing world, but in the manufacturing sector at large.

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An Israeli 3D printing startup announces move to print stem cells

In an unusual move Nano Dimension, an Israeli company called focused on printing electricity-conducting nano-material ink, is expanding into the biotech sector

Nano Dimension, a 3D bioprinting company located in Ness Ziona, Israel, has successfully tested a prototype for a new type of printer that uses stem cells to produce 3D models. The trial was done in conjunction with Haifa-based Accellta.

The move by Nano Dimension is a major pivot. As the name implies, they have been focused on printing nano-sized components for durable electronics. Calling it a pivot might be a leap in itself though, as this could be a rare effort by a 3D printing startup to expand simultaneously into both biotechnology and electronics manufacturing. Their products depend on a combination of inkjet printing, proprietary software and of course nanomaterials, mainly printing conductive and dielectric inks for printed circuit boards (PCBs).

“3D printing of living cells is a technology that is already playing a significant role in medical research,” said Amit Dror, CEO of Nano Dimension. “But in order to reach its full potential, for the field to evolve further, there is a need to improve printing speeds, print resolution, cell control and viability as well as cell availability and bio-ink technologies.”

Accellta is the biotech expert in the relationship. The company manufactures “reproducible suspension-based cell culturing systems” which were essential for Nano Dimension’s system.

“By enabling high precision 3D bioprinting and differentiation of stem cells into required tissues, our combined technologies have the potential to enable vast areas of development,” said Dr. Itzchak Angel, Chairman and CEO of Accellta. “We hope and believe that this will bring the mutual capabilities and know-how of both companies to create 3D bioprinting solutions that combine a high precision, high-throughput printer with dedicated bio-ink technologies, derived from stem cells.”

Various estimates exist for the future value of the industry. Grand View Research forecasts a $1.82 billion industry by 2025, while IDTechEx predicts it will be worth more than $6 billion by 2024.

There are several competitors in the market: EnvisionTEC’s 3D Bioplotter, Organovo’s NovoGen MMX 3D BioPrinter, RegenHU, Cyfuse Biomedical, Russia-based (and not-so-inspiringly named) 3D Bioprinting Solutions, Regemat3D, the BioAssemblyBot, GeSim Bioscaffolder, and many more.

Several companies in the field have also broken the stem cell barrier. Biopen might have the most advanced concept, which is testing a device that would allow 3D sketching by doctors during surgery using stem cells and other biomaterial. That wouldn’t make the larger printers obsolete, but help real-time improvisation by surgeons who might need material in imprecise dimensions faster than specific printing preferences could be uploaded to a bioprinter. A team at Heriot-Watt University in Scotland is also working on a valve-based technique to print the cells.

“By combining our high speed, high precision inkjet capabilities with Accellta’s stem cell suspension technologies and induced differentiation capabilities led by a world-renown group of experienced engineers and scientists, we can enable 3D printing at high resolution and high volumes,” Dror added.

Founded in 2012, Nano Dimension is run by CEO Amit Dror, CTO Sharon Fima, COO Dagi Ben-Noon and CBO Simon Fried. The company will present at the LD Micro Invitational in Los Angeles on June 7.

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Sure, we have a 3D printer ... but we're not using it much yet

Pella has been using 3D printing for 14 years to make prototypes, but only recently started using the technology to make parts for its windows and doors.

The company still doesn't make too many pieces that way, though. While the technology and materials have improved, the costs haven’t hit their sweet spot yet, said Kevin Gaul, the Iowa-based company's engineering manager. 

“Materials can still be a little bit of a bear, either from capability or cost,” he said. “If we’re going to use hundreds of thousands of these parts a year, it doesn’t make sense to 3D print.”

Experts say many companies that invested in 3D printing are hitting road blocks with their machines, ranging from cost issues to lack of digital manufacturing expertise.

“People are interested enough to buy it or invest in the technology, but there’s this lag in how they can actually use it effectively or match their expectations,” said Mike Vasquez, founder of Chicago-based digital manufacturing consulting company 3Degrees.

With promises that 3D printing could help people eat healthier or create body parts, expectations have risen pretty high in the past couple of years.

Scientists say they're closer to 3D printing body parts

Many companies got caught up in that hype before they figured out the right ways to incorporate the technology, Vasquez said. They may lack the know-how to use it, and with some companies, it might not make good business sense.

Three of every four companies that are using 3D printing don’t think they’re using the technology to its full potential, according to a survey 3Degrees released earlier this month. 

Fifty-four companies from around the country responded to 3Degrees' survey, 38 of which use 3D printing technology. Only half of those 38 said they had moved past prototyping to experiment with end products.

Even if a company has a perfect execution plan and expertise to back it up, it takes time to implement, to train engineers how to think differently about design.

“There’s going to be a little push back,” Vasquez said. “It’s going to take some time to mature.”

Society as a whole needs to change the way it thinks before that can happen, said Julie Friedman Steele ⇒, founder of the 3D Printer Experience in River North.

Those using 3D printers need to start thinking more like creators than consumers, she said.

"Makers and hackers tend to utilize it pretty easily, because they think pretty differently about what they want to do," she said. "It's just about how you think about manufacturing and the products that you use."

She’s seen many companies that jumped into the 3D printing fray without realizing what it takes to maintain the machines, and investing in the wrong kind of technology.

Even schools, which have been populating labs with the machines and adding them to curriculum, are underutilizing 3D printers, Steele said.

Some companies outsource 3D printing needs.

Urban Architecture Studio, which works out of WeWork in River North, has 3D Printer Experience create some of its models, mainly because they don’t have space or the capacity to maintain a machine of the necessary caliber, said architectural designer Daniel Caven.

Gaul, from Pella, said his company intentionally hasn’t reached full capacity with their 3D printers. They buy machines that are more advanced than they need, hoping to grow into the printers' capabilities. Pella also experiments with 3D printing technology before making the investment.

“We really try to learn before we buy,” Gaul said. “When we bring it in house, we know the technology and what the applications are going to be, so we can make good use of the technology once we make that investment.”

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'Alien' boy gets new skull in pioneering 3D printing surgery

A YOUNG boy often compared to an "alien" since birth has been given a chance at a normal life thanks to 3D printing technology.

OPPORTUNITY: The operation has given the young lad a chance at a normal life

Doctors creating a detailed model of the boy’s misshaped head – who suffered previously because of a rare skull defect.

Now eight months old, the boy known as Xiao Yu, is now recovering following the successful surgery.

SURGERY: Doctors were able to print the young boy a 3D skull

OPERATION: The surgery proved to be successful as the young lad is recovering

Craniosynostosis, which is estimated to affect six babies in every 10,000, causes the joints between the patient’s skull bones to close prematurely before the brain is fully formed.

More worrying than the effect on the subject’s appearance, however, is the fact that the condition can impair brain development – which could cause seizures and even death.

Xiao Yu was put in the care of Dr Bao Nan and his colleagues at the Shanghai Children’s Medical Center in East China.

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Repurposing Portland Stone Waste with the Novi 3D Printer

Background

Dealing with the waste in this world is now, more than ever, of crucial importance. In the limestone quarrying industry, for instance, it has been suggested that valuable waste is around 80% to 90%. In an effort to sustainably deal with this high amount of valuable limestone waste, Jack Biltcliffe, in collaboration with ASTUDIO and the Portland Sculpture and Quarry Trust, developed Novi, a 3D printing mechanism that has been designed from the ground up to work with the extrusion of limestone slurry. This project was developed as part of a major project for an undergraduate degree at Brunel University London.

Quarrying Limestone – An Inefficient Process

The architecture industry, which is the primary market for quarried limestone, has set high quality standards and requirements for limestone. Inefficiencies which cause waste during the quarrying and masonry stages are largely due to the fact limestone is a natural material which contains many natural faults. For the quarries it is not economical to cut around these faults and so extracted stones with faults in them are often wasted. The whole masonry process produces waste at such a fast rate it seems impossible to keep up, and so vast areas are needed to store and process waste. When a large enough quantity has accumulated the waste stone can then be transported to a crusher to be turned into aggregates.

Working with the Isle of Portland

The Isle of Portland has been built around the limestone quarrying industry. Portland Stone is some of the most sought after limestone, notable buildings such as St Paul's Cathedral (London, UK) use it as a building material. Through contacts on the Isle of Portland such as the Portland Sculpture and Quarry Trust (PSQT), this project has been able to collaborate with quarries and become involved with the exciting regeneration project happening on the island. The objective of this project is to reuse the waste material produced during the quarrying in a manner that will help with the regeneration project on the Isle of Portland through a sculptural piece.

Limestone Paste Extrusion Development

Through a series of iterative experiments, a limestone paste extrusion process was developed as part of a major project for an undergraduate degree at Brunel University London. Initially, it was observed that a fine grain of Limestone would mix with coolant during the stone cutting process to create a limestone slurry. This slurry can be left to dry out, then hardens completely and is bound together. The process of drying out slurry can be exploited for paste extrusion and ultimately 3D printing purposes.

Material Development

Testing of the pure limestone prints presented many challenges. For instance, once the printed object comes into contact with water it disintegrates back into slurry again. Structural testing also showed the pure limestone parts were extremely weak in tension. Material development through the addition of external compounds into the mix has been ongoing, with positive results so far.

3D Printer Development

The first physical experiments involving 3D printed limestone objects involved hacking a ‘Mendel90’ desktop 3D printer to use a 10ml syringe, as a form of controlled paste extrusion. After optimizing the syringe setup and managing to successfully print in limestone, it quickly became apparent that safely extracting prints was a problem because of the long drying time. The small scale test objects had to dry for over 12 hours before they could be handled or removed from the build plate. This means the 3D printer cannot be used for long periods of time while a print dries. To combat the need for waiting on prints, further research into tri axial movement mechanisms was conducted. A version of a robotic arm seemed a great fit because of its versatile nature. Further research into robotic arms found that one of the simplest mechanism, giving all 3 axis of movement required, is the SCARA mechanism. The SCARA robot is traditionally used as a pick and place robot in assembly line operations. The two arms work together to recreate the XY positional values. Unlike conventional 3D printers it is not constrained to a self contained build plate, instead any flat surface can become a build plate and the printer can move to a new build plate. A custom developed SCARA robotic arm called ‘Novi’ was designed and developed as part of the project with 3D Printing specifically in mind.

Larger Scale Extruder

A larger format paste extruder was developed alongside ‘Novi’, to allow for larger prints. The new extrusion system builds upon the previous system, a larger format syringe with a capacity of 200ml was chosen to fit on the end of the arm. The benefit of continuing to use syringes at this stage is ease of use and the ability to buy in multiple syringe bodies which can be filled with different material mixes and used as a cartridge drop in drop out system.

Application

The hope for this project is that it will help with the regeneration happening on the Isle of Portland through the creation of sculptural pieces. Further development is underway to build more ambitious designs and to also explore other practical applications that could impact the architectural industry.

Please visit the Made in Brunel student showcase 16-19th June to see the printer in action!

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HACKLET 109 – Complex 3D Printed Projects

If you can’t tell, we’re on a roll with 3D printers and printed projects this month. So far, we’ve covered printers, and simple functional 3D prints. This week we’re taking a look at some of the awesome complex 3D printed projects on Hackaday.io.

Complex 3D printed projects are things like robots, quadcopters, satellite tracking systems, and more. So let’s jump in and look at some of the best complex 3D printed projects on Hackaday.io!

We start with [Alberto] and Dtto v1.0 Modular Robot. Dtto is [Alberto’s] entry in the 2016 Hackaday Prize. Inspired by Bruce Lee’s famous water quote, Dtto is a modular snake-like robot. Each section of Dtto is a double hinged joint. When two sections come together, magnets help them align. A servo controlled latch solidly docks the sections, which then work in unison. Dtto can connect and separate segments autonomously – no human required. [Alberto] sees applications for a robot like [Dtto] in search and rescue and space operations.

Next up is [Szabolcs Lőrincz] with Broke Hackers’ Model Railway. Anyone who’s read Steven Levy’s classic book ‘Hackers’ knows that model trains and hardware hacking go hand in hand. Unfortunately, model trains have gotten prohibitively expensive. Broke hackers’ model railway is the perfect solution. Nearly every part is 3D printed. The tracks are 3D printed sections with copper tape conductors. The locomotive has a 3D printed frame. Automated track switches use hand wound coils on 3D printed bobbins. This isn’t a dumb railway either – a Raspberry Pi controls the action, making sure the trains stay on time.

Next we have [Rob] with Quadrup3D, his 3D printed quadruped robot. Quadrup3D uses 12 beefy R/C style servos to move its four legs. An Arduino with a Bluetooth handles on-board processing. This robot is built from 25 individual 3D printed parts. From the center frame to the legs, just about every major structural piece has been spit out by an FDM desktop printer. [Rob] uses his  SpaceMouse Pro as a remote control unit. A laptop processes commands from the mouse and sends them to the robot. Using a control scheme like this allows [Rob] to quickly and easily experiment with different gaits and stances for his four legged friend.

Finally we have [tlankford01] with LOKI 4G (Locate Observe Krack Isolate) 4th Gen. Who says you can’t 3D print your own drone? LOKI uses 3D printed parts for most of its major components. Carbon fiber rods act as the quad’s spine. Riding on these rods are 3D printed propeller guards, battery holder, and electronic enclosures. One of the most interesting parts is the 3D printed gimbal, used to stabilize aerial video. LOKI was used as a test mule for Project ICARUS, [tlankford01’s] poacher hunting 3D printed fixed wing drone.

If you want to see more awesome complex 3D printed projects, check out our new complex 3D printed projects list! If I missed your project, don’t be shy, just drop me a message on Hackaday.io. That’s it for this week’s Hacklet. As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

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3D Printing: The Stories We Didn’t Cover

This week’s news reports that Hong Kong researchers are using 3D printing to aid in heart surgeries, Minnesota students 3D printed a violin, and Magma Global Ltd. has 3D printed the longest-ever PEEK subsea pipe. Sculpteo has been 100% successful with its new Express Production Mode, and Nano Dimension has received recognition as a very cool vendor. Finally, WillowFlex has made its biodegradable filament available in 2.85 mm diameter.

Hong Kong Researchers Use 3D Printing for Heart Surgery

The Chinese University and the University of Hong Kong have come up with a way to create complex heart structures with 3D printing technology. The actual heart structure is first captured via ultrasound imaging, followed by the creation of “a silicone model using specially developed computer software.” It takes two days to complete the whole process, from ultrasound scanning to the completion of the 3D printed structures. The technology has been applied during three operations, the first involving a 78-year-old woman who had suffered several strokes. In the successful surgery, an occluder was used; this is a device covering a hole in the heart to stop blood clot formations in the patient’s heart.

Prince of Wales Hospital in Sha Tin was the first in the city to apply the technique in heart operations; previously, it had been too difficult to select the proper device without a model that helped gauge the size of the hole in the patient’s heart. According to Dr. Gary Cheung Shing-him, Clinical Assistant Professor at the Chinese University’s Division of Cardiology, doctors had to prepare different sizes of occluders when performing operations in the past:

“If the size didn’t match, we had to use a catheter to retrieve the occluder. The time and risk of the operation would be increased too.”

With 3D printed models of patients’ hearts, doctors can determine the properly sized occluder before surgery, thus saving time and minimizing risk to the patient.

Minnesota Students Create a 3D Printed Violin

At a Lake Elmo, Minnesota high school science program, students have created a 3D printed violin. High school junior Jennah Slayton, who was conducting an experiment on sound waves for her physics class, chose the design for the plastic violin online, then printed and assembled it in her high school’s lab.

“It has a potential to be a way for more students who wouldn’t otherwise be able to afford a violin to get a student a starter violin,” Slayton told CBS affiliate WCCO.

This development comes on the heels of a recently created 3D printed open source violin, the Hovalin, along with several other 3D printed violins. Slayton’s project shows that not only is 3D printing good for science and technology, but also for the arts. In many cases, instruments can be 3D printed much more cheaply than instruments made with traditional methods. How’s that for a great STEAM project?

Magma 3D Prints PEEK Subsea Pipe

Houston-based Magma Global Ltd has 3D printed a continuous pipe using PEEK, a thermoplastic from Pennsylvania-based Victrex Inc. The lightweight pipe is the largest and longest PEEK-based structure ever made, and utilizes “flexible m-pipe technology for subsea oil and gas systems that can be deployed to depths of 10,000 feet — handling pressures of up to 15 ksi.”

The thermoplastic composite pipe, which was printed in continuous lengths of up to 4,000 meters, was produced using S-2 glass and high-grade carbon fiber from Japan’s Toray in addition to Victrex PEEK. The result is “a reliable subsea intervention line that meets demand for a hydraulic pumping system that can handle high pressures and high flow rates.”

Sculpteo’s Express Production Mode a Success

Since the beginning of April 2016, Express Production Mode has been available on the Sculpteo website. They promised “we’ll ship your parts in 48 hours or you’ll have your money back,” and this week the company announced that they have been 100% successful in making all Express deliveries on time (with the exception of one instance where UPS didn’t show up). The only case where Sculpteo won’t give you your money back is when they have problems treating your file. To avoid this, you can check your file before uploading. Here’s how you can get the service:

“You can add Express Production Mode option in your manufacturing toolbox. You must be aware the option is usable for white non-polished polyamide parts. When preparing your order, you now can choose among different production modes: standard, express and economy. To help you prepare an order, you can refer to the last blog post on Express Production Mode, which explains in many details how you can apply this mode to your productions.”

Once your project is uploaded and the Express Production Mode is on, your file goes through a “production validation process.” Sculpteo technicians check each file, then it goes to the printing manufacturers. The whole process lasts a day, including cooling, with the 3D printers working all night. You can pick it up at the factory, or use a courier or delivery service to get your order in that quick time period.

Nano Dimension Called “Cool Vendor” by Gartner, Inc.

Gartner Inc. has named Nano Dimension Ltd. to their “Cool Vendors in 3D Printing 2016” report. Simon Fried, Nano Dimension Chief Business Officer and Co-Founder, describes what this honor means to the company:

“Being named to Gartner’s list of 2016 ‘Cool Vendors in 3D Printing’ is an honor and a validation of the impact that we believe the DragonFly 2020 3D Printer will have on the design and production of PCBs and electronics.”

Amit Dror, CEO and Co-Founder, also adds: “The 3D printing market is extremely crowded, so we feel being named affirms that we have developed a truly disruptive product that will fundamentally change the way electronics are designed and manufactured.”

Nano Dimension’s DragonFly 2020, the world’s first desktop electronics 3D printer, is expected to become commercially available later this year.

Biodegradable Filament WillowFlex Is Now Available in 2.85 mm

Described in a recent press release as “ecological, safe, unique, and compatible,” the biodegradable filament WillowFlex is now available in 2.85 mm diameter. Brian Crotty and Thorsten Perl, founders of BioInspiration’s WillowFlex, explain that the backers of last year’s Kickstarter campaign have all received their rewards, so they are now expanding their product line to accommodate users of Ultimaker, bowden or other printers that utilize 2.85 mm filament; thus far it has only been offered in 1.75 mm diameter.

The first 120 spools of 2.85 mm Willowflex will be ready for shipping on June 9 – available in Charcoal, Engine Red and Natural for the first production run. You can pre-order now at the BioInspiration online shop, or check out a promotional video for more detail here. The filament has received fantastic feedback, has a natural smell and is heat/cold resistant. So, if you have been waiting for that wonderful filament-related opportunity to save the planet, check out WillowFlex now!

That’s all for this week’s 3D printing news! Discuss further over in the Week’s 3D Printing News forum at 3DPB.com

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3D Printer User Guide : 123D Design - Grouping objects

Learn how shapes that you've cruised or snapped together become grouped, so you can apply commands to the objects as a unit instead of individually. See how you can also group and ungroup objects manually.

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HATCHBOX 3D Printer, How it Works ?

HATCHBOX Alpha 3D Printer makes solid, three-dimensional objects. The control software will translate your 3D drawing from STL, AMF, OBJ format into GCODE, which instructs the 3D printer to print the model via USB cable or SD Card. The 3D printer filament then feeds through the PTFE guide tube to the extruder’s hot end, creating a 3D product layer by layer. This method is called Fused Filament Fabrication (FFF).

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