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Fabrication Process

SkelETHon wins 1st Prize for Design Innovation at the 16th Concrete Canoe Regatta in Germany

3D printed plastic formwork for a fully-functional concrete canoe.

skelETHon
[/media-credit] the skelETHon team at the awards ceremony in Cologne
The Concrete Canoe Regatta

Every other year, a two-day long concrete canoe race takes place in a city in Germany, bringing together a fun sporting competition and the latest advancements in concrete technology. This year, over 1’000 participants from universities from all over Europe raced 90 boats made entirely out of concrete on the Rhine river in Cologne. The teams competed for the lightest, fastest, most beautiful, and for the most coveted award – best design innovation.

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[/media-credit] The keel of the concrete canoe viewed from above
ETH collaboration   

Since 2005, ETH has consistently taken part in the concrete canoe regattas with great success, and this year ETH won the 1st prize for Design Innovation for the 3rd year in a row. SkelETHon, the 114 Kilogram concrete canoe, was a collaboration between DBT – who provided the computational design and digital fabrication expertise – and the PCBM Group – who developed the concrete mixes and processes used in the construction of the boat.

skelETHon
[/media-credit] The 3D printed plastic formwork of the concrete canoe
Design innovation

In the past, the Concrete Canoe Regatta has already served as prototyping framework for emerging research projects at ETH, such as Mesh Mold and Smart Dynamic Casting, which have become in the meantime successful, mature researches. This year, Free Formwork, a research project developed at DBT was used to build a boat which was highly praised by the jury for the unique design approach.

skelETHon
[/media-credit] The fibre reinforced concrete three dimensional skeleton of the canoe, designed through topology optimization algorithms
The four meter-long boat has a stiff steel fibre-reinforced concrete inner skeleton, covered by a two to three millimetre-thick waterproof concrete skin. The skeleton is designed using topology and shape optimization algorithms which reduce the material of a traditional canoe design and redistribute it in a skelleton-like structure in order to maximize the stiffness of the boat.

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[/media-credit] skelETHon ready for being transported from Zürich to Cologne
For the fabrication of this skeleton, a submillimetre thin plastic formwork was 3d printed and cast in ultra-high-performance fibre-reinforced concrete. The formwork for the entire boat weighed just over four kilogrammes and a precise, high-resolution surface texture, with details as small as half a millimetre, was transferred to the concrete skeleton to increase the contact area with the outer skin.

skelETHon
[/media-credit] High resolution texture on the skeleton, for a better contact surface with the concrete skin
The construction process made possible a highly complex concrete skeleton with bones as thin as 15 millimetres in diameter which would be impossible to fabricate with any other digital fabrication technologies. 3D printing, a precious fabrication process, was used minimally, but had a significant impact on the overall design.

skelETHon
[/media-credit] The Bow of the concrete canoe skeleton, with 0.5 millimetre texture details
Categories
Fabrication Process

3D Printing Lets Kids Combine LEGO And Lincoln Logs Into One Toy

3D printing increasingly has the potential to generate unique experiences on an individual level by empowering consumers to use or create products in new ways. Instead of being beholden to the designs or intentions of a generalized product, buyers will soon have the ability to tailor products to their specific needs.

http://www.psfk.com/2012/03/3d-printed-lego-lincoln-log.html

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Fabrication Process

Overview of 3D printing technologies

Professional 3D printing or additive manufacturing refers to several technologies that produce parts in an additive way. The table above provides an overview over the technologies by the type of material they work with (vertical axis) and how the parts are built out of this material (horizontal axis).

Additive manufacturing, or professional 3D printing, refers to several technologies that produce parts in an additive way. Starting point is a digital 3D model of a part, which is then “sliced” in thin layers by a specific computer software. An additive manufacturing machine is building these layer on top of another and thus is creating the physical part.

https://app.additively.com/learn/3d-printing-technologies

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Fabrication Process

PAM, the new-generation 3D printer

After five years of Research & Development, Cédric Michel and Victor Roux, the two founders of Pollen AM, announce the market launch of PAM, the new-generation 3D printer. PAM uses only clean, environment-friendly materials and has the broadest range of materials available on the market. Pollen can also develop specific materials on demand. The PAM printer heads use autonomous and versatile technology to produce perfectly functional pieces made of composite and plant-based materials (wood, etc.), rigid or supple objects (silicones, etc.), that are ready to use without any post-processing.

In short, PAM is revolutionary since it allows printing that is:

  • multi-material: up to four different materials per production run, on the fly
  • adapted to the material mix: two materials mixed on the fly for better appearance and more functions
  • associated with a smart platform: no post-processing – the object is ready to use.

Read more at: http://www.3dprintingprogress.com/articles/9706/pam-the-new-generation-3d-printer

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Fabrication Process

Open Dot Lab Milano – Think Big, then Print It!

http://www.opendotlab.it/it/content/think-big-then-print-it

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Fabrication Process

RAPTYPE

Ziel dieses Projekts ist die Entwicklung eines 3D-Druckers auf Basis der FDM (Fused Deposition Modeling) Technologie. FDM bezeichnet ein Fertigungsverfahren, bei welchem ein Werkstück schichtweise aus flüssigem Kunststoff aufgebaut wird. Ein drahtförmiger Kunststoff wird in einer in der Fertigungsebene frei verfügbaren Heizdüse (Hot End) erwärmt und verflüssigt, um anschliessend durch Extrusion auf das sich im Aufbau befindende Werkstück aufgetragen zu werden.

https://raptype.wordpress.com

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Fabrication Process

Model Car Competition

We have had another successful year and another successful iteration of the model car design challenge.

Member of EDAC and of the TZ/CAD team would like to thank all the students who have participated, your designs never cease to surprise us.

Congratulations to the winners of both the design and the race challenge. Remember to collect your prizes!

http://www.edac.ethz.ch/education/car-competition-winners.html

https://www.youtube.com/watch?v=Pxabz6JiSaQ

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Fabrication Process

Festo – 3D Cocooner

Just like a caterpillar, the 3D Cocooner spins delicate lightweight structures freely in space. With the help of a high-speed handling system, the spinneret is precisely controlled and glues a glass fibre into the desired bionic lattice shape with UV-curing resin.

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Fabrication Process

3D Printed Motorcycle by Jonathan Brand – Ultimaker: 3D Printing Story

Jonathan Brand is an artist from New York and created a life-size 3D printed 1972 Honda CB500 motorcycle.
Isn’t this one of the most amazing 3D prints you’ve ever seen?

https://ultimaker.com/en/blog/38-jonathan-brand-3d-printed-motorcycle

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Fabrication Process

How To Make Any 3D Printed Part Much Stronger

The traditional way to make stronger 3D printed parts, at least on plastic extrusion machines, is two-fold:

Pick a strong material, such as ABS over PLA
Print with higher internal density, even 100% solid
Either of those work, but the printing solid objects quickly raises the cost. It also delays your print significantly. Instead of a two hour 3D print operation, you might be looking at six hours or more.

But now there’s another approach. The folks at Lantern Robotics have been injecting hot melt adhesive (basically a glue gun) into sparsely filled 3D prints.