Dream Job

My dream job is definitely working for a company like the german-based FESTO. These guys create some of the most amazing things all inspired by the nature. Beyond simple biomimicry in form language, the mechanisms that actuate these machines are based on the underlying structures within living organisms. In essence we are talking about the mechanical equivalent of true muscles. Below is the most recent (re)creation based on a seagull. Pretty amazing stuff that marries cutting edge technology, with a strong foothold in nature-

also check on youtube for the jellyfish and searay- both are equally amazing.

Hello world!

First full 3 axis test of the printer!

...and yes, that is a purple marker tapped to my machine, deal with it-

Final Product Criterion for the Appropriate use of Digital Fabrication

• The design must be as innovative as the means to produce it. Without such a cyclical relation, the designer is a slave to his tools (predictable) or the design may become so naively idealistic that it exists outside of the realm of manufacture (unattainable).

• Challenge the expected outcome of mechanical and manual processes and in doing so blur the distinctions between them.

• Strike a balance between the necessity of process with the noise of possibility.

Print Bed

The large size of my printer design presents an interesting challenge of how to create a 4'x4' flat surface for the build platform. Ideally this would be perfectly flat, practically thats nearly impossible without using a precision ground slab of granite. There's also considerations with respect to weight: a heavy platform will require more force to move, and once moving will carry greater inertia and require even more force to stop.

It was originally suggested that I simply use a piece of manufactured lumber such as MDF, around 1" thick so it doesnt warp over time. While this may satisfy my requirement of consistent flatness, it surely is not a lightweight solution. Instead I chose to use a sheet of 2" foam insulation, laminated in 1/8" acrylic or polycarbonate. This solution is extremely light, the foam core weighing around 4 lbs, as well as durable. The foam is rigid but lacks any tensile strength, the lamination process solves this problem and from an engineering perspective, is similar to an I-beam. In my research of of other existing FDM 3D printers, Molten ABS or PLA sticks well enough to acrylic during manufacturing and can be easily removed once it cools. It may be adventageous to later score a grid into the surface.

Large scale 3D Printing

3D Printed Bike is as strong as steel but 1/3 the weight of aluminum

"This funky bike is making news today not just for its design but for how it is made. UK engineersprinted the bike using a powder composed of nylon and metal which results in a frame that has the strength of steel while also being 65% lighter than aluminum. The Air Bike is a demonstration of a technology called additive layer manufacturing which was able to create the fully working bike with only six parts. The goal is to show how the technology can revolutionize product design from airplanes to satellites to more down to earth items like bike"

Via inhabitat.com

A perfect example of the promise for rapid fabrication technology to reduce material consumption while preserving an object's design and functional integrity.

More Custom Parts

Hopefully this weekend was the last one I have to spend making custom parts. Here are some process photos, and a few finished ones too.

This weekend:

3 Motor Mounting Plates

4 1" Bearing Mounting Plates

1 2" Bearing Mounting Plate

3 Motor Couplings

2 Geared shaft couplings

and 1 mounting plate for an ENORMOUS iron nut