NASA Chooses Carnegie Mellon University to Research 3D Printing for Aviation

Tony Rollet and Jack Beuth, faculty co-directors of Next Manufacturing, will lead the Carnegie Mellon project, with faculty Erica Fuchs, Elizabeth Holm, and Kenji Shimada joining the team as well. The team will receive $7 million over three years to test and analyze various methods of designing, fabricating, and post-processing of aircraft components using 3D printing technologies. “We are truly honored to be selected for this NASA ULI,” said Rollett, a professor of materials science and engineering. “Over the last eight years, metals AM has had a significant impact on aviation manufacturing for jet engine components, airframe structural elements, and other applications. We believe this project will continue to substantially advance U.S. manufacturing capabilities in the aerospace and aviation industries.” Professor Rollet isn’t the only one who thinks that as Lockheed Martin, General Electric, Pratt & Whitney, Northrop Grumman, Metal Powder Works, Siemens, and Materials Solutions, among others, are also partnered with the project. It makes sense. All of those companies manufacture parts for planes; any gains realized by the project could directly improve their lead times and profit margins. Testing will take place in Carnegie Mellon’s new advanced manufacturing facility in the Hazelwood neighborhood of Pittsburgh that’s being constructed inside a historic steel mill, Mill 19. Mill 19 will be home to MFI, the Next Manufacturing Center, and the Advanced Robotics for Manufacturing (ARM). As such, it will serve as a center for advanced additive manufacturing collaboration. This dynamic will certainly benefit the NASA ULI project as Professor of mechanical engineering Jack Beuth explains, “Process qualification is one of the most important challenges for additive manufacturing over the next five to 10 years. This project, our university-industry team, and the facilities at Mill 19 are coming together at just the right time.” An initial goal is to create a qualification framework for laser powder bed fusion 3D printing, which will greatly reduce the manufacturing costs of short production runs and replacement parts. The framework will then be used to help small contractors qualify their AM equipment and processes to produce aviation components.

Neurosurgeons successfully implant 3D printed skull

A 22-year-old woman from the Netherlands who suffers from a chronic bone disorder -- which has increased the thickness of her skull from 1.5cm to 5cm, causing reduced eyesight and severe headaches -- has had the top section of her skull removed and replaced with a 3D printed implant. The operation was performed by a team of neurosurgeons at the University Medical Centre Utrecht and the university claims this is this first instance of a successful 3D printed cranium that has not been rejected by the patient. The operation, which took 23 hours, was led by Dr Bon Verweij. The patient's skull was so thick, that had the operation not been performed, serious brain damage or death may have occurred in the near future. "It was only a matter of time before critical brain functions were compromised and she would die," said Dr Verweij. Major surgery was inevitable, but prior to the 3D printing technique, there was no ideal effective treatment.The skull was made specifically for the patient using an unspecified durable plastic. Since the operation, the patient has gained her sight back entirely, is symptom-free and back to work. It is not known whether the plastic will require replacing at a later date or if it will last a lifetime. The lead surgeon had previous experience with 3D reconstructions of skulls, but such a large implant had never been accomplished before. "It is almost impossible to see that she's ever had surgery," said Dr Verweij in the university's official statement. It is hoped this technique can also be used for patients with other bone disorders or to repair severely damaged skulls after an accident or tumour. The operation was carried out three months ago, but the hospital has only just released details of the surgery. Credit : UMC Utrecht

Metal Casting using 3D PRINTING

A common technique in jewelry making and manufacturing is lost-wax casting or investment casting. A model or “pattern” is made in wax, then a plaster mold is made around the wax model. When the mold is fired in a kiln, the wax is burnt out or “lost”; then metal parts can be cast in the mold.This same technique can be used with PLA filament. Jeshua Lacock of Boise, Idaho, used the lost-PLA technique and a homemade furnace to cast aluminum parts for his home-built CO2 cutting laser, going from design to print to metal part in just one day. He thoroughly documented the process at Backyard furnaces fueled by charcoal or propane can get hot enough to melt aluminum (1,220°F) and bronze (1,742°F). Engineers at Coreprint Patterns in Hamilton, Ontario, even used the lost-PLA method to cast stainless steel (2,750°F), taking their mold to a local foundry that could attain the higher temperatures needed

3D printed, artificial tissues that heal bone, cartilage may give a new lease of life to athletes' careers

WASHINGTON: Scientists are developing 3D-printed artificial tissues that may help heal bone and cartilage typically damaged in sports-related injuries. The researchers at Rice University in the US engineered scaffolds that replicate the physical characteristics of osteochondral tissue - hard bone beneath a compressible layer of cartilage that appears as the smooth surface on the ends of long bones. The gradient nature of cartilage-into-bone and its porosity have made it difficult to reproduce in the lab, but the scientists used 3D printing to fabricate what they believe will eventually be a suitable material for implantation. "Athletes are disproportionately affected by these injuries, but they can affect everybody," said Sean Bittner, a graduate student at Rice University.

AI SpaceFactory Builds 3D Printed Mars Prototype for NASA

TERA will be a futuristic terrestrial home for this planet – one that emphasizes the beauty of its natural environment. Unlike conventional buildings, it can be be harvested from the earth and returned to the earth.⠀ ⠀ Astronauts often talk about experiencing a profound appreciation of Earth when they look back at our Planet from Space, but we shouldn’t have to leave our Home in order to reach that realization. ⠀ ⠀ TERA was designed with this in mind, aiming to foster a deep appreciation for Earth while promoting a sustainable way of living on this Planet.⠀ Architecture and technology company AI SpaceFactory has completed the autonomous construction of MARSHA, a proposal for a Martian surface habitat for NASA. The 3D printed shelter is one of five finalists in an international competition to design and build a habitat for a crew of four astronauts on a mission to Mars. AI SpaceFactory formulated their own material – a “Martian polymer” that can be made from matter found or grown on the planet. Using state of the art robotics and their proprietary polymer, AI SpaceFactory is contending for the final top prize to print a sub-scale habitat in the third and final phase of the construction competition. The 1:3 scale prototype will be printed in front of a live audience at Bradley University in Peoria, Illinois, from April 29 to May 4. In five weeks, AI SpaceFactory progressed from basic tests to an autonomously-printed large-area slab validated by NASA in November 2018. Four weeks later the team successfully printed, in only 24 hours, a large cylinder designed to hold twelve-hundred gallons of water complete with prefabricated wall penetrations robotically placed and sealed “on the fly”.

Indian Engineering student makes Micro Jet Engine using 3D Printing.

3D Printing has emerged by 500% in last 3 years and is changing people’s live everyday. Another great work using 3D printing is done by an Indian engineering student,who built Micro Jet Engine which produces 20kg thrust and also can be used as electricity generator turbine. It all started as a college project at first but now it has future potential to be used as an electricity generator.He combined the 3d printing process and investment casting process to make the Jet Engine Rotating at 100000 RPM ! When he first saw the jetcat turbines on the internet it was only when he saw the price of around $12000 that he realised how inaccessible the technology truly was.Using 3D Printing and working with 3D OnSpot, he designed and built a Micro Jet Engine which actually produces thrust. The dream started when he wanted to fly like iron man and he found creating the micro thrusters was the only possibility to make it happen. So he decided to design and fabricate it himself.The first thing to be done was to design it in any 3d modelling software then run the analyses on different parts of the jet engine. With the help of youtube he learned to use the softwares required for designing and analyses part and also took some help from his teachers regarding the use of softwares. After this , he made some components using conventional machining methods but main problem was to create the turbine wheel and nozzle guide vanes as these cannot be made with conventional machining methods or if so, then the cost would get extremely high for these two parts only but this didnt stop him, he contacted various manufacturing units for making these parts but they agreed only on one condition that they could only make it in bulk (above 1000 pieces).Only then he decided to make those parts himself with the same accuracy. Then he discovered a way by struggling online for hours. Then he came to know that with 3D Printing its possible . Thats how parts were made using 3D Printing. So first he 3d printed the components in plastic then he applied technique of lost wax casting in his college’s furnace and used the 3d printed part as a mould in casting process and casted single piece of turbine and nozzle guide vanes with high accuracy.FDM Technology was used and the parts were printed in PLA material ,good part is both are easily accessible and have low cost. It could take no less than Rs.30000 ($434)per part if made using conventional methods but with 3d printing and it was possible with merely Rs.2500 ($37)(BOTH PARTS).Thats the Magic of 3d printing.

Researchers Just 3D Printed The First-Ever Complete Heart Using Human Tissue

Israeli researchers say they have created the world’s first three-dimensional ,or 3D-printed heart using a patient’s own cells. The researchers, from Tel Aviv University, recently announced the experiment and showed off the new 3D printed heart. Their findings were published in the journal Advanced Science. They described the experiment as “a major medical breakthrough.” The lead researcher on the project was university professor Tal Dvir. He said in a statement that it was the first time that human cells had been used with 3D printing technology to successfully create a whole heart. Dvir added that the “printed” heart contains blood vessels which are needed to pump blood. Until recently, scientists working on medical methods combining biology and technology were only successful in 3D printing “simple tissues without blood vessels,” the research team said. The engineered heart introduced by the Israeli team was not big enough to be transplanted into a human. "At this stage, our 3D heart is small, the size of a rabbit's heart," Dvir explained. "But larger human hearts require the same technology." The development marks a step forward for 3D printing in the medical field. The technology has already expanded into many industries and has been developed to produce devices like guns, cars and homes. The researchers wrote that they took samples of fatty tissue from patients. This material was then used to develop “ink” for the 3D printing process. First, the researchers created patches of tissue from the patient’s own cells. Later, they used that same process to create a small version of a whole heart. Dvir says using the patient's own cells is important to reduce the risk that the body’s system to fight infection will reject a transplanted organ. Source : Voanews

Five Things to Know For Starting Up in the Home Interiors Industry in India

1. Know Thyself Early on, take a call on critical strategic decisions. This means determining your business model, your key strengths and focus areas. Decide if you want to take a White label approach or if you’d rather be a Marketplace. In this Industry, it is also critical to strike the right balance between Technology and Design. There are umpteen firms with a design focus in this space, both in an offline and in an online context. To carve out a niche for yourself, it is critical to use cutting edge technology and constantly innovate. We are a tech-led organization which ensures that the processes that we create are relevant to changing customer needs and henceforth increase efficiency. 2. Cultivate High Customer Sensitivity It pays to be receptive to customer needs. In our early days, we offered only modular kitchens and wardrobes, but quickly realized that most consumers look for a one point contact to execute full interiors. Hence the decision to onboard not just specialist brands, but also design firms with turnkey project execution capabilities. It also meant a shift in focus from modular to semi-modular, in order to cater to the demands of a larger audience. 3. Create Multiple Touch-Points Most consumers go through the process of buying interiors just once in their lifetime. And they are expensive. It’s a high involvement product that customers want to experience before buying. It pays to have both online and offline customer touch-points for deeply engaging with your target audience. Indians are still on a learning curve when it comes to buying furnishings completely online. The Online to Offline (O2O) model works immensely well for this industry with quality lead generation being the critical online aspect and showrooming, the offline one. 4. Empower Your Sales Personnel Considering the consultative nature of selling home interiors, it is a good idea to invest in an efficient sales force. They lend your online entity a face, an identity that consumers can connect with. It is crucial to empower your sales personnel and also keep them updated on latest trends and technology. And lastly, be Patient! This industry is characterized by a long cycle time. Consumers are deeply involved and decision making is usually collective and prolonged. Just remember that the unit economics is excellent and every single customer is worth your effort and mindshare! Credits :

You too could now 3D print a Lamborghini Aventador at home

Remember when we told you that life-size 3D printing was a thing? Apparently, it’s already a lot more than that. Or at least it’s a lot more than life-size. In an epic-size project, physicist Sterling Backus has been working on a life-size, functional and mostly 3D printed Lamborghini Aventador in his own backyard. His goal – described in the dedicated Facebook page – is to show his kid, and kids in general, how cool science and engineering are, demonstrating the power of technology. The car is not entirely 3D printed of course, however, many parts are and the project would certainly not have been possible or even remotely affordable if affordable 3D printing systems had not been available. “My son asked if we could build it,” Sterling recalls. “His inspiration – he says – came from racing video game Forza Horizon 3. I have always wanted a supercar, so it did not take much asking.” As you can see in these photos, the project is quite far along. And while it does show that one skilled enough person could build a Lamborghini in their own backyard, there is a lot more to it. Backus and his son used many other manufacturing processes along with 3D printing, including carbon fiber vacuum infusion and encapsulation, CNC machining (using a mill and lathe from Backus’ work), waterjet cutting for door hinges and suspension parts. It is all part of an amazing learning experience. “We even put encapsulated parts out in the summer sun for more than 6 months here in Colorado’s intense sunlight for a science experiment to see if they would hold up. They did, of course,” Sterling says. Apart from the chassis, the engine, transaxle, and other structural parts (such as the door inner structure, etc.) the entire body of the car was 3D printed using a total of 220 spools of thermoplastics including PLA for the carbon fiber encapsulated parts. ASA and ABS were used for the non-encapsulated parts, such as headlight buckets and tail light housings. PETG was used for the running rear light and tail light lenses. CF nylon was used for the shifter gate. The PLA was printed using a Creality CR-10S and Creality CR-105S 3D printers, while the tougher materials were printed on a $699 QIDI Xpro system. At least 50 spools went to “mistakes” but it was all part of the experience. “We decided that we would use advanced technology to build the car, However, we needed to do it on the cheap,” Backus reveals. “This led us to research different automotive construction techniques. We wanted the car to be safe, so we decided on steel for the frame. In the end, after choosing 3D printing for most of the body of the car, we needed it to be strong.” There were very few choices for materials that could stand the heat and stresses a car body would see so Sterling turned to YouTube. “I saw a youtube video on carbon fiber skinning, and vacuum molding which led us to carbon fiber encapsulation of the 3D printed parts,” he recalls. “After all this, our objective became showing the car off at the local schools as a STEAM project, to get kids interested in Science, Technology, Engineering, Art, and Math.” All body panels, headlights, taillights, interior parts, and air vents are 3D printed. Most are encapsulated in carbon fiber, or carbon fiber kevlar. The 3D printed parts were designed in SolidWorks while many other parts were sourced from a combination of eBay, Wilwood brakes, Holley Dominator ECU and some Lamborghini parts suppliers. “Some Lamborghini parts are not that expensive, or are used,” Backus says. Source

International Space Station Crew 3D-Prints Meat In Space For The First Time!

For the first time in the history of space, meat was ‘created’ on the International Space Station (ISS) and no animals were harmed in the making of this 3D bio-printed ‘space beef.’ On October 7, Aleph Farms, an Israeli food company, announced that its experiment aboard the space lab resulted in the first lab-grown meat in space. Albeit climate change was the main motivation for the company to produce slaughter-free meat, it seems like a breakthrough for space as an entire piece of real, edible meat was grown out of just a couple of cells in a lab- Bovine cell spheroids to be precise. The experiment was carried out by Russian cosmonaut Oleg Skripochka in the space lab’s Russian segment using a 3D printer developed in Moscow. It involved growing meat by mimicking a cow’s natural muscle-tissue regeneration process. Aleph Farms collaborated with the Russian company 3D Bioprinting Solutions and two U.S.-based food companies to test this method in space. Bioprinting is a process in which biomaterials like animal cells are mixed with growth factors and the material ‘bioink’, and they’re printed into a layered structure. Although the technology has been used and tested on Earth for producing cartilage tissues, it works a little differently in microgravity. According to Yoav Reisler from Aleph Farms, bioprinters on Earth create it layer by layer, requiring a support structure, while printing in zero gravity allows the tissue to be created only with cell material as the cells float in space and don’t need any intermediate support, reports. The meat that astronauts eat at the ISS is vacuum-packed or dried on Earth. But if we’re flying further from Earth to other planets in the solar system, we cannot take that volume of food with us. In such cases, growing and producing food onboard the spacecraft will be the way to go and this technology will be crucial for long voyages into deep space in the future. Source- Mashable

World's Biggest 3D-Printer Makes World's Biggest 3D-Printed Boat

University of Maine’s Advanced Structures and Composites Center just printed a 25-foot, 5,000-pound boat, the largest object that has ever been printed. The exorbitant act earned the college no less than three Guinness World Records. The awards are as follows: one for the world’s largest prototype polymer 3D printer, one for the largest solid 3D-printed object, and one for the largest boat which has ever been produced by a 3D printer. The 3D printer is designed to print objects as long as 100 feet by 22 feet wide by 10 feet high, and can print at 500 pounds per hour. “As we saw today, the University of Maine Composites Center does award-winning, cutting-edge research that makes Maine proud and will bring jobs to our state,” said U.S. Rep. Jared Golden. “Their work, like the boat and 3D printer we’re here to see, has impressive potential to change how we make things out of all sorts of materials — including Maine wood fiber. Today is about three Guinness World Records, but it’s also about celebrating innovation that will help protect and create good-paying Maine jobs in forest products and manufacturing.” Source - Interesting Engineering

An Austin startup can 3D-print tiny homes in 24 hours for a fraction of the cost of traditional homebuilding - here's how Icon could revolutionize affordable housing

In 2017, ICON co-founders Jason Ballard, Evan Loomis, and Alex Le Roux met Brett Hagler, co-founder of the non-profit New Story, and realized that they had a united mission: To employ 3D printing and new building technologies to transform the construction industry and provide affordable, durable, and sustainable homes to those in need. It was almost as if the two companies were destined to join forces: New Story was searching for innovative ways to bring quality housing to more families, and ICON was developing proprietary 3D printing technology and materials that could do just that. Just eight months later, in March 2018, ICON and New Story completed the first permitted 3D-printed home in Austin, Texas. The 350-square-foot home was printed by a device called the Vulcan I in approximately 48 hours. What’s more, the cost for the printed portion (the roof was not 3D printed) was about $10,000—a sum well below the average cost for a home of similar size and quality. How exactly is that possible, you ask? ICON's founders focused on designing 3D printing technology specifically for the developing world—and after about two years, they arrived at a feasible solution. Because site characteristics, weather, and availability of materials can vary tremendously, the Vulcan I is mobile, weighs approximately 2,000 pounds, and prints on-site in a continuous fashion. The printing material is a type of cementitious mixture that ICON developed specifically for their needs (they have several patents pending on both the hardware and materials). Although the mortar is proprietary, it is composed of basic materials that are easily accessible throughout the world. The team wanted the home to be both recognizable and desirable as a house—but, as Ballard explains, they also "wanted to show off a few possibilities that are opened up with 3D printing," like curves and other non-uniform shapes. This is an area where 3D printing excels—elements that were traditionally bespoke can now be completed cheaper, faster, and often at a higher and more consistent quality. For example, the home is essentially rectangular in shape, but it has two filleted, curved corners that give it a distinct exterior. On top of the 3D-printed exterior walls sits a clerestory window for ample daylighting, topped with a cantilevering shed roof that creates a wraparound porch. Source - Dwell

These Huge 3D Printers Want to Save the Earth (and Maybe Mars)

What are we planning, here on Earth to get us ready for next-stage planetary exploration and terraforming tasks? One thing's clear: we'll have to build out habitats with materials on hand. There's no Amazon Prime Mars (yet) for Earth-to-Mars shipments, which is where industrial-scale 3D printing comes into play. One company that might help with that effort is Houston-based re:3D. With the tagline "Think BIG, Print HUGE," re:3D makes the Gigabot, the world's largest, affordable, industrial 3D printer, which is now available in 50-plus countries. It donates one Gigabot for every 100 sold commercially to a group or individuals making a difference in their community. It's committed to turning plastic waste into 3D-printed projects and is still involved in post-disaster efforts in Puerto Rico. We spoke with re:3D's Co-Founder and CEO Samantha Snabes to find out more. Here are edited and condensed excerpts from our conversation. I've read that re:3D started in 2013 when you and co-founder Matthew Fiedler were working at NASA Johnson Space Center, as social entrepreneurs in residence. How did the experience inspire you to start the company, and why? [SS] While working at NASA I volunteered for Engineers Without Borders NASA JSC, a group of NASA astronauts, engineers, and scientists who wanted to translate what they were learning about solar energy, confined spaces, water quality, and water purification and take it to the developing world. I got the opportunity to travel to Nicaragua, Uganda, Rwanda, and saw a lot of frustrations around dependence on aid, imported goods, as well as high unemployment and the problem with plastic-based waste. It gave Matthew and I the idea to use open-source 3D printers as a way for people to make their own stuff independently, using this plastic waste. The maker movement was just building momentum back then, but we realized industrial 3D printers were too expensive, and not modular, so we came up with a better solution, applied to Startup Chile, which offers $40,000 to start, or scale, your idea in Latin America, quit our jobs, moved to Chile, and started the company. How do you turn plastic waste into reusable 3D-printed materials? It's not easy, but it is possible. Gigabot X can handle multiple types of reclaimed plastic, but there is still a lot of research to do. The easiest to cope with is plastic trim, known as "virgin plastic" because it's clean and dry and we're now working on printing from water bottles, investigating ways to separate the label, bottle cap, and adhesive via an optimum grinder, and drying and feeding solution, to characterize the size of flake that best extraudes. Your Gigabot range can now print objects up to 30 times larger than competing desktop models. What's the entry-level Gigabot functionality and cost? Gigabot starts at just under $10,000 as a kit for a 2-foot cubed build volume filament-based 3D printer. Gigabot X, our pellet printer, starts at $15,000 for a similar build volume. Both platforms can go as large as your budget. We also offer contract printing, training, and design services. Who are your main customers today and how are they using the Gigabot? Our customers today use Gigabot for a variety of applications ranging from automotive to healthcare to construction. We'd love to hear what application your readers would like us to highlight next! Do you have contracts with NASA? Are you working on the Mars program? While we are not working on the Mars program directly, we do have many customers at multiple NASA campuses as well as contractors that serve the space agency. Source : PCMAG

Meet The World's First 3D Printed Hybrid Hypercar - Czinger 21C

It's been in the works for a few years now but it's been finally revealed and we will see the car at the Geneva Motor Show as well next month. Czinger has revealed its groundbreaking 21C hypercar which comes with a drivetrain that has been developed in-house and it in fact is the world's first hybrid hypercar to be 3D printed. The Czinger 21C is designed, built and manufactured in Los Angeles and assembled by a team of artisans, from the fit and finish of each and every part - from seat brackets to suspension components - to the hand-crafted carbon fibre parts and multi-layer paintwork. The 21C is designed and manufactured from the ground up by the Czinger team in Los Angeles, California. Lightweight, high-performance alloy and carbon fibre multi-material structures form the 21C chassis. But it's the hybrid powertrain which has been designed in-house which really makes the headlines here. It drives all four wheels and Achieves a true 1:1 power to weight ratio. There's a 2.88-litre, flat crank V8 with twin turbos located mid-vehicle, and an electric motor assigned to each front wheel drive the 21C to a 8.1 second quarter mile, 0-100 kmph is done in 1.9 seconds, 0 to 300 kmph is achieved in 15 seconds and 0 to 400 kmph takes just 29 seconds.

Doctors 3D-Print An Emergency Airway Tube To Save A Child’s Life

Score one for technology: Doctors 3D-printed an emergency airway tube that saved a 20-month old baby boy’s life. After imaging the boy’s faulty windpipe, doctors at the C.S. Mott Children’s Hospital printed 100 tiny tubes and laser-stitched them together over the trachea. “Quite a few of the doctors said that he had a good chance of not leaving the hospital alive,” said the mother of the baby boy, who suffered from a severe version of tracheobronchomalacia, causing his bronchus to collapse. Desperate for a solution, the doctors obtained emergency clearance from the Food and Drug Administration to surgically sew the 3D-printed splint on the child’s airway. “It was amazing. As soon as the splint was put in, the lungs started going up and down for the first time and we knew he was going to be OK,” said University of Michigan Professor Dr. Glenn Green, who came up with save-saving solution, with his partner Dr. Scott Hollister. “The material we used is a nice choice for this. It takes about two to three years for the trachea to remodel and grow into a healthy state, and that’s about how long this material will take to dissolve into the body,” added Hollister. Considering that most of the news around 3D printers has been about lethal, undetectable firearms, it’s nice to know that people are also using humanity’s newly found technological powers for good. Source -