Solid Edge ST10 P47 Siemens

KeyShot 7NX 7.0P53

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TECHNOLOGY FOR THE PRODUCT LIFECYCLE JULY / AUGUST 2017 | 6 | 7 | $10 | DEVELOP3D.COM

GARAGE
BANDITS
Meet the renegades taking
on the automotive world

BEST OF NEW DESIGNERS WARHAMMER POWER FIST 3D PRINTED EYEWEAR

p01_D3D_JULYAUG17_front cover.indd 1 19/07/2017 16:45
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Laser Lines Ad.indd 1 19/07/2017 14:01

 WELCOME
EDITORIAL
Editor-in-Chief
Al Dean
al@x3dmedia.com
+44 (0)7525 701 541

Managing Editor
Greg Corke
greg@x3dmedia.com
+44 (0)20 3355 7312

Digital Media Editor

Stephen Holmes
stephen@x3dmedia.com
+44 (0)20 3384 5297

Special Projects Editor

Tanya Weaver
tanya@x3dmedia.com
+44 (0)20 3384 5296

Consulting Editor
Martyn Day
martyn@x3dmedia.com
+44 (0)7525 701 542

T
DESIGN/PRODUCTION
Design/Production
Greg Corke wo editors, a former stuntman/movie director and the head
greg@x3dmedia.com of design for Hot Wheels walk into a bar in Vegas... I wish
+44 (0)20 3355 7312 that was how every issue of the magazine started but, in
this instance, its true. Martyn and I ran into Hackrods Felix
ADVERTISING Holst and Mouse McCoy at the end of last years Autodesk
Group Media Director University, entirely by accident no press meetings, no
Tony Baksh conferences and no guided tours. After an evening spent
tony@x3dmedia.com swapping stories (theirs were mostly better than ours) and
+44 (0)20 3355 7313 drinking a few too many tobacco infused rum cocktails (if
Deputy Advertising Manager you havent yet, try it), we parted ways but I knew I wanted them in the magazine
Steve King (they are this months cover stars). Then earlier this year, I got to meet up with
steve@x3dmedia.com them, for coffee this time, at Deus Ex Machines place in Venice Beach.
+44 (0)20 3355 7314 If you google Hackrod, most of the stories focus on the artificial intelligence
angle and how generative design is everything. The reality is not quite that and
US Sales Director
Denise Greaves once you get to know these two characters, a different story starts to emerge.
denise@x3dmedia.com Mouse and Felix are two of a bigger team that, yes, are taking advantage of
+1 857 400 7713 a whole range of advanced technology, but whats really driving Hackrod is the
desire to change accessibility to the benefits of that technology. Theyre taking
SUBSCRIPTIONS the build it yourself ethic of the hot rod, custom car and motorcycle community,
mixing it up with some of the most advanced design and engineering technology,
Circulation Manager and doing something truly ground breaking. Yes, the end result, at the moment, is
Alan Cleveland
a succession of vehicles that blow your mind, but the goal is way beyond that a
alan@x3dmedia.com
+44 (0)20 3355 7311
true democratisation of production. Well follow up with them as they progress.
And if this little story tells you anything, its that when your parents told you
youll never achieve anything from staying out late and talking to strangers in
ACCOUNTS
bars, they were most definitely wrong.
Accounts Manager
Charlotte Taibi
charlotte@x3dmedia.com
Financial Controller
Samantha Todescato-Rutland
sam@chalfen.com

ABOUT
DEVELOP3D is published by
Al Dean
Editor-in-Chief, DEVELOP3D Magazine, @alistardean

465C Hornsey Road, 1st floor, Unit 2,

London, N19 4DR, UK
T. +44 (0)20 3355 7310
F. +44 (0)20 3355 7319
2017 X3DMedia Ltd
All rights reserved. Reproduction in
whole or part without prior permission
from the publisher is prohibited. All
trademarks acknowledged
Opinions expressed in articles are those
of the author and not of X3DMedia.
X3DMedia cannot accept responsibility Join our online community
for errors in articles or advertisements
within the magazine

DEVELOP3D.com facebook.com/DEVELOP3D @DEVELOP3D groups/DEVELOP3D

DEVELOP3D.COM JULY / AUGUST 2017 3

p03_D3D_JULYAUG17_Editor.indd 3 19/07/2017 16:46

 fro

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BOSTON
USA
OCTOBER 23 - 24, 2017
Boston University
Boston, USA

DEVELOP3Ds celebration of
product design and engineering
is coming to Boston, USA, on
23 and 24 October 2017.
The two day event will feature
presentations from some of the most
innovative designers, engineers and
technologists, an exhibition where
you can get hands on with the latest
technology and an evening food and
drinks reception.

SAVE THE DATE For updates, stay tuned to d3dliveusa.com

D3D LIVE A4 2017 V1.indd 1 19/07/2017 18:03

 CONTENTS

Solid Edge ST10 P47 Siemens

KeyShot 7NX 7.0P53
beta P40 Ansys Mechanical P56
JULY / AUGUST 2017 ISSUE NO. 90

TECHNOLOGY FOR THE PRODUCT LIFECYCLE JULY / AUGUST 2017 | 6 | 7 | $10 | DEVELOP3D.COM

6 NEWS
Formlabs launches desktop SLS, Autodesk reveals
generative design tech in Netfabb, PTC acquires
Plug-In 76 and AMD targets entry-level CAD users

COMMENT
13 Robert Games offers advice on how IP can help leverage
GARAGE all the value you can get out of a product idea
BANDITS 15 Tanya Weaver reveals some of the main takeaways from
Meet the renegades taking
on the automotive world the inspiring #9PercentIsNotEnough conference
BEST OF NEW DESIGNERS WARHAMMER POWER FIST 3D PRINTED EYEWEAR

FEATURES
17 This months role model is Dr Sina Sareh
18 Visual Design Guide: Masuri Vision Series helmet
20 Product Design Gallery: Best of New Designers 2017
24 COVER STORY Meet the team behind Hackrod
32 An eyewear project seizes on the potential of 3D printing
36 Q&A with Richard Ling of Paved With Gold
39 Nikes in-store sculptures get the gold treatment
42 Bringing the Warhammer Power Fist to life

REVIEWS
47 Solid Edge ST10
53 Luxion KeyShot 7 beta
56 Ansys Mechanical R18
60 Lenovo ThinkPad P71
62 Autodesk FeatureCAM 2018

64 DEVELOP3D SERVICES

66 THE LAST WORD

Al Dean considers how vendors are starting to look into
swapping large, costly machines for cheaper ones

The wood used to produce this magazine

comes from Forest Stewardship Council
certified well-managed forests, controlled
sources and/or recycled material

DEVELOP3D.COM JULY / AUGUST 2017 5

p05_D3D_JULYAUG17_Contents.indd 5 19/07/2017 16:46

 NEWS
NEWS
FORMLABS LOOKS TO REPEAT SLA SUCCESS
WITH NEW DESKTOP SINTERING MACHINE
The Boston-based company launches new desktop plastics sintering can it
repeat the success it has seen with resin-based stereolithography (SLA)?
F
ormlabs, which built its reputation
on bringing SLA to a wider, more cost
conscious market, has announced its
latest 3D printer. This desktop-sized
selective laser sintering (SLS) machine,
priced at 9,999, looks to bring the benefits of
stronger parts built using sintering technology,
typically reserved for the more industrial end of the
additive manufacturing spectrum, to the desktop.
Offering a build volume of 165 x 165 x 320 mm,
the Fuse 1 launches with Nylon PA 12 and PA 11
materials, both of which have been the long standing
benchmark materials for sintering from the likes of
3D Systems, EOS and many others.
When we launched the worlds first desktop
SLA 3D printer in 2012, Formlabs created new
possibilities for designers and engineers to
create physical products by giving them access
to professional 3D printing
technology that had hitherto
6 JULY / AUGUST 2017 DEVELOP3D.COM
p06_D3D_JULYAUGUST17-NEWS.indd 6
PRODUCT DEVELOPMENT NEWS
been unavailable, said Formlabs CEO Max Lobovsky
at the launch.
With Fuse 1, we have taken the same approach to
making powerful SLS technology available to a huge
range of customers.
The company is offering a complete package that
includes a post-processing station with material
recovery, an extra build piston for continuous usage,
and initial material load.
Theres no word as to what sort of facilities
requirements will need to be in place for this
machine to operate in the design office or workshop,
but thatll come with time.
Extraction and ventilation will be more rigorous
than with SLA so were not expecting the Fuse 1 to the Form 1 and Form 2 SLA machines.
appear on desktops at scale anytime soon but, with
the companys track record, things look good.
Formlabs has been testing units with a number
of customers, with the company currently giving
details of two. One of which is New Balance which it
has been working with to make 'high-performance
footwear.
The other is Google ATAP Skunkworks. David
Beardsley, manager of Google ATAP Skunkworks,
commented: SLS technology enables designers and
engineers to accelerate their prototyping process
by combining realistic material properties with the
minimisation of 3D printing design constraints.
"With the Fuse 1, a combination of high precision
parts, reduced cycle time and robust materials allow
teams to easily iterate throughout the design process
and accelerate from whiteboard to final parts.
formlabs.com
WHAT WE THINK
The sintering market has been on the
cusp of doing something to reduce
costs for a couple of years now.
Most of the key patents expired a
few years ago and there have been
a number of start-ups promising
to bring the technology to a wider
audience.
Formlabs machine isnt going to be
the cheapest on the market, but that
didnt stop it achieving success with
Judging by the companys track
record, theres a mix of smart design,
cost reduction and quick ramp up to
scale production at play here that
could see it succeed where many
others havent gained traction.
Theres also the fact that it
has probably now sold more SLA
machines than anyone else so has a
pretty rich set of contacts in some of
the most advanced engineering and
design companies in the world.
What will make or break the
success of the Fuse 1 will not just
be the build machine itself, but also
how it handles all of the ancillary
equipment that typically goes
alongside the core machine.
19/07/2017 16:46
SLM Solutions Group AG
Roggenhorster Strae 9c | D-23556 Lbeck
Fon +49 451 16082-0
slm-solutions.com
 NEWS
AUTODESKS GENERATIVE
DESIGN TOOLS DEBUT IN
NETFABB ADDITIVE SUITE
A Plataine offers
utodesk has announced
that its generative design
technology will appear as
a commercially available
product inside of its Additive
Manufacturing (AM) suite, NetFabb.
For some years now, Autodesk has been
showing off its set of generative design
tools and while details have been scant, the
company has made great stock of several
public facing projects (with Airbus and
others) that demonstrated the potential for
machine learning and artificial intelligence
(A.I.) in the design world.
What hasnt been quite so clear was how
the company intended to bring it to market
and turn it from technology into a tool that
can be used by a wider audience.
That recently changed with the news that
Autodesk is looking to make its generative
design tools available inside NetFabb.
For those that arent aware, NetFabb was
PTC adds social analytics to design with Plug-In 76 acquisition
F
ollowing a low-key
announcement at its LiveWorx
user event earlier this
summer, PTC has fully unveiled
its acquisition Plugin-76, a
small Swedish social analytics start-up.
Having already developed a set of tools
for PTCs Retail, Footwear and Apparel
(RTA) focussed FlexPLM product line, the
addition builds on PTCs aim of bringing
social analytics into the ThingWorx
environment.
It is hoped that, while ThingWorx focusses
8 JULY / AUGUST 2017 DEVELOP3D.COM
p08_09_10_D3D_JULYAUG17-NEWS.indd 8
acquired from its Bavarian parent company
(FIT AG) a couple of years ago. The
software tools are probably best known
for its, now defunct, NetFabb free version,
which allowed basic STL file repair. But the
reality is that the Netfabb product range is
much more.
Alongside file preparation, the higher-
level packages and modules equip the
advanced additive manufacturing specialist
with the tools to prepare data, not just in
terms of fixing part files, but a great deal
more. From build and platform chamber
stacking and optimisation tools, to lattice
design, metal process simulation, near net
shape design and much more.
The news released from Autodesk says
that generative design will become part
of the NetFabb suite (presumably in the
high-end, NetFabb Ultimate, bundle) later
this year.
autodesk.com
on quantitative data, analytical tools
targeting social media such as Amazon
reviews will be able to provide live
consumer feedback throughout a products
lifecycle.
Specific feedback about certain functions,
workflows or other oddities that might arise
during a products use can be gleaned from
social comments, before being redesigned
for future product iterations.
Currently named Inspiration App, the new
toolset built by Plugin-76 will act as a digital
whiteboard for designers and marketers,
Latest Onshape
updates
I
t seems that summer is for
surfaces at Onshape, with the
July feature releases focussing on
new surfacing tools, with fills and
enclosures to make solids.
Users can now create a surface defined
by a closed boundary of edges or curves by
using the Fill tool, making it easy to close
off a face, and automatically transform a
collection of surfaces into a solid.
The tool adds intelligence for when
the surface needs to match surrounding
geometry. By selecting edges with the
fill command, the Tangency option sets
Onshape to create a surface that has
continuity to the surfaces around it. This
can be set to show ISO curves, as to better
reveal the underlying surface.
Also in this release, users can create
a solid part from an enclosed selection
of existing surfaces or planes, with the
surfaces being removed by default, or kept
to the users preference.
onshape.com
Stanley Black
& Deckers
newly-formed
Breakthrough
Innovation group
full traceability
I
has been running a
pilot program for ndustrial IoT software firm
generative design Plataine launches the latest
with NetFabb
version of its Material and Asset
Tracker software.
As part of the new Version 4.0,
Plataine has expanded support for the
entire manufacturing supply chain, where
OEMs and suppliers can collaborate on a
single platform for integrated visibility of
manufacturing status and traceability.
Analytical algorithms can now analyse
large-scale databases and drive alerts
and recommendations, while users have
complete visibility of the production floor,
with real-time tracking of the location,
condition and status of critical assets.
plataine.com
with built-in tools to aid in capturing
imagery, video, colours, patterns, trends
and other design elements when initially
planning product lines.
It has built-in connectors to leading
social media platforms to enable real-
time capture of the latest trends.
Although Inspiration App is initially
focussed on the RFA market, PTC
believes the tool will have broader
application across other consumer-
facing design industries.
ptc.com
19/07/2017 16:47

On demand 3D printed parts to take off
A
n announcement by Airbus
that it will use Stratasys FDM
3D printers for non-structural
parts such as brackets on its
A350 XWB aircraft, sees the
aerospace industry increase its adoption
of 3D printed end-use parts.
Airbus will now use Stratasys Direct
Manufacturings 3D printing capacity and
infrastructure for parts on demand for its
next generation of aircraft, with Airbus
signalling that this will allow it to achieve
greater supply chain flexibility, and improve
cost competitiveness, while leveraging on
reduced material consumption and waste.
The companies have worked together
since 2013 on the implementation of 3D
printing FDM applications, leading to the
qualification in 2014 of the Ultem 9085
material for the production of flying parts
on Airbus aircrafts. With thousands of parts
installed on aircraft since 2015.
The announcement follows on the back of
news that Hong Kong-based Western Tool
& Mold (WTM), a specialist for the aircraft
interiors market, is producing aircraft cabin
MTC to heavily test HPs 3D printing tech
A
gauntlet of tests and
scenarios are already
being lined-up at the
Manufacturing Technology
Centre (MTC) in Coventry, as
it takes the wrappers off its new HP Jet
Fusion 4200 3D printer.
The machine forms part of a
comprehensive technology line-up at
the UKs National Centre for Additive
Manufacturing and will be available to
all companies interested in testing the
technology.
Being the first company to buy a specific
3D printer is not news in this age, but with
the MTC having links to all manufacturing
industries, its outcomes could be key to the
technologys advancement.
Supplied by the MTCs newest technology
New workshop to spill the beans on AM
C
roft Additive Manufacturing
(CAM) has launched a new
industry workshop for those
wanting to find out more
about metal 3D printing.
Attendees will be given a detailed
introduction to the fundamentals of metal
additive manufacturing (AM) as well as a
chance to get hands-on with the process.
The workshop will take place at CAM's
Warrington headquarters and company
directors Neil Burns and Louise Geekie
will be running the course.
p08_09_10_D3D_JULYAUG17-NEWS.indd 9
ROUND
UP
Altair has announced
PBScloud.io, its latest
appliance solution to enable
users to model, build and
run High Performance
Computing (HPC) appliances
on both public and private
clouds. The platform also
offers a secured set up with
the ability to customise
security policies
pbscloud.io
components that meet stringent FAA and 3D printed
EASA certification requirements. polymer parts,
such as brackets,
WTM is now using the Stratasys will feature on
Chaos Group has added
technology to 3D print aircraft cabin parts Airbus A350 XWB a new hybrid rendering
with complex geometries and low quantity aircraft technology to V-Ray for
demand such as first-class overhead bin 3ds Max that adds CPU
lockers and lavatory components. support to its Nvidia CUDA-
By 3D printing these parts directly from powered GPU renderer.
CAD designs, bypassing metal tooling With version 3.6 users can
processes, WTM says that its customers can render a scene using GPUs,
test parts earlier in the design process and CPUs or a combination of
save hundreds of thousands of dollars in both and produce the exact
manufacturing costs. same results
stratasys.com | airbus.com chaosgroup.com
FogHorn has launched
Lightening ML, its latest
platform for the industrial
Internet of Things (IIoT).
partner, Europac 3D, the printer will The platform can run on
support the MTCs SME engagement premise or connect to any
program, as well as taking part in private or public cloud.
internal research projects with members It's also systems-agnostic
to determine equipment capability and supports 32-bit
mechanical, dimensional accuracy, and implementations of ARM
surface finish of the prints, plus assessing Cortex-A processors
the limitations of the process. foghorn.io
Chris Ryall, operations manager, additive
manufacturing at the MTC, said of the new
HP technology: By housing one of the Vicon has announced the
printers here at the National Centre we acquisition of IMeasureU, to
are able to open the use of it to industry, add further sensor-driven
allowing them to explore and test the movement measurement
latest technologies and see what benefits capture to its portfolio of
3D printing may be able to offer their engineering solutions. The
operations. small wearable sensor will
www8.hp.com | the-mtc.org add an extra dimension for
europac3d.com those looking to add more
real world sensor data to
their products
vicon.com | imeasureu.com
Lenovo has introduced a
AM has the potential to revolutionise micro desktop workstation
how products and machines are designed that is even smaller than
and built. But with so much information out the HP Z2 Mini. The Lenovo
there, it can be disconcerting for anyone ThinkStation P320 Tinyis
who wants to find out how they can use the only 35mm x 179mm x
technology themselves, says Geekie. 183mm in size and one
Our new course will offer a jargon-free, litre in volume, making it
non-academic introduction to the design an attractive proposition
and manufacturing processes that will be for those with space
accessible to those with even the most basic constrained workplaces
understanding of the technology. lenovo.com
To book a place, visit:
letsspillthebeans.co.uk
DEVELOP3D.COM JULY / AUGUST 2017 9
19/07/2017 16:47
 NEWS
GB ATHLETES BENEFIT FROM
NEW WATT TRAINING TOOL
I
n preparation for the recent World
Para Athletics Championships,
BAE Systems helped create the
UKs first computerised indoor
trainer for racing wheelchairs.
With 13 wheelchair racers having
competed around the track at the
Queen Elizabeth Olympic Park, the team
benefitted from using the specially
designed Wheelchair Athlete Test and
Training system (WATT) system by the UK
engineering company.
Described by coaching staff as a
groundbreaking advancement, the WATT
system consists of an adjustable frame that
holds the athletes wheelchair in place and
two electric motor brakes, adapted from
the Tacx virtual reality bike trainer, that
rest against the wheels.
There are a number of problems that
the GB Team face when training in poor
AMD targets entry-level CAD users with new low-profile GPUs
A
MD has added two
entry-level models to its
Radeon Pro WX Series of
professional GPUs: The
Radeon Pro WX 2100 and
WX 3100 are designed for entry-level 3D
CAD and are certified for applications
including SolidWorks, Creo and Revit.
The pair join AMDs other Polaris-based feature 2GB and 4GB of GDDR5 memory
professional GPUs, the Radeon Pro WX
4100, WX 5100 and WX 7100, which were
launched in 2016.
In terms of performance, AMD reckons the
10 JULY / AUGUST 2017 DEVELOP3D.COM
p08_09_10_D3D_JULYAUG17-NEWS.indd 10
weather conditions, said Henry White, BAE
Systems UK sport technology partnership
lead. But with this new system theyll be
able to complete whatever training they
need and access courses from all over the
world, from wherever they are.
An NTCADCAM customer, BAE Systems
used SolidWorks to first conceptualise
and then design and fully engineer the
frame and electrical set-up in time for the
athletes to test and give their feedback.
The company also designed a new
advanced composite racing wheel, which
can help Britains wheelchair racers
improve their acceleration by up to 20
per cent, being three times stiffer than
previous designs, its rigidity reduces a
force know as a toe-in where the wheel
bends inwards, reducing friction and
improving speed and acceleration.
baesystems.com | ntcadcam.co.uk
Radeon Pro WX 2100 and WX 3100 boasts
up to 95 per cent and 2.3x improvements
over its previous generation.
Both of the new GPUs are low-profile
graphics cards, which means they can fit
inside Small Form Factor workstations such
as the HP Z240 SFF and Dell Precision 3420.
The Radeon Pro WX 2100 and WX 3100
respectively and are rated at 35W and 50W.
Both GPUs have 1 x DisplayPort and 2 x mini
DisplayPort outputs.
pro.radeon.com
Design Museum
celebrates 70
years of Ferrari
O
ffering a behind-the-
scenes look at the design,
manufacturing and
engineering of one of the
most iconic car brands on
the planet, Ferraris 70th anniversary is
to be celebrated by a new exhibition at
London's Design Museum.
Ferrari: Under the Skin celebrates seven
decades of precision design, from the
launch of the first Ferrari car in 1947 to the
latest car production.
The ambitious display will bring together
early design models, drawings, letters
and memorabilia. Key exhibits include
rare personal memorabilia and archival
material relating to Enzo Ferraris life,
early cars, wind tunnel models and hand-
sculpted models in both clay and wood.
Opening on 15 November 2017 the
exhibition will run until 15 April 2018.
designmuseum.org
GB athlete Richard
Chiassaro prepared
Converge: Date
for the World
Para Athletics
for the diary
Championships
with help from this October
T
the WATT training
system he European Converge
conference, hosted by
solidThinking, will return to
the SANAA building in Essen,
Germany, on 17 October 2017.
solidThinking calls upon industrial
designers, design engineers, architects, and
others active in product creation to register
for this conference that will explore the
intersection of design and technology. It
states that attendees will learn how a clever
combination of engineering tools, natures
evolutionary power, and human creativity
result in game changing solutions.
event.converge2017.com/europe
19/07/2017 16:47
 Smarter &
Easier Prototyping
The new Stratasys F123 Series is easy to operate and maintain for all
levels of experience. Its adept at every prototyping stage, from concept
verication to design validation to functional performance. The most
commonly used CAD le formats can be imported directly into GrabCAD.
The three printers in the platform, the Stratasys F170, F270 and Stratasys
F370, support a broad range of capabilities and budgets for every stage
of prototyping.

Minimal setup means you can simply plug and play to give your entire
oce access to professional 3D printing.

Auto-calibration ensures you spend less time troubleshooting and

more time prototyping.

Fast and easy material swaps help maximize your design teams
productivity.

Versatility and Smarter Prototyping: Thermoplastics: The Strongest

Performance The Stratasys F123 Series Choice for 3D Printing

The Stratasys F123 Series lets you print everything from fast, low-cost concept models to durable assemblies as well as the
option of up to four dierent materials, along with our easy-to-remove soluble support material.* Create complex parts
and assemblies with no compromise on accuracy, detail and repeatability. Even for your earliest design iterations, you can
expect Stratasys quality and dependability.

Emco is a major distributor of Stratasys F123 Series 3D printing technologies

Call us on 02392 637 100 or visit www.emco.co.uk
Emco Education Ltd, Emco Industrial Ltd, Units 4, 6, 7, Hayling Billy Business Centre, Furniss Way,
Hayling Island, Hampshire, United Kingdom PO11 0ED sales@emco.co.uk


REVERSE ENGINEERING MADE SIMPLE

IN YOUR OWN CAD ENVIRONMENT

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3dcompound.co.uk/px-prole Intelligent Practical Apps

12_D3D_Ads.indd 1 19/07/2017 14:03


For any product developer one of
the biggest challenges in making an
idea a reality is funding. Robert Games
offers advice on how intellectual
property can help leverage all the
value you can get out of that idea
S
o youve had your
eureka moment
but now you need to
turn your idea into
a reality. To do this
you will likely need to
secure funding for its
development. This is
where intellectual property (IP) can
help; while the innovative design and
functionality of your product will make
it desirable and marketable, it is the IP
that makes it valuable.
If you protect the work you do by
registering your brand as a trademark, your
designs through registered designs and your
technical developments as patents, then
youre creating a value proposition in your
product and business.
IP becomes even more important once you
start spending money on research, product
development, branding and marketing.
While these are all necessary costs, if you
dont then go on to protect these aspects
of your business then they will only ever be
expenses, because you are not adding any
long-term value to the business.
LEVERAGE VALUE IN YOUR IDEA
IP allows you to quickly create value in
the business. In the UK, trademarks can
be protected indefinitely; designs can be
protected through registration for up to 25
years and patents for up to 20 years. This IP
value (dependent on what you do) could last
for the lifetime of the business, or certainly
for the lifetime of the product.
On the other hand, it can be a very costly
process if you spend money on product
development and branding but dont consider
IP early enough. For example, if you havent
checked to see what other similar brands
exist, or what other patents or designs exist,
you run the risk of unwittingly treading on
someone elses toes.
A patent attorney can help with
searches and steer you away from pitfalls.
Changing a design and/or packaging is an
expensive process and negotiating away
an infringement position can be stressful.
You can save yourself money and stress by
thinking carefully about what it is you are
trying to achieve and undertaking research.
p13_D3D_JULYAUG17_ALLbright IP comment.indd 13
Once you are satisfied that your branding
and product is different to the competition,
you need to protect yourself, otherwise you
wont gain a monopoly on the work that you
have done. Without IP rights your product
may have very little value associated with it
and in a competitive trading environment,
that could be highly detrimental!
SHOW ME YOUR IP
As part of the due diligence for funding, any
lender will likely want to know that your idea
is protected and that your IP has been filed
properly. This is also true if you wanted to sell
your idea or business. It may be hard when
starting a company to think about your end
game, but if you think you might want to sell
your company in the future, then again IP will
play a big part.
Buyers will want to know that they have the
exclusive right to use the brands and products
which have been established. They will also
want to know that they are not at risk of
infringing other peoples patents.
As the seller, you will need to show that all
the IP has been filed correctly in order to get
maximum value for your business.
CROWDFUNDING BE CAREFUL
The most common mistake when undertaking
crowdfunding is not protecting your IP
adequately. When crowdfunding, youre
putting your invention out there for the world
to see it and you need to have robust IP
protection in place first.
A public disclosure, such as putting your
invention up on a web based crowd funding
platform, is a bar to UK and European
patenting. Without IP protection, you are
at risk of being copied and your options for
protection will be extremely limited.
Another area of weakness when
crowdfunding is having an underdeveloped
product. If your idea hasnt been developed
properly and there are clear ways to improve
it, then people may take the opportunity to
do it better themselves, or you may simply
lose potential investors.
To gain investment people will judge the
design very quickly and obvious flaws will
impact on the products appeal.
In the first instance, its important to protect IP, a professional firm of British and European patent and trade
your products look, functionality or branding. mark attorneys. albright-ip.co.uk
COMMENT
When This can be achieved by securing patents for
functional elements, registering designs for
crowd- appearance and registered trademarks to
protect your brand.
funding, Equally you dont want to build a complete
youre crowdfunding campaign and then find
that you have to change your products
putting functionality, appearance or name because it
your infringes on someone elses IP rights.
invention MAINTAINING YOUR VALUE
Once you have your IP in place and have
out there built up the value in your product then
for the you need to think about the next stage of
product development. Continuous product
world to development helps to put time between
see it and you and your competition and the further
development of your technology, which allows
you need you to keep the innovation moving forward.
These advantages or improvements can
to have effectively help you to extend the life of your
robust IP patent protection. If youre five years into
a patent and you develop an improvement
protection on the patented technology, then you will
in place be able to file a new application to the
improvement, limiting infringers to copying
first outdated versions of your products when the
original patent term runs out, ensuring youre
always ahead of the competition.
This can create significant tax benefits, as
income from patented products or processes
is subject to significant tax relief under the
patent box scheme.
By the time somebodys figured out how
to get around your patent, youve already
got the next version standing by. When they
launch, you launch the better version.
My advice is simple, build access to funds
into your business plan at an early stage to
enable you to get some protection in place
through an attorney.
Its always difficult at the start of any
business to try and find sufficient funds
to protect your products and brand, but
ultimately protecting your IP is a very
worthwhile investment which will create value
in the company and more importantly help to
keep it there.
Robert Games is managing director of Cheltenham-based Albright
DEVELOP3D.COM JULY / AUGUST 2017 13
19/07/2017 16:47
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7459 B Lenovo Develop3D Workstation Promo advert v6.indd 1 17/07/2017 17:04


On 23 June, on International Women
in Engineering Day, Tanya Weaver
headed to the #9PercentIsNotEnough
conference in Birmingham. Here
she reveals some of the main
takeaways from an inspiring event
S
unday 16 July 2017
may not go down in
history for Roger
Federer clinching a
record-breaking eighth
Wimbledon mens title
or Lewis Hamilton
winning a historic
fifth British Grand Prix at Silverstone
but rather for Jodie Whittaker being
announced as the new Doctor Who.
There have been 12 doctors before
her, all men, since the science-fiction
franchise began in 1963.
Although the announcement was
dramatically revealed on the BBC, following
a shroud of secrecy and much speculation
for weeks, I found out through the furore
that ensued on Twitter. I whooped! Firstly
as a feminist, secondly because I think shes
a brilliant actor and thirdly because what a
great role model for young girls who are fans
of the show.
It also made me immediately think of a
conversation amongst female engineers
Id heard on BBC Radio 4s Womans Hour profession to be an engineer they choose
programme a few weeks back. It was part
of the The Womans Hour Takeover Week
in which a different host effectively takes
over the show for that day. On 28 June
it was Dame Ann Dowling, president of
the Royal Academy of Engineering, with,
amongst other guests, Naomi Climer, the
immediate past president of the Institution of
Engineering and Technology (IET). She spoke
about how we need to change the stereotype
of engineers in this country and one way is
for the media to portray women in all sorts
of different engineering roles. She thought
that as Doctor Who, who she would argue is
effectively an engineer, should be portrayed
by a woman (Im guessing she whooped
when she heard the news too).
In fact, this very theme was also addressed
a few days earlier on International
Women in Engineering Day at the
#9PercentIsNotEnough conference held at
the IETs Birmingham offices. (By the way, the
nine per cent statistic comes from the fact
that in the UK that is how many women are
currently in the engineering and technology
workforce).
Nadia Savage, director at Laing ORourke,
p15_D3D_JULYAUG17_tanya.indd 15
COMMENT
a multinational construction company,
kicked off the morning session by stating
Getting more women into
the huge influence the media has over our engineering doesnt only bolster
young people and how many hours of media
content they absorb everyday. She said that
the engineering ranks but there
we have to depict engineering in a positive was much discussion about how
light and get inspiring female engineering
role models in front of the camera. a gender balanced workforce can
fundamentally it is really hard to be what
you cannot see, she said.
benefit everyone
This led on to another discussion about 
changing the language of how we sell
engineering to girls. Clare Wildfire, chair,
advance network and global practice
lead for cities, at construction company
Mott MacDonald, went on to say, In the
construction industry engineering has a
major role in helping to save the planet I
think that is one of the things that will attract
girls. I read recently that UCL [University
College London] received an immediate
increase in the number of girls applying for
civil engineering courses when they dropped
the requirement for A-Level maths and
physics. So actually girls dont choose the
that profession because they want to improve
peoples lives. So in terms of how we sell it, I A few of the But, as Flint rightfully argued, everyone
think the key point is solving problems. #9PercentIsNotEnough in the company needs to be onboard
conference delegates
Of course, getting more women into with getting more female engineers and
putting their hands up
engineering doesnt only bolster the to be counted as part technologists into the company it has to
engineering ranks (which is desperately of the nine percent of be driven from the managers at the top,
needed) but there was also much discussion the UKs engineering who take this agenda seriously and support
about how a gender balanced workforce can and technology it, and then encouraged at grass roots too.
workforce that are
benefit everyone. He suggests having it as a key performance
women
Peter Flint, chief executive, building + indicator (KPI) within the business because
places EMIA at engineering firm AECOM, said, then everyone is accountable and involved
Our business is really about creativity and to in creating this inclusive culture. As he says,
be creative we need teams to work together which was the standout quote from the
and it is proven that diverse teams can conference for me, Men have a massive
actually be more creative. So its fundamental role in addressing this issue, there should be
to business to have a diverse workforce more men in the room today, its not just a
and not have a single gender dominant. At womens issue to solve.
AECOM we are striving to create diverse There you go. Lets work together in
teams who can flourish because of a highly moving that needle from nine per cent into
inclusive culture. double figures!
Both Elizabeth Hill, chief product engineer
at Jaguar LandRover, and Mark Elborne, CEO
and president of GE UK & Ireland, spoke GET IN TOUCH: Email me on tanya@x3dmedia.com or say hi on
about what their respective companies are twitter @tanya_weaver. Tanya admits to having never watched a
doing to address this imbalance with various single episode of Doctor Who and although Jodie Whittaker may
apprenticeship, graduate and employment change her mind, shell need to do some swotting in time for the
schemes. Time Lords regeneration in the Christmas special.
DEVELOP3D.COM JULY / AUGUST 2017 15
19/07/2017 16:47
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 PROFILE

ROLE MODEL
NAME DR SINA SAREH
JOB ROLE ACADEMIC LEADER IN
ROBOTICS, SCHOOL OF DESIGN AT THE
ROYAL COLLEGE OF ART (RCA)
Whether youre still in education or a few rungs up the career
ladder, we could all do with inspiration to show us what is achievable
and to gain an insight into what others are doing in the field of design
and engineering. This month our role model is Dr Sina Sareh who
provides a vision of the role of a roboticist, the constant drive to
invent new technological solutions and the benefits of team work

D
r Sina Sareh is a roboticist
whose specialism lies in
creating interactive physical
systems using soft materials
and integrated computational
and mechanical intelligence.
He was appointed as Academic Leader in
Robotics within the RCAs School of Design
in May 2017, a role that will see him assist
the College in developing design-led robotics.
As Dr Sareh said of this new position, It is
an extremely exciting moment to join RCA
and be involved in shaping the ambitious
future of modern education in the College.
I am very much looking forward to leading
the integration of robotics into the Colleges
research, its international programmes and
in collaborations with industry.
Prior to his appointment at the RCA,
Dr Sareh was the coordinator of research
activities within the EPSRC-funded project
Aerial ABM (Aerial Additive Building
Manufacturing) and led the Soft Aerial
Robotics theme within the Aerial Robotics
Lab of Imperial College London. He has
also contributed to a number of high-profile
research projects, including the EU FP7
STIFF-FLOP (STIFFness Controllable
Flexible & Learnable Manipulator for
Surgical Operations) at Kings College
London.
Dr Sareh holds a PhD in Robotics from
the University of Bristol, an MSc in Control
Systems from the University of Sheffield,
and a BSc in Electrical Engineering from
Amirkabir University of Technology, Iran.
What do you most enjoy about your job?
As roboticists, we enjoy working on new
technologies that many people will use in the
future.
What inspired you to become an engineer?
I think it happened naturally. I was really
interested in physics and maths in high
school, which guided me to study an
engineering discipline at university.
What has been one of the biggest
challenges youve faced in getting to where
you are?
The biggest challenge Ive faced as an
engineer is the ongoing challenge of
inventing technological solutions that can
improve lives.
What has been a career high or most
memorable work moment?
Having been greatly fascinated by cross-
disciplinary R&D activities, my most
exciting moments at work are often related
to the times that I bring team members
with diverse backgrounds and experience in
design and engineering together to solve a
challenging problem.
In terms of your career, who has been your
role model?
Of course professionally attractive people
usually get the credit of doing things
differently and more effectively. This can
be learned by observing their approach
to problems, strength in conquering and
consistency. I would greatly credit my
parents whose visionary acts have made a
lasting impact.
What is your view on diversity in the
engineering and design workforce?
Engineers need a deep understanding of
the societal contexts of their activities, as
their work can have long-lasting effect on
the quality of our life and the environment.
Cross-disciplinary research in engineering
and design will make sure the future
technological advances will address the
societal needs.
What technology or design tools do you
use day-to-day in your job?
We use a wide range of hardware and
software including computational tools
for iterative design, and rapid prototyping
systems and benchmarking platforms for
manufacturing and validation.
With the advantage of hindsight, what
career advice would you give to your
younger self?
The advancement of robotic technologies
requires vast knowledge and experience
in many different areas from material
sciences and mechatronics to design and
manufacturing. I would advise roboticists in
their early years of research not to commit
to a specific discipline too early, but explore
a wider range of projects covering different
aspects.
If you were hosting a dinner party who
would you invite and why?
I would invite George Devol and Joseph
Engelberger who were fathers of the modern
robotics.
The biggest challenge
Ive faced as an engineer
is the ongoing challenge
of inventing technological
solutions that can improve
lives
DEVELOP3D.COM JULY / AUGUST 2017 17

p17_D3D_JULYAUG17_role model.indd 17 19/07/2017 16:48

 VISUAL DESIGN GUIDE
MASURI VISION SERIES
With cricket bowling speeds reaching over 90mph,
players need serious head protection. Visitech has
helped develop the latest Masuri Vision Series helmets,
which will be seen on wickets around the world

HALO
REINFORCEMENT
SYSTEM
The rim circumference and peak of each
helmet acts as Masuris Halo reinforcement
system. Made from reinforced plastic, the
band significantly increases protection by
ensuring minimal deformation of the helmet
shell during an impact

EYE-LINE GRILLE
The Eye-Line Grille has been designed from
every angle, even from the wearers point of
view, in SolidWorks, and then 3D printed to
validate the design. Its special double top bar
provides an optimum field of vision while also
deflecting the ball away from the players face
by forcing it upwards, towards the peak

18 JULY / AUGUST 2017 DEVELOP3D.COM

p18_19_D3D_JULYAUG17_VDG helmet.indd 18 19/07/2017 19:01

 HOT HEADED
Vents in the helmet are strategically placed as
not to impact the rigidity of the structure, but to
also allow batsmen to keep cool during a long
innings out in the blazing summer heat

BALL STRIKE
An energy-absorbing foam minimises
the impact of the cricket ball being
transmitted to the wearer. Injected into
a cavity between its inner and outer
shells, the kinetic energy of a ball strike is
dissipated by the foam crushing, reducing
the impact pressure on the head

STEM GUARD
Masuris StemGuard design gives
protection to the vulnerable region at the
back of the head and neck a rare place
to be struck, but potentially deadly. Made
from TPU honeycomb material and military
grade crush foam to maximise impact
absorption, they are designed to attach
with a moulded clip to the helmet. Since
most people would naturally turn away
with a fast ball coming at their face, this
attachment not only appeals to batsmen
but also to wicket keepers and fielders in
short positions close to the wicket

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p18_19_D3D_JULYAUG17_VDG helmet.indd 19 19/07/2017 19:01

 PRODUCT
DESIGN
SHOWCASE
NEW
DESIGNERS
2017
Stephen Holmes went along to the annual
hotbed of graduate design talent that is New
Designers and of all the wares on display, here
are the three he thought were the best
IMOGEN ADAMS | BRUNEL UNIVERSITY
ALLY FOOD ALLERGEN TESTER
W
ith nearly everyone aware of someone
with a food allergy, chances are youve
heard of a dramatic incident in which
a meal has somehow snuck in an offending
ingredient.
With this in mind, Imogen Adams, inspired
by her own time travelling abroad and, as a
vegetarian, having to question some restaurant
meals, has designed Ally, a pocket-sized
allergen tester.
The user crushes a small food sample with
a few drops of water before dipping in a test
strip and then inserting it into a slot in the
Ally. The Bluetooth enabled device, roughly
the size of a doughnut, connects with the
users smartphone and corresponding app,
before processing the results of the test in
under 60 seconds.
The strip used to test food samples is a
modified glucose test strip containing lactose
enzyme on half the strip.
If lactose is present within a sample the
glucose strip will change colour, with a greater
colour change indicating more lactose present.
This information is then read by a colour
sensor in the electronic Ally unit.
Although Adams working prototype
currently senses lactose, the designer is
looking to target more life-threatening
p20_21_22_23_D3D_JULYAUG17_PDG new designers.indd 20
allergens with the next iterations.
The unit already benefits from its
portability, and receives a huge boost from its
cost effectiveness. Adams estimates that Ally
could be mass produced for around 30 per
unit, with each test costing less than 20p.
A comparable product on the market today,
solely for gluten allergies, costs in excess of
200, with each test around 5.
As with any modern connected device,
Adams has designed its partner app to not
only signal the sample tests allergen status,
but to also build an ecosystem for Ally users
to share their experiences, much like a
typical restaurant social media check-in and
review.
For anyone who would prefer not to appear
rude by checking their phone at the dining
table, the Ally device also signals a positive
or negative result to a set allergy with a quick
vibration.
At New Designers Adams product stood
out for its problem-solving approach
to a wide spread and potentially deadly
issue, presenting a working product with
considered aesthetics, digital ecosystem
and an understanding of its place in the
marketplace.
linkedin.com/in/imogen-adams-11018194/
19/07/2017 16:49
 PROFILE

DEVELOP3D.COM JULY / AUGUST 2017 21

p20_21_22_23_D3D_JULYAUG17_PDG new designers.indd 21 19/07/2017 16:49

 LEWIS CALDERWOOD I RAVENSBOURNE UNIVERSITY
MORF APARTMENT SEATING
M
orf is a modular sofa system
designed for generation rent,
the ever-growing population that
cant afford to buy a property, so live their
lives often at the peril of short-term rental
contracts and unscrupulous landlords.
Its designer Lewis Calderwood looked
to create a seating system that could
reduce in size for ease of transportation
and easy storage, making it light enough
to move easily, but sturdy enough to be
comfortable.
Inspired by the delivery of mattresses
purchased online, the Morf design utilises
a standard household vacuum cleaner to
reduce the size of each seating unit.
The ingenuity is in the different densities
of a series of foams that make up the
structure.
Much of the project was spent
22 JULY / AUGUST 2017 DEVELOP3D.COM
p20_21_22_23_D3D_JULYAUG17_PDG new designers.indd 22
researching compatible foams, with
hands on experimenting with different
combinations, a vacuum cleaner, and
ultimately creating a collection of
minimalist parts that can routinely
compress.
The modular design benefits the
consumer in two ways: the parts can be
purchased over time, spreading the cost
of what can often be the most expensive
domestic purchase for a renter.
Secondly, the shapes can be used to build
flexible set-ups that can adapt and grow
as the user inevitably has to pack up and
move on. Moving to a bigger apartment?
Simply extend your Morf sofa with a new
unit. Downsizing? Transform your layout
into a compact corner unit, or series of
stools.
Calderwood has also put effort into the
design of the quick-change covers. His
extensive research showed that the key
reason for jettisoning structurally sound
furniture is the routine wear and tear of
the coverings.
The quick change, machine washable,
materials allow the consumer to refresh
its design at a fraction of the cost of
purchasing a new sofa, while giving them
the creativity to adapt their furniture
DEVELOP3D MONTHto 200X
a 22
change in dcor.
Calderwood has high hopes for the
design, prompted by the levels of industry
interest shown by furniture retailers at
New Designers including an award from
John Lewis.
He hopes to carry on the project and to
further develop the technical aspects given
its high chances of releasing to market.
calderwooddesigns.com
19/07/2017 16:49
 KARL MOTTON | BOURNEMOUTH UNIVERSITY
SNUG INCUBATOR
S
nug is the comprehensive design by
Karl Motton for an affordable neonatal
incubator with a reliable secondary
power supply, for use in developing
nations.
Designed with the aim of saving the lives
of infants in desperate need of basic and
cost-effective healthcare, the Snug has an
estimated production cost that is a tenth of
that of a traditional incubator.
Motton had no prior knowledge of
preterm births before starting it as his
final year project, meaning everything was
produced from extensive research and
seeking out professional medical opinions,
including those of neonatal care charity
BirthLink UK.
The design is a pared back, functional
and ergonomic incubator that can heat or
cool the baby chamber to a pre-set level,
p20_21_22_23_D3D_JULYAUG17_PDG new designers.indd 23
with several innovative considerations put
in place, such as the refocussing residual
battery warmth to assist with heating.
An aluminium sub-structure enables
Snug to cope with the harsh environments
found in sub-Saharan Africa, while all
necessary parts can be easily accessed for
cleaning or repairs.
Its controls are based on the lack
of professional neonatal training in
developing nations, so put great emphasis
on simplified visual feedback.
With a LED lighting system acting as a
considerate alternative to audible feedback,
it is easy from across the room to spot
any temperature changes, or spot which
incubator is experiencing problems in a
crowded neonatal ward.
Continuing the designs Braun-esque
lines, three buttons control on/off, and the
temperature on a low-cost display, meaning
anyone can operate the incubator without
medical training.
At New Designers Motton showcased his
fully working prototype, built from scratch
and seemingly without compromise from
the initial designs (Motton produced a
time-lapse video showing its construction).
Impressively finished, the incubator
showcased a range DEVELOP3D
of fabricationMONTH
skills. 200X 23
Elsewhere his original designs in
SolidWorks were rendered and animated
in Keyshot to produce marketing materials.
An outstanding piece of work, along with
the exceptional research, documentation of
the process, Motton went so far as to create
a mock campaign to help with charitable
fund raising to assist the adoption of Snug
incubators in developing countries.
karlmottondesigner.com
19/07/2017 16:49
 GARAGE
BANDITS
The co-founders of digital industrial design company
Hackrod left their successful careers to follow a dream
that has taken them into the depths of what new technology
can offer the design and development process. Al Dean met
the pair to discuss what they are up to and how they plan
to democratise design. Tanya Weaver reports
24 JULY /AUGUST 2017 DEVELOP3D.COM

p24_25_26_27_28_30_31_D3D_JULYAUG17_cover story Hackrod.indd 24 19/07/2017 16:50

 PROFILE

If three kids wanted to start a software
company, youd say Hmmm, Amazon web
services, connected world. Sure. But if
those same kids wanted to start a car
company, youre told youre not allowed
to play. F**k that.
Mouse McCoy, co-founder of Hackrod

DEVELOP3D.COM JULY / AUGUST 2017 25

p24_25_26_27_28_30_31_D3D_JULYAUG17_cover story Hackrod.indd 25 19/07/2017 16:50

 1

he two garage bandits are Mouse McCoy and Felix Holst. 1 The second
generation of
One has spent most of his life driving fast vehicles whilst
the La Banditas
the other knows a thing or two about designing them. Not chassis. The La
averse to taking risks, the pair, who refer to themselves as Bandita is Hackrods
dreamers and futurists, saw an opportunity to disrupt the high-performance
sports car and
status quo and so threw themselves into a new startup. proof of concept
They aim to develop a manufacturing platform (see box demonstrating the
on page 28) that brings new technologies and processes key elements of the
Hackrod platform
together. We are going to build a cloud-based engine
that is going to drive the next industrial revolution,
2 The design process
of the La Bandita
says McCoy. An engine that can reimagine the way that kicked off with
hardware products are designed and engineered, made and sketches
distributed.
3 The team then
moved onto renders
A pretty ambitious vision so lets backtrack three years to
what set them off on this path.

MEETING OF KINDRED SPIRITS

McCoy has been racing his whole life: I started racing
motorcycles when I was a little bitty kid and Mouse McCoy
was my kid racer name [his real name is Mike].
From motorcycle racer to stuntman he then moved into
producing and directing and founded entertainment studio
Bandito Brothers. A notable box office feature film McCoy
directed was Act of Valor, which was released in 2012.
Meanwhile, Holst had completed his industrial design
degree at the University of Northumbria in Newcastle, UK,

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 PROFILE

We are
and was planning on doing a masters in car design at the
Royal College of Art (RCA). That was until he spotted a job
replica cars that the stunt drivers would race. It was an
ambitious and daring spectacle that broke records and won
advert that piqued his interest. awards (just Google YouTube videos of Hot Wheels Double
going to While I was preparing my portfolio for the RCA Loop Dare).
build a I answered an ad in Design Week back in 1996 for a We were building these cars in a secret facility in radically
cloud- temporary designer at Hot Wheels UK. At the time I short time frames with a lot of risk involved. We could have
thought, Holy shit, Hot Wheels are they still around? started thinking we were pretty cool but I was like Dude, I
based I landed a six month contract and realised that not only think we kinda suck, admits McCoy.
engine was I a really good toy designer naturally, but also it was far We pulled everything off, we didnt scratch or hurt
that can more fun designing toy cars than designing door handles anybody and our margins were really thin but our tech was
reimagine at an automotive company every day of my life. So, apart from the 60s. It took a lot of balls, brains and wizardry from
from a few years at the end of the 1990s to be in a band, I the engineers and the guys who knew how to build this shit
the way stuck with Mattel and Hot Wheels until 2015 when I left, but we were doing it pretty much old school.
that explains Holst. Holst adds, High tech for us was a GoPro with some
hardware Up until 2011, Holst, who by this time was head of design ribbons tied to the roll cage so when the driver did the
at Hot Wheels globally and had relocated to Los Angeles, jumps we could see what the air was doing inside the car.
products was responsible for the design of toy race cars but in an
are initiative to reinvent the brand, Hot Wheels decided to THE FUTURE OF MAKING THINGS
designed create life-size versions of these cars to race in a series of With a new film project on the horizon for which he needed
and automotive media stunts. To bring this Hot Wheels for to build 40 to 50 prototype cars, McCoy decided to set
Real campaign to life it commissioned McCoys studio himself on a mission to discover what the future of making
engineered, Bandito Brothers. things looks like. Having come across Autodesk through
made and the visual effects work hed done previously, he decided
distributed HOT WHEELS FOR REAL they would be a good starting point to learn about new

McCoy and Holst worked alongside their teams to create

enormous custom-built orange tracks, including a 100-foot
technology and so knocked on their door.
I met all the right dudes at the right time. They really
ramp and a 60-foot double loop, as well as the prototype pulled the curtain back for me and I started to see glimpses

DEVELOP3D.COM JULY / AUGUST 2017 27

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 PROFILE

of what the future looked like, says McCoy. of their generative design research project called
4 The La Banditas

As well as Autodesk, he also engaged with America
Makes, an Ohio-based accelerator for additive
manufacturing (AM) and 3D printing. I was well
positioned in the government after one of my projects so
got introduced to all of those guys too.
I was in San Francisco, but I spent a lot of time with the
America Makes folks thinking about large scale additive
and what that would mean for large scale prototyping,
comments McCoy.
After about six months to a year in San Francisco he called
on Holst, Dude, Im seeing all this shit thats like science
fiction its crazy, and beckoned him to come see it for
himself.
I went along with it, says Holst. After all that wed been
through I thought McCoys not feeding me with bullshit
and theres got to be something at the end of this rainbow.
So I quit Hot Wheels and got on a plane. When we
walked into Autodesk we saw one of the first interactions
Dreamcatcher, which at the time was just starting, and we form has been
developed using
looked at each other and said Dude, imagine using this to Autodesk Fusion 360
make a car chassis. From that point it was game on.
McCoy adds, We got to a point, as Felix said, where we
saw the first sketches of generative design and the first bits
of additive and said Holy shit, these learning trends VR,
AR, generative design, machine learning, simulation,
additive manufacturing, crowd, cloud and IoT what
happens if we start to aggregate these things, start to
connect some dots? If this shit is for real, then it starts to
mean that a kid with a dream, like we had with Hot Wheels
for Real, or three kids in a garage who want to start a car
company or a large industrial company, can.
If three kids wanted to start a software company, youd
say Hmmm, Amazon web services, connected world.
Sure. But if those same kids wanted to start a car company,
youre told youre not allowed to play. Fuck that.
The pair embarked on a deep dive research project with

THE KEY ELEMENTS Engineered with

generative design using
OF THE HACK ROD cloud processing
Designed in VR
Developments in virtual
reality now mean that
Made using advanced
manufacturing
Delivered by the supply
chain of the future
Once youve chosen your There is no longer any

PLATFORM
Generative design uses
machine learning or
artificial intelligence (AI)
to process information. So
the user sets goals (such
as size, weight, strength,
style, materials, cost etc.)
and then utilising the
power of cloud computing
the software will create
thousands of new design
solutions. These calculations
would take a human
infinitely longer to achieve
and provides a smart
solution that is lighter,
quicker to develop, uses less
material and costs less to
manufacture.
teams can work together
in different locations on
the same 3D model. Life-
size components can be
adjusted and scrutinised
in a photorealistic
experience. This means
that no prototypes need
to be made. With a cloud
subscription, simulations
and analysis can easily be
carried out to refine the
design further, foregoing
the need for a wind tunnel.
design and lived in the need to invest in factory
virtual world with it for infrastructure by sourcing
instance, with VR gaming, components through a
you could even race it distributed manufacturing
virtually and get others process, users can have
in your community to components made by
test it too then hit the different suppliers and then
make button and have either assemble themselves
it manufactured using locally in a workshop or at a
additive manufacturing tech shop.
techniques.

28 JULY /AUGUST 2017 DEVELOP3D.COM

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 PROFILE

Autodesk to see whether they could indeed connect the dots per second. Before it would have taken a lot of engineers a
5 Shredding the
chassis through
and placed themselves as those kids in a dorm room with long time to work through this complex math, says Holst.
Californias Mojave
the ambition of starting a car company. With the interior chassis evolving, Holst set to work on the Desert in order to
speedsters exterior design and recruited his old partner in capture the real-time
CAPTURING FORCE LOADS IN THE DESERT crime from Hot Wheels, Fraser Campbell, to help him in data and force loads

The first step in creating their high-performance sports car,
which they called La Bandita speedster, was capturing the
data to feed into Project Dreamcatchers generative design
engine. To do this they needed an existing chassis and
having access to some of the best race car builders in the
world, this wasnt a big ask. The resulting chassis weighed
in at 470 pounds, which gave them their target to beat.
The chassis was scanned and the 3D model uploaded
to the cloud. It was then wired with hundreds of sensors
to capture the real-time data and shredded through
Californias Mojave Desert. Mouse did literally drive the
wheels off that car so we knew our data was good as we had
pushed it to the absolute limit, says Holst.
The result was some millions of data points about the
cars structure and the forces acting on it, which were then
plugged into Project Dreamcatcher and applied to the
3D model in the cloud. Here the software uses machine
learning to generate multiple design options by evaluating
design trade-offs.
The big thing that cloud processing has given us is the
ability to now tackle millions and millions of calculations
this task. They moved from napkin sketches into Autodesk 6 Mouse McCoy and
Felix Holst, Hackrods
Fusion 360 and although they were following the narrative co-founders
of being kids in a dorm room, they knew full well that their 7 Fraser Campbell, a
idea of a dream car would not be theirs. colleague from Felix
We are not ashamed that we are from a different Holsts Hot Wheels
days, was recruited
generation to those kids. This is the car that we aspire to help on the design
to have. The idea is to tie us into the ethos of the early of the La Bandita
speedsters basically a four-wheel motorcycle with one speedster
purpose: to go fast and stay light, says Holst. 8 Dr Slade Gardner,
who previously
All the surfacing and design review was then carried out worked at Lockheed
in multi-person, multi-location VR with the various team Martin, has joined
members interacting with a life-size model of the car in a the Hackrod team
as chief technology
photorealistic experience. officer
Weve been working with a modeller in Buenos Aires,
Argentina. We would record our sessions in a virtual realm
and when he woke in the morning he could watch the
recording as if he had been there in person anyway and
make all the changes to the surfacing.
Its super quick. When you start going down the rabbit
hole of what these new technologies offer beyond the
immediate benefits, its phenomenal. Its a whole new way

6 7 8

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The part
of working, describes Holst.
This of course meant that they didnt make any clay
The part you design doesnt have to be compromised
for a hundred year old production method. Up until
models as you would in a traditional automotive design now, everything we ever made had to still talk within
you design process. Additionally, all simulations and testing were the parameters of draft angles and cutting paths but
doesnt performed digitally too. A wind tunnel could cost you $35 now the part comes out exactly as designed rather than
have to be million but a monthly cloud subscription is $35 and it will compromised by any adjustments for the manufacturing
run all your CFD and ow analysis in the cloud. methodology, says Holst.
compro- What was radical about this process is that we went from As for the other components, this will be managed
mised for sketch to rendering to a complete ready-to-manufacture through a cloud-based supply chain. What we see
a hundred design in a matter of weeks. This completely collapses happening is a new world of distributed manufacturing
year old the trajectory of two-year design cycles. We just achieved and local assembly where you pass components out and
what the biggest car companies do in a fraction of the different factories around the country will make them
production time,comments McCoy. and send them back to you very quickly for local assembly
method. Up whether in a workshop or in a membership-based tech
until now, GETTING IT MADE shop, adds Holst.
For this first generatively designed chassis Hackrod wanted To lend expertise on the manufacturing side and to head
everything to manufacture it using the same technique and materials up Hack Rods technical vision, the pair have brought a
we ever as the original. A hot-rod fabrication shop in LA was able to new team member onboard Dr Slade Gardner. Having
made had custom weld the 300 tubes in the chassis using chromoly previously been a Fellow at Lockheed Martin Space Systems
to still talk (chromium-molydenum steel) and the result was a 25 per and a Fellow at Lockheed Martin Aeronautics in the Skunk
cent weight saving. Works division, Gardner is a foremost expert in industrial
within the Although this validates their process in that a lighter additive as well as being a materials scientist.
parameters but structurally superior design can be achieved, they Slade wanted to do something more radical than what he
of draft ultimately aim to utilise AM as the manufacturing process. was doing at Lockheed Martin, which is saying a lot, and so
angles and This will not only be cheaper (its just as cost effective to joined our little startup, says Holst.
print one off as it is a 100 as there is no tooling involved) but As we go to press, the Hackrod team are currently starting
cutting also means that complex parts and shapes can be printed. to explore the AM process required to build the next
paths but evolutionary stage of the cars chassis. According to Holst,
now the they will print a full size generatively designed chassis,
part comes 9 optimised for additive manufacture in aluminium using
metal deposition printing on a 15 bed. The aim is to have
out exactly this part of the project completed by October 2017. Also,
as designed the next generation of the Bandita will not be burning fossil

fuels but rather a hacked Tesla powertrain.

THE BIG PLAN

Essentially Hack Rod is working towards creating a
cloud-based manufacturing platform that democratises
manufacturing enabling anyone to create, design and
build what they want. When asked for a description
of our startup, we say we want to be the Red Bull of
manufacturing. We want to build radical stuff using new
10 tools and then make these tools accessible to everyone,
says McCoy.
Holst adds, What we are doing could be dominated by
the big corporations and go towards making them even
more money or we could go in, cause a bit of a fuss and
carve a big chunk out for the every man and build new
industry, new innovation.
And that is such a big part of what we are doing
powered by the notion that all of the biggest inventions in
history didnt come out of big corporations, the came out of
garages and dorm rooms.
hackrod.com

11

9 A rendering that reveals the
generatively designed chassis

10 A model of the chassis that was
created using Autodesks generative
design tool Project Dreamcatcher
11 The La Bandita chassis was
manufactured using the same
materials and techniques as the
original in order to demonstrate the
weight savings gained

DEVELOP3D.COM JULY / AUGUST 2017 31

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 PROFILE
An eyewear project from a lens-making giant and Materialise looks
to have finally seized on 3D printings potential. Stephen Holmes travelled
THE
to Belgium to see how the future looks in purest 20:20 vision
PERFECT
FIT
T
oo big. Too square. Not round
enough. Too Harry Potter. Makes
my nose look funny. Keeps sliding
down my nose. Not in that colour. Not
that brand. Those will do.
Choosing a pair of glasses is a trial
for most people, a process that varies
little the world over: people cursing
their faulty optical performance
while stood before racks of different frames, trying to find
something that suits their face, taste and budget.
Putting aside fashion, most of us are unaware that the
shape of the frames is as important to your vision as the bits
of glass that sit in them.
When the frame is chosen the optician sits down and
selects the lens, and the lens manufacturer has to do the
magic, says Felix Espaa, global new media manager at
Hoya, one of the worlds largest optical lens manufacturers.
Sometimes the fit of the lens is not ideal, he explains,
listing a number of parameters that the lenses have to
match to attain perfect vision quality: inclination in front of
the eye; distance between eyes and lens; primary position
of the eye (never horizontal with the ground). Even the
wearers height plays a part.
Present frame manufacturing methods, which leave the
lens designers trying to get the best performance out of the
shape of its glass, makes this a challenge at best.
Youre going to an optician to get your vision fixed, but
you end up having to compromise between your fashion,
your style and a kind of visual quality that is acceptable,
comments Espaa.
32 JULY / AUGUST 2017 DEVELOP3D.COM
p32_33_34_D3D_JULYAUG17_YUNIKA EYEWEAR.indd 32
DIGITAL SOLUTION
The solution is digital; a combination of measurement,
design and manufacture that gives customers the ability to
walk away with a product that is not only perfect for vision
and fit, but exactly the style they want.
Yuniku is the partner project between Hoya and 3D
printing experts Materialise, who have together built a
business model a giant leap beyond the current lens and
frame setup.
The Yuniku sales cabinet appears like any other, yet
uses 3D scanners to gather data about the shape of the
customers nose, the position of their ears, and any other
features of the facial anatomy and proportions that could
affect the comfort and fit of frames.
Software determines the ideal position of the lenses in
relation to each eye, while the customer chooses a style of
frame from a range of designs.
The design data works to the parameters set by the
lenses, and once perfectly fitted Materialise then uses it
to manufacture the frames using SLS 3D printing, while
exporting the CAD file of the lens shape for Hoya to
produce.
All the data used is accurate to the finest detail, making
The latest Yuniku
You go to an optician to get your
frames from Belgian
designers Hoet, all
vision fixed, but end up compromising
designed to adjust to
the wearers exact
between your style and your vision
needs Felix Espaa of Hoya
19/07/2017 16:51
 DEVELOP3D.COM JULY / AUGUST 2017 33

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 PROFILE
manufacture, assembly and fit perfect each time.
We decided to think the other way around, says Espaa.
Lets put the lenses in the ideal position, where we know
they will perform the best ever, and then the frame can
change some parameters to accommodate this.
When we explained that to the opticians they said: Wow!
Youve nailed it!. Of course, for the consumer it is also
excellent.
Given the list of proper fitting directives for frames (most
of which are an unknown to the customer) Yuniku acts as a
guide.
If the frames are improperly fitted then your cheeks might
interfere when you smile, prompting the frame to bounce
up and down. Equally, if the frame sits too far above your
eyebrows, or if your eyelashes are too close to the lens.
Most effective is Yunikus ability to compensate for
asymmetrical faces, which 99 per cent of humans have,
something the designers of frames constrained by mass
manufacturing processes are unable to do anything about.
The system has boundaries respecting the best visual
performance, the frame designers vision of the shape and
styling, as well as the customers unique fitting needs.
ADDED VALUE
Finding the real added value in 3D printing, something
many have struggled to set aside from the novelty of the
process itself, is where the true potential still lies, and
from its headquarters in Leuven, Belgium, Materialise has
endeavoured to focus on the bigger picture.
How are we going to make the right choice for a tech
thats going to have a transformative impact? asks Alireza
Parandian, corporate business development at Materialise.
34 JULY / AUGUST 2017 DEVELOP3D.COM
p32_33_34_D3D_JULYAUG17_YUNIKA EYEWEAR.indd 34
Each pair is SLS The answer, he says, is through working with companies
3D printed by
Materialise in a skin-
to make the right decisions, not simply for the design or
safe material and manufacturing stage, but at a boardroom level.
finished to give a high Parandian explains that while 3D printings hype
quality feel
continued to rise and fall, out of the limelight, Materialises
teams of designers, engineers and material scientists
continued to look at full end-to-end digital supply chains
with various industry partners.
With expertise in the medical sector, producing and
verifying materials for daily on-skin contact is already in
the company arsenal. Equally, not being tied to any one
single additive process means that Yuniku can develop and
flourish along with more exciting materials and processes
in the future.
The project continues apace, with more designers and
opticians around Europe signing up, while more materials
and lens shapes are added to the roster.
By changing the optical eyewear process from a frame-
centric to a vision-centric process, the digital technologies
used have transformed an entire industry ecosystem, all
with an eye on the future.
yuniku.com
materialise.com
Lets put the lenses in the ideal
position and then the frame can change
some parameters to accommodate this
Felix Espaa of Hoya
19/07/2017 16:51
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 INTERVIEW
Q&A RICHARD LING
WE TALK TO THE CO-FOUNDER OF PAVED
WITH GOLD ABOUT HOW ITS HELPING
HARDWARE COMPANIES TURN PRODUCT
IDEAS INTO SUCCESSFUL BUSINESSES
P
aved With Gold is a London-based creative consultancy
founded in 2014 by Kaye Symington and Richard Ling.
Having had experience in launching products and
creating brands at the in-house product development
studio at Mint Digital, they had a desire to set up
a company that would help other people launch
their own products successfully. As Ling says, We
started Paved With Gold because we get a kick out
of equipping inventors and makers with the tools,
support and services they need to turn ace product ideas into successful
businesses.
Over the following three years, the pair have assembled a multi-disciplinary
team, each with their own specialisms, who work with clients to propel their
projects forward. Clients are based all over the world, some of which include
the Ding smart doorbell (which was featured in DEVELOP3Ds November
2016 issue), the BleepBleeps connected device and the Smoovie mini-
steadicam for your smartphone or GoPro.
D3D: What is it that Paved With Gold provides?
RL:At Paved With Gold we specialise in launching
innovative ideas and products by growing loyal online
communities. We work with passionate founders across
design and tech to turn products into businesses and
businesses into community-centric brands.
We work on developing successful Kickstarter
campaigns to bespoke digital marketing and PR services.
Our team are a multi-talented bunch of consultants so
were able to help with building campaigns and brands
from scratch.
D3D: Why do you think were seeing so many hardware of this ready weeks before launch.
startups at the minute?
RL:Its become easier and cheaper to prototype hardware early and who should you be targeting?
ideas and test them in the world. From 3D printing to
open source electronics, now anyone is able to design and RL:It always depends on the product but for the majority
iterate on their ideas themselves.
A lot of these projects grow into startups that use
crowdfunding for market validation and, if successful,
turn their ideas into businesses.
This do-it yourself approach supported by the knowledge You can then reach out to influencers from these areas to
sharing amongst makers, from the likes of hubs like
Makerversity and the Central Research Laboratories to
name a few, means inventors and designers can innovate
36 JULY / AUGUST 2017 DEVELOP3D.COM
p36_37_D3D_JULYAUG17_Paved With Gold Q&A.indd 36
and even compete with industry leaders.
Theres a lot of opportunity across the hardware
industry from the smart home to VR, and I think its this
excitement thats helping draw more people to work on
hardware startups.
D3D: What are the big mistakes made by crowdfunders
early on?
RL: Not working on PR and marketing before launching
their project. You need to line up press, grow a community
and get your personal network all ready to back and share
your project as soon as your project launches.
Adding too many features. We always recommend
focusing on your core features and doing them really well,
rather than offering everything for everyone. Its the work
on those additional features that will mean you take longer
to get to launch and ultimately to market.
D3D: At what stage should a designer be thinking about
marketing?
RL: In most cases marketing can start around three to
four months ahead of launch. This gives time to refine
messaging around what the product is and who it is for.
Plus it allows enough time to find press and influencers to
target as well as warm up your own personal network and
grow a community around your idea.
If youre looking to crowdfund then youll also need to
create your campaign page with videos, photography and
rewards. Youll want to share a preview of your campaign
with press and influencers so its much better to have all
D3D: What are the best ways to get your product seen
of hardware products its usually a good idea to focus on
reaching male, early adopters, aged 25 to 35.
But whoever your audience is, find out what they like,
what they read and what social media platforms they use.
see if theyd be interested in sharing about your product or
even being part of your campaign.
19/07/2017 16:51

Theres a lot
of opportunity
across the
hardware
industry and I
think its this
excitement
thats helping 1
draw more
people to work
on hardware
startups

D3D: What content can companies be sharing on social

media?

RL: Tell your story. Its not just about the product, its 2
about you and the team. Share what your team have been
working on, the interesting people you hang out with and
what your mission is. Keep in touch with your community,
to help share your vision and bring them on the journey
with you.
To help grow your community and reach more people, 1 As a small
share about relevant brands or influencers you like. It can startup with no
help you get on their radar and If they like what you do, dedicated marketing
team, BleepBleeps
theyll share your project too. approached Paved
With Gold for help in
D3D: As a team spread out across the world, do you promoting Sammy
Screamer, a cute
have any tips on remote working? little motion sensor
device, in time for
RL: We use the usual tools like Slack, Skype and Google Christmas 2015 3
Drive, to keep in touch and collaborate on work. We
2 Following the
success of that
regularly meet up with each other and clients to catch up project, Paved With
face-to-face too. Then theres our annual Paved With Gold Gold worked with
retreat where we fly in the collective for a couple of days. BleepBleeps to grow
a community and
Its more of an opportunity for us to get together and hang
it embarked on its
out, but we also spend time talking through projects weve second Kickstarter
worked on and our goals for the year ahead. campaign for Suzy
pavedwithgold.co Snooze

3 Paved With Gold
created an end-to-
end Kickstarter
campaign for Ding
and its smart
doorbell product
including everything
from strategy,
4
management,
outreach, PR and
social media updates

4
5 Technology
Will Save Us is a
startup that creates
make-it-yourself kits
for kids. Paved with
Gold helped initially
in creating a social
media strategy and
Youve had an amazing idea but how do you present it to the
then an end-to-end
world and make sure it is seen by the right people? This is Kickstarter campaign
what Kaye Symington and Richard Ling of Paved With Gold for its Mover Kit,
discussed during their talk at this years DEVELOP3D LIVE which met its
Kickstarter target
at Warwick Arts Centre in March. within 48 hours and 5
Visit develop3dlive.com to watch the video. raised over $129,000

DEVELOP3D.COM JULY / AUGUST 2017 37

p36_37_D3D_JULYAUG17_Paved With Gold Q&A.indd 37 19/07/2017 16:51

Frankfurt, Germany, 14 17 November 2017
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GOLDEN GOAL
In-store sculptures for sports giant Nike got the full gold star
treatment from 3D printing experts Digits2Widgets. Stephen Holmes
finds out how an animation was transformed into the tangible
S
neaker launches are big business, with
few more so than those taking place
in a flagship London store during an
international football tournament
hence Nike wasted no chance to
upstage rivals with four incredible
golden footballs.
Glimmering, geometrically unique
and styled to capture the characteristics
of the brands signature football boot types, each of the balls
was placed to showcase a new off-pitch Nike F.C. sneaker
that mirrored its on-pitch equivalent.
The original campaign for Nike, developed in time for
the UEFA European Championships in summer 2016, was
produced by Madrid-based creative agency Tavo.
Using Cinema 4D to create graphics and animations,
these designs were then developed and made physical using
traditional hand modelling skills, sculpting all four balls.
Although the results were effective, London-based 3D
printing bureau Digits2Widgets (D2W) was approached to
p39_40_D3D_JULYAUG17_Nike store.indd 39
PROFILE
see how the designs could be advanced to produce the same
results faster and more accurately to the original digital
designs.
D2Ws in-house CAD designer took all the original
Cinema4D 3D models and exported them as STL.
We helped to complete the process by using Materialise
Magics software, which makes the files printable in the
SLA material, adds D2W CAD production manager Bart
Radecki.
Although 3D printing the balls in real gold is a possibility,
the cost and time involved meant that gold plating during
the post processing stage over a smooth plastic would be
much more economical.
All parts were 3D printed in resin which has a high
resolution, giving us the ability to create sharp detail on the
Styled to capture
the characteristics individual designs of each ball.
of Nike football The joy of using rapid prototyping is that you can print
boot types, the off more than one, so if one breaks, for example, its
sculptures each
have unique relatively easy to replace, unlike the lengthy process of hand
characteristics carving a new one from scratch.
DEVELOP3D.COM JULY / AUGUST 2017 39
19/07/2017 16:51
 PROFILE

Pressure does bring out the

best in peoples ability, so although
at times production was difficult,
it was also an exciting challenge
to be a part of

1
1 The polished
The parts were printed using 3D Systems iPro 8000 with final line-up await
2
its proprietary Accura 25 stereolithgraphy material. being placed into
displays
With only two weeks to prepare the CAD files, print four
complete footballs, electroplate them to a high standard, 2 Underneath it all
lies a SLA 3D printed
gold plate and finish each one, before delivery to the client, base, produced on
the pressure was on right up until the final whistle. a 3D Systems iPro
8000
If one of the SLA balls had broken then, given the size of
the print, it would be another 24 hours to print a new one,
3 A nanocrystalline
copper plating
explains Radecki of the delicate project. forms a base for the
Pressure does bring out the best in peoples ability, so gold to attach
although at times production was difficult, it was also an
4 The final product
in the Nike Store
exciting challenge to be a part of. alongside its
Once the printed parts had been cleaned, a corresponding
nanocrystalline copper plating was added, giving a smooth sneaker
and even base all over the resin part, which makes it easier
for the product to be gold plated in the final stages.
Some final polishing brought out the full detail of the
gold drips, sharp edges and the footballs stitched panels,
before the displays were erected, complete with partnering
footwear, for the Nike Town store in London.
digits2widgets.com

4 3

40 JULY / AUGUST 2017 DEVELOP3D.COM

p39_40_D3D_JULYAUG17_Nike store.indd 40 19/07/2017 16:51

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 PROFILE

SEGA with help from Rewind and Luma-iD was able to

create a fully-functional Power Fist to mark the launch of
Warhammer 40,000: Dawn of War III. Tanya Weaver reports
42 JULY / AUGUST 2017 DEVELOP3D.COM

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 1

F
ans of the Warhammer franchise and We also got some rough dimensions and basically it was
1 The Power Fist,
which is 400mm
fantasy wargaming in general were no a process of copying what they had created into SolidWorks long, is a close-
doubt aware that video game developer and then working out how the whole thing was going to fit combat weapon
SEGA was releasing Warhammer together. designed to give the
user superhuman
40,000: Dawn of War III earlier this The client wanted a rapid turnaround and within a week
punching power
year. But as well as this niche market, and a half of receiving the internal components Luma-iD
SEGA also wanted to create a buzz was able to send the completed files to the manufacturers. Page 44
around the release in mainstream The main fist component was sent to 3D Systems Europe, An image-led
breakdown of
media too. It decided to do this by which created the 3D print as a single piece in glass the Power Fist
giving members of the press an opportunity to wear a real- reinforced nylon. Meanwhile the fingers were sent to development process
life working replica of the Warhammer Power Fist. Proto Labs where they were CNC machined from solid
In the game, the Power Fist endows the Space Marines aluminium. The lead time for the 3D printing and the
with superhuman punching power making it easy for metal machining was another three to five days, which is
them to hammer there way through an armoured tank, for still pretty fast, says Passmore.
instance, to tear out the passengers. Although SEGA didnt
exactly have that kind of power in mind, it wanted to at least PUT THE FIST TO THE TEST
give wearers the ability to punch through a brick wall or a The parts, which together weigh 9.6kg, were then shipped
hefty object such as a toilet. to Rewind for assembly, painting and additional testing.
The challenge was to ensure that while smashing up
FROM VIDEO GAME TO REAL LIFE various objects the wearer themselves werent hurt. They
Creative agency Rewind was tasked with making this would be fitted with a harness with an iso-elastic kinematic
fist a reality and while it would create the internals and camera stabilising platform incorporated into it. This
electronics for the fist, it called upon London-based product harness would also hold two air canisters that are used to
design consultancy Luma-iD to create the external housing. power parts from the industrial pneumatic cylinder which
REWIND had created a visual representation of what the delivers up to 3000 PSI to the Power Fist in addition to the
Power Fist was going to look like and our role was to then users strength.
turn that visual image into a 3D CAD model that could then The press day at Holborn Studios was a resounding
be made into an actual prototype, says Matt Passmore, success and thankfully no one got hurt. As SEGA head of
Luma-iDs product design manager. PR Peter Oliver, says, The press who tried it out came away
REWIND had already worked out that they wanted to with massive smiles on their faces saying how awesome
use a pneumatic system and they actually sent over all it was to be able to punch through walls and toilets. The
of the internal components to our studio. So there was a coverage was fantastic and that is really what we were
drill handle, a pneumatic ram, a valve control block for looking for.
controlling the punch and a few little bits of electronics luma-id.com
that had to go inside. rewind.co

DEVELOP3D.COM MAY 2017 43

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 PROFILE

THE POWER FIST DEVELOPMENT PROCESS

2 A visual approximation
of where the internal
components would
be using a quick scale
drawing produced in
SolidWorks

3 The main housing of
the Power Fist takes shape
in SolidWorks

2 3

4 The internal
components are modelled
to ensure an accurate fit

5 The eagle logo on the
Power Fist is 3D printed to
double check the design

4 5

6 Rewind realise how
heavy the Power Fist
really is!

7 A full body camera

stabilising harness is
needed to support the
immense weight of the
Power Fist

6 7
8 The fingers are
attached to the palm for
the first time using almost
half of the 43 screws
that hold the Power Fist
together

9 The press get their
first look at the almost-
finished fantasy weapon

8 9

10 Painting begins

11 The Power Fist is

unleashed on an
unsuspecting breeze
block

10 11

44 JULY / AUGUST 2017 DEVELOP3D.COM

p42_43_44_D3D_JULYAUG17_PowerFist.indd 44 19/07/2017 18:23

 Technical-Sales-2015-Half-Page-Develop3D_v2.pdf 1 13/03/2015 15:34:31

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 REVIEWS
Solid Edge ST10
In the world of mainstream 3D design and engineering systems, Solid Edge has
been a consistent player for over two decades. Al Dean takes a look at the latest
version that brings some of Siemens brand new technology to bear
S
olid Edge has been on the market
for over two decades now. Since
the acquisition by Siemens, it
has been through something of
a renaissance in interest, particularly
with the introduction of Synchronous
Technology back in 2008. This brought
non-history based modelling techniques
to the system alongside its more
traditional capabilities.
This years major release sees this work
continue, but the big news is going to be
the introduction of a couple of pieces of
technology from the wider Siemens PLM
group (and some third parties) that adds
brand new capabilities to the system. So
lets dive in.
CONVERGENT MODELLING
The biggest news for Solid Edge ST10
has to be the integration of Siemens
convergent modelling technology (which
first debuted in NX in the last release).
For those that arent up to speed, this is
building on the ability to work with a mix
of both solid and surface modelling tools
and adds in the ability to work with mesh-
based data.
In the context of Solid Edge, this has
p47_48_49_50_D3D_JULYAUG17_SolidEdgeST10.indd 47
Product: some interesting workflows. If youre
Solid Edge ST10 importing geometry from another source,
Supplier: be that a laser scan, a downloaded or
Siemens PLM supplier model, you can import it and
Price: See text
carry out some functions with it. Where
solidedge.com
convergent modelling gets interesting
is when you need to start to combine
these forms with more traditional forms
of CAD. Because the two can co-exist
in the system, its possible to use this
data as reference material for modelling
around, but when it comes to carrying out
additional operations, then you need to
understand the limitations.
Convergent modelling allows you to
carry out operations, for example, placing
a hole through a part, adding additional
features, to any mesh-based part. As soon
as you do, the system converts everything
to a mesh-based form. While the features
remain editable (theyre shown in the
history/feature tree), the end of that
history list is a mesh form and influences
what you can do next.
1 Solid Edge ST10
gets Siemens
convergent modelling
REVERSE ENGINEERING
tools as well as Another area thats worth addressing
Frustums topology is the simple fact that mesh-based isnt
optimisation engine always perfect. If it has been exported
from another CAD system, chances are its
watertight. If not, and if its from a laser
scan, then chances are that youll have
areas to clean up, repair and patch.
To assist with this Siemens has built in
a pretty well developed set of reverse
engineering tools that you can dive into
to edit and repair portions of your mesh.
Whether thats to remove artefacts from
your mesh, or to patch up areas that
arent needed, the tools are there.
Once you have your model in a fit state
to continue with, there are then tools
to fit more traditional geometry to the
mesh. Whether thats primitive faces
(planes, cylinders etc.) or something
more advanced, these tools allow you
to find regions in your mesh (based
on curvature changes) then add in the
geometry you need.
If youve worked with other reverse
engineering systems (such as Geomagic
or RapidForm, or indeed, Delcams
PowerShape), youll be familiar with the
type of thing that can be accomplished.
While this isnt a wholesale mesh-
based modelling system, its certainly
comprehensive enough to allow you to
work with the data you have. For those
DEVELOP3D.COM JULY / AUGUST 2017 47
19/07/2017 17:58
 SOFTWARE REVIEW

working with laser scanned data in company integrated a set of topology The topology optimisation process is 2 Solid Edge ST10

particular, itll let you repair and clean
up your mesh so its useful, then add in
the features you need to progress things
further. And dont forget, youve got the
surface modelling tools that Solid Edge
has had for many years.
TOPOLOGY OPTIMISATION
Those that follow what Siemens PLM
does in both Solid Edge and NX will
know that in the last release of NX, the
optimisation technology from Frustum,
which alongside the introduction of
convergent technology, made for a very
interesting set of tools, primarily aimed at
the additive manufacturing world.
The good news is that the same
technology and workflow has now been
integrated into Solid Edge. So lets step
through what they bring - there is a visual
below but the devil, as we all know, is in
the details.
found under the Generative Design tab brings a range of
reverse engineering
(we wont go into why thats a bad name
tools for working with
here). Your starting point is a single body mesh-based data
of geometry. This should describe your
design space/domain and any features
you want to retain.
The next step is to define the material to
give an accurate estimate of mass saving
when its all done and used in validation
of the results against yield strength and
a factor of safety. You then work through

WORKFLOW: TOPOLOGY OPTIMISATION IN SOLID EDGE ST10

1 Start by developing your design domain for the 2 Once material is defined, you then define any regions 3 The next step is to define the loading conditions acting
optimisation process. This can only be a single body of you want to preserve. This is done using an offset from a on the design space, such as forces, pressures and torques.
geometry and needs to include any regions of interest. selection, such as those highlighted in green. Again, select the geometry and add the details.

4 The final requirement for load conditions is to define

5 The last step prior to computation is to define the study
6 The result can be validated against the yield strength
any fixed or pin constraints in the design space. You can quality (namely, the mesh quality) and your target mass from the material and factor of safety using built-in FEA
also build in manufacturing constraints as well. reduction (as a percentage). tools. In the Pro licence, this can be progressed further.

48 JULY / AUGUST 2017 DEVELOP3D.COM

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 defining your boundary conditions for the study.
This involves defining any keep out regions or
preserve regions that you dont want touched,
loads (such as forces, pressures and torques) and
constraints (either pinned or fixed).
At this point you can also define the
manufacturing settings. These allow you to
guide the result to avoid any internal voids or
any overhangs (in a specified direction) both
of which are useful if youre either machining or
additively manufacturing the end result.
Once all these are set up, you need to define the
optimisation parameters. Topology optimisation
is all about mass reduction. You define the
quality of the solution, which essentially
controls the mesh element size (more elements
mean a smoother result but a longer compute
time) and a mass target.
This can either be a hard mass value or a
percentage. Most will probably go for the
percentage value. Where the Target value is
useful is if youre using an existing component as
your design space or have specific requirements
you need to reach. You can also add in a factor
of safety, which will be used in validation of the
results.
Handily, the system also gives you an estimate
for the computation time. Note, this is a
pretty compute heavy process and you could,
particularly with the instance shown here, be
talking about hours.
Once the compute is complete, youre shown a
stress plot that will map your loading conditions
to the resultant form to give you an idea of how
the new form works.
In terms of what you can do next, youve
got a couple of options. Of course, these are
inextricably linked to the convergent modelling
tools as the result is a mesh-based form. That
means you can start to build up or rebuild
engineering features where needed (though
bear in mind that if you do, you wont get hard
surfaces theyll become a mesh as you merge
them).
As youd expect, this type of tool is ideal for
experimentation and youre able to run multiple
studies, rerun optimisation studies after design
changes and generally see where you can get to.
Finally, if youre looking to take these forms to
manufacture, you can export them to STL or the
newly added .3mf format.
At this point, its worth discussing the pricing of
the generative design tools introduced into ST10.
There are basic tools included in all levels of Solid
Edge. Thats Classic and Premium not, however,
the 2D, drawing only entry level bundle. That
said, theres some heavy limitations on what you
can do both during the optimisation process and
with the end result.
Essentially, you can load and constrain a design
space (using basic forces and constraints) and
view the results. Thats it.
If you are looking to use the more advanced
loading conditions (including torques and
pressures and pinned constraints), manufacturing
controls, conduct a stress-based validation (and
view the results) and export the results (either
directly to STL or back into Solid Edge for further
work) and duplicate your studies, then youre
looking at a Generative Design Pro add-on, which
isnt going to be cheap.
3D PRINTING & ADDITIVE
MANUFACTURING
With the addition of the topology optimisation
tools and convergent modelling tools in ST10, its
clear that Siemens has its mind on the Additive
Manufacturing world. Interestingly, it has also
done some work at the opposite end of the
spectrum to greater support desktop-level 3D
printing.
The STL export options have been expanded
both in terms of format support (it now adds
3mf format for richer 3D print communications)
as well as some tools to assist in previewing your
part (or group of parts) on a build platform. You
can then export the data (most likely) or connect
to a third party to order the parts.
Siemens has integrated with a German outfit
called 3yourmind to build its 3D print brokerage
service into Solid Edge. This means youll get
a quick preview of the part, an indication of
printability, a list of possible materials and a
good idea of cost. 3yourminds service gives you
a good set of filters for not only build technology
and material, but also location. Most of us have
existing relationships with suppliers that we
favour, but if youre looking for more exotic
materials or looking to explore other options, its
a good starting place.
UPDATES TO SYNCHRONOUS
TECHNOLOGY
While theres been a slew of updates across the
board for this release, you might be forgiven for
thinking that theres not been much work done
on the synchronous technology front. Although
it hasnt been the focus for the ST10 release (the
toolset is mature already), this isnt to say that it
hasnt been addressed.
Perhaps the most useful, particularly for those
working on complex assembly models with a lot
of repetitive fasteners or sub assemblies, are
the new tools to help clone assembly mating
conditions. Whereas in previous versions it
was possible to pattern components based on
the locations of other components (e.g. a cap
for every bolt head), this has been extended
to pattern based on feature recognition (e.g.
a retaining clip assembly for every mounting
location), but whats cool is that while this is
feature-driven patterning, theres no need for an
actual feature, it uses geometry recognition.

ADD-ONS FOR SOLID EDGE: CAM, CFD AND TECHNICAL PUBS

Alongside SOLID EDGE CAM SOLID EDGE FLOW SIMULATION SOLID EDGE TECHNICAL PUBS
the core tools
updated and
added in this
release, theres
been some work
done on the in-
house add-ons for
Solid Edge.
While the Solid
Edge bundling
is pretty simple, First introduced back in the early 00s, Introduced a couple of years ago, FloEFD For this release, theres been work done
these add more Solid Edge CAM (formerly known as was a Mentor Graphics developed third with QuadriSpace to enhance the technical
specialist tools if CAM Express) is a side seat of Siemens party add-on for Solid Edge to add illustration and publication tools that are
you need them. enterprise level NX with many of the Computational Fluid Dynamics (CFD) sold alongside Solid Edge. These have
As ever, theyre advanced tools stripped out, but retaining simulation tools directly into the Solid been rebranded as Solid Edge Illustrations
either integrated the machining capabilities for which the Edge interface. In the intervening time, and Solid Edge 3D Publishing.
into the same system is known. Siemens has acquired Mentor so the The difference is that the first is the
interface or they Things havent changed a great deal FloEFD application is now an official part entry-level and gives you the means to
work alongside for this release apart from some new of the product offering. develop technical illustrations, with a set
it, with good data tools that allow you to quickly repurpose As youd expect, it gives you a designer/ of tools to repurpose your CAD geometry
connectivity. geometry from Solid Edge for machining engineer-focussed fluid flow and heat and then adds in those all important
whether thats building jigs and fixtures transfer simulation capability. So whether annotations and other elements.
or adding machining stock. Theres also youre concerned with heat or flow, youve Solid Edge 3D Publishing, on the other
the integration of Siemens own take on got a good set of tools available to do just hand, is aimed at those looking to develop
adaptive roughing, which adapts your that. And because of the systems maturity live work instructions as well as other
cutting operation to increase tool life while (its based on Flomerics tools which have technical publications and gives you
enabling the cutter to use a large portion been around for a decade or more), its a whole host of tools to create staged
of the flute length. Theres also access to a well developed, capable and pretty well assembly, disassembly and service
web-based post processor hub. thought out. instructions.

DEVELOP3D.COM JULY / AUGUST 2017 49

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 SOFTWARE REVIEW
DATA MANAGEMENT &
COLLABORATION
To round things out, lets talk about
the last two updates that were looking
at for this release, starting with data
management.
Those that are familiar with Solid
Edges development will know that, some
time ago, the default data management
solution was built on Microsoft
SharePoint. This changed in the last
release (ST9) with Siemens introducing
a set of tools that enhanced the indexing
tools native to Microsoft Windows to add
in some CAD flavoured knowledge.
The result was a basic data management
system that worked, out of the box,
without any special server requirements
and was just as applicable to the smaller
workgroup using a network drive
arrangement as it was to the sole trader
just working with their file system.
This continues for this release with
extra sophistication added to those tools
focussed around enabling teams to ensure
that theyre both working on the same,
up to date data, as well as managing file
duplicates across projects (which has the
benefit of reducing repetitive work and
potential inventory) using a new Design
Manager utility.
While the built-in data management
tools are the entry-level in the Solid
Edge range, theres also a good level of
integration with Siemens Teamcenter
PLM system. This release sees the
ActiveWorkspace technology from
Teamcenter integrated into SolidEdge,
which offers a pretty slick gateway into
the PLM world.
50 JULY / AUGUST 2017 DEVELOP3D.COM
p47_48_49_50_D3D_JULYAUG17_SolidEdgeST10.indd 50
Now, on to the collaboration aspects
over and above data management and
sharing in a workgroup. Starting later this
year, Siemens will be beta testing a new
Solid Edge Portal. This will allow users to
upload files for sharing with partners in a
secure environment.
IN CONCLUSION
Solid Edge ST10 looks like a
comprehensive release across the
spectrum of the system. The introduction
of convergent modelling and the
associated reverse engineering tools are
going to make life easier for folks working
with imported mesh geometry or perhaps,
more commonly, data from laser scan
systems. For instance, whether thats
capturing physical models for progression
into design and engineering or for
capturing existing forms for interfacing
(think: aftermarket products).
Alongside this, youve got a bunch of
tools that bring some sophistication to
the 3D print or additive manufacturing
workflow.
On the subject of generative design,
I think we need to address two things.
Firstly, Siemens is calling this generative
design. But it clearly isnt its topology
optimisation, pure and simple.
The second matter to address is the
price. Siemens wont confirm the price
for the add-on, but having seen ball park
figures, its going to be expensive and
thats on top of your existing licence or
subscription. Yes, theres some value in
the freemium tools, but the pro tools
are based on early stage technology
(Frustums own cloud-based service is
only just on its first, 1.0, release cycle). To 3 While not a
make use of this type of technology, users core focus for this
release, synchronous
need to experiment and to be able to take technology sees
it into production and find the value for a few updates,
their own products. Hiking up the price particularly in the
for the ability to do that isnt going to help area of assembly
aid adoption. automation and rapid
insertion of multiple
Elsewhere, some good work has sub-assemblies
been done on other aspects of the
core of the system. The shift to make
the operating system more useful as a
data management tool is a good one,
particularly to help those that dont
see the need for such a tool (as it just
works). The updates to synchronous
technology will also help out where you
need it.
Then you get to items like the new
CFD focussed add-ons and the changes
made to Solid Edge CAM (Formerly CAM
Express) both of which are additional cost
options.
Its interesting to see how Siemens
mainstream team planning and executing
of Solid Edges development are starting
to take advantage of the wealth of
technology available in Siemens arsenal.
Yes, theyre going to add to your
investment, but these are productive
tools that will benefit you if you have the
need for them.
All in all, its a good update to an already
mature and comprehensive system.
As you might guess, it looks like the
development of synchronous technology
has started to slow down as its reaches a
level of maturity the good news is that
Siemens is exploring new avenues while
continuing to refine existing tools.
solidedge.com
19/07/2017 17:58
 Solid Edge ST10 allows you to take advantage of the
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 SOFTWARE REVIEW
Luxion KeyShot 7 beta
With KeyShot 7 on the horizon, Al Dean takes a look at what Luxion has in store
for the release. With new materials, new rendering and set-up options and the
companys first pass at virtual reality support, it looks like a good one
W
hen it comes to design
focussed visualisation,
the benchmark for ease of
use and time to incredible
results has to be Luxions KeyShot.
The system combines the benefits
of progressive rendering with high
dynamic range (HDR) image-based
lighting and some pretty sophisticated
associativity with your workhorse CAD
system.
Since its first release eight years ago, the
system has grown in both sophistication
of what you can do with it and the results
that can be achieved. The image focussed
system has seen animation and new
material models added and, as such, has
helped bring high-quality visualisation to
the mainstream.
The last couple of releases have also seen
capabilities added to enable you to further
dig into your scene in order to fine tune it
and get it exactly how you see it. You can
now add your own physical lights, make
up more complex material definitions and
much more.
So shall we take a look at what it has up its
sleeve for the KeyShot 7 release? Lets start
with the user experience.
p53_54_55_D3D_JULYAUG17_KeyShot7 beta.indd 53
Product: KeyShot 7 USER EXPERIENCE
Supplier: Luxion
The KeyShot interface, still as clean as
Price: See text
keyshot.com it ever was, has seen a pretty extensive
overhaul for this release. Theres now a
huge amount of customisation for docks,
tabs, menus and more.
On top of this, you now have the ability
to save separate workspaces, which
retains your dialog position and visibility.
This could prove beneficial in shared
workstations or moving between them.
Itll also be useful if you like to keep your
interface focussed on the workflow at
hand and have separate workspaces for
material definition, for scene set-up or,
indeed, animation.
Also useful for the experienced user
is that you can now define your own
keyboard shortcuts, rather than just
relying on the defaults.
MATERIALS DEFINITION
Elsewhere in this release, theres been
1 KeyShot 7 further work done on the materials definitions
extends material the lifeblood of any good rendering
options, adding in
project. As existing users will know,
the ability to import
measured materials KeyShot is moving towards using the
from X-Rites AXF Material Graph as the preferred method
format of defining materials. Although it remains
a pro level feature the existing
materials dialogs and definition tools are
still there.
This release sees a complete reworking
of the supplied materials library with
some of the less than ideal materials
being removed and many texture-based
materials swapped out for procedural
ones. Theres also been work done to
bring proper units to the materials
definition process, rather than relying on
an arbitrary value.
There are also new materials for
this release and if youre working with
transparent materials then this is a good
release for you. There are new dielectric
materials (for glass, liquids and gem)
which have a unit aware transparent
distance which, in short, lets you
control when colour starts to be achieved
in an object.
Metals have been reworked with more
accurate representations and are material
specific for common metals including
aluminium, copper, gold, nickel, silver,
titanium and such. You can also add in a
transparency film, which allows you to
quickly and accurately simulate anodising.
Related to this is the ability to throw on
DEVELOP3D.COM JULY / AUGUST 2017 53
19/07/2017 17:59
 SOFTWARE REVIEW

a Clear Coat to metallic paints even with
control over the thickness of that clear
coat.
Theres a new option for cloudy plastics.
If you work with these, youll know that
trying to build your own material to
accurately represent them is something of
a challenge in any system.
Also introduced to this release is
the ability to define multi-materials.
Essentially, this supports the definition
of product colour ways in a single
environment, containing multiple material
definitions assigned to a single part. Itll
make switching between them easier and
more manageable.
The last new material type well cover is
the new movie-based texture. This allows
you to load a video file to represent a
device interface (though Im sure there
are many other applications). The system
strips out each frame and will display
them as youd expect during animations.
The final thing for materials (which
we explore in our box below) is greater
support for measured materials. This is
a growing field, driven by the automotive
visualisation industry, but which is
starting to trickle down into other areas.
Measured materials are captured using a
range of methods and capture absolute
realism in terms of colour, texture and
how that material interacts with light.
While the work was started in the
KeyShot 6 release, it has been expanded
for 7.0 to support X-rites AXF and XML
based files. To use them, you need to 2 Materials is a
define your material as Measured (from strong focus for this
the Type drop-down) this then allows release, from new
materials (like the
you to load your material file.
belting new Cloudy
plastics) to more
STUDIOS specific plastics,
While KeyShot has given users the metals and much more
capability to store variations of models
and scenes in a single file for some time
(using View Sets and Scene Sets), the
ability to switch colours, configurations
and such quickly, has been tidied up.
Scene variants are now called Studios,
these allow you to create a scene,
including environment, lighting as well
as multi-materials, and switch them
out on demand. If youve got a bunch of
commonly used set-ups for your models,

MEASURED MATERIALS: CAPTURING ABSOLUTE REALISM

T
he process of capturing a physical
material for reuse in the visualisation
workflow has always been a complex
one. Remember, were not just
talking about a rough colour match
and a texture map, but something altogether
more complex, but ultimately more accurate.
There are a number of companies that are active
in this space, but one of the leaders has to be
X-Rite.
Its hardware portfolio is developed from a
background in print calibration and monitoring and
has resulted in a range of devices that allows you
to add in a material swatch and end up with a file
that can be loaded into your visualisation system
(support is being added to many systems, both at
the rendering engine level and the product level).
But lets be clear, this isnt the sort of thing that
the average company buys for in-house use its
always going to be an outsourced service. The
process requires that the material sample is
measured for all manner of data, including the
TAC7 Scanner, which efficiently measures and
stores colour, size, texture, gloss, transparency
among others.
These are typically then exported to the
required format for your system. There are a
range of formats capable of holding this type of
information, from X-Rites own AXF format to the
MTL library format thats also gaining traction.
The Chaos Group has been active in this field for
some time, establishing both a service for capturing
materials as well as offering a library of prescanned
materials for use in various Vray products.

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 then this will make life a lot easier as
your need for managing multiple files is
dramatically reduced.
View Sets are replaced with Model sets
and allow you to manage your model and
variants within it much more easily. The
combination of these two also leads on
nicely to the new Configurator tool.

KEYSHOT CONFIGURATOR
As you might have guessed, the new
KeyShot Configurator is all about using
the power of visualisation to create highly
realistic configuration applications.
Whether thats a kitchen showroom, a
new model of a car or a piece of industrial
machinery, it doesnt really matter.
The idea is that you have a number of
model sets that represent the top level
of your product, then work through it 3
to define each sub-category of options
and variations, both in terms of physical
objects as well as visual appearance with
regards to material.
You can then move onto either using
the system as is (which is ideal for design
review, as you can quickly switch options
and variables) or to start customisation.
Its entirely possible to overlay a custom
interface and interaction methods on the
KeyShot window. So if youre looking at
this from a point of sale perspective, its
ideal theres even a toggle for enabling
touch sensitivity.

VR HMD SUPPORT
With the rise of affordable VR HMDs and
general interest in virtual reality, its
perhaps no surprise that the KeyShot team
has been experimenting with how they can
benefit the visualisation workflows.
In the first instance, youre now able 4
to define a panoramic camera that will
allow you to render out both images and
animations that can be loaded into any VR
device, from the crappy things everyone IN CONCLUSION and sales/marketing. 3 Theres a first pass

had this past Christmas that requires
your phone strapped to your face to the
more sophisticated end of the spectrum.
While these wont let you wander around
your model, they could prove useful,
particularly for marketing.
When it comes to HMD support, youve
got a couple of options. Perhaps the most
interesting is the ability to use VR as
an alternative to large-scale projection
screens or powerwalls. Having your model
on screen, youre able to switch to the
VR headset (its found under the Camera
settings) and view your model in your HMD
and itll appear just as you would see it on
a 20-foot screen in front of you.
The system doesnt support movement
tracking at the moment, so dont expect to
be able to get up and wander around your
scene just yet, but its a good first pass at
VR support.
Its also worth noting that KeyShots
existing KeyShotVR tools, which allow
you to create interactive and rotatable
assets for use in presentations and web
page, have been renamed in light of these
additions are now under KeyShotXR.
KeyShot is always fun to use. The results,
even if youre new to the visualisation
process, are both impressive and easy to
achieve. That has always been the case.
What KeyShot changed was that you didnt
need two years of experience running a
rendering system to make it work and get
useable results. It got you a 85% done
image in five minutes, then let you dial it
in to achieve true realism.
Whats changed in the last few years
is that the KeyShot team has started to
add depth and sophistication to the set
of tools already there. The materials
definitions are becoming more accurate
and afford you more control than ever
before. The presets are good, but if you
want to dive in, you now can.
This release sees the culmination of
the ground work done in KeyShot 6 to
enable better management of complex
visualisation projects from the ability
to keep multiple material variations
associated to a part with multi-materials
to the KeyShot Configurator, which brings
this together with model sets to give you a
truly useful tool both for design review
Then theres the new support for todays at VR support in this
release of KeyShot,
more affordable and more impressive
which allows you to
VR head mounted displays. This is a first export VR spherical
pass at support, but its good and usable images as well as
for a variety of processes or workflows. use an Oculus Rift or
If theres a downside, the compute HTC Vive as a display
device
requirements to not only drive your
headset, but to also handle the processing 4 KeyShot
Configurator can be
of that visualisation dataset, mean
used as-is for design
youll need a hefty beast of a machine to review or taken
work with it effectively. If Luxion could through customisation
introduce some form of texture and for point of sale
shadow baking for this VR mode, then it visualisation of
variants and options
could be onto a killer.
But while all this talk of complexity
might make you think that Luxion has got
away from its founding tenets of easy to
use visualisation tools, youd be incorrect.
In fact, while looking over these tools
and seeing what can be done, it struck
me that, although the depth of control
you now have is incredible, the team has
managed to maintain that ease of use
ethic, meaning that its still as much fun
as it has always been.
keyshot.com

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 SOFTWARE REVIEW
Ansys Mechanical R18
R18 is a major update across Ansys whole product portfolio for the next 12 months.
Al Dean begins a two part look focusing on mechanical simulation and FEA first
A
nsys product portfolio has
grown extensively since
many of us first started to
work with (or at least were
aware of) its tools. With its origins
in mechanical simulation, through
acquisition of both CFX and Fluent for
Computational Fluid Dynamics (CFD),
SpaceClaim for 3D modelling and into
the brave new world of the digital
twin and systems-level engineering
simulation, Ansys has a lot to offer the
engineering enterprise.
As ever, amongst the specialist tools for
simulating the effects of ice on aeroplanes
and safety in driverless vehicles, the core
focus for most will be the FEA and CFD
related updates. So well look at these two
areas in some depth starting with FEA
and mechanical simulation this month and
then the fluid dynamics related updates in
the September issue.
Before we get into the specifics, however,
there are some changes that apply to both
groups of products. So lets get those out of
the way first.
Perhaps the biggest change for this
release is consolidation of the product
offerings. Rather than a highly modular
approach that Ansys has relied on
previously, things our now much more
56 JULY / AUGUST 2017 DEVELOP3D.COM
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Product: Ansys R18 straightforward. In both the Mechanical
Supplier: Ansys and Fluent product there are three levels
Price: On application Pro, Premium and Enterprise.
ansys.com Each contains an incrementally more
sophisticated set of tools and as you
move higher up the cost level, so does the
complexity of simulations you can perform.
There are also changes to bundling.
Ansys has finally realised that modern
workstations have more than a single core
and has adapted its licensing on a core/CPU
level to reflect todays hardware. Now, each
basic licence will allow you to run solves
on multiple cores, rather than just one
about time many would say. The Fluids and
Mechanical products seem to be coming
more into alignment in the way they are
packaged.
ANSYS MECHANICAL
Mechanical simulation is where Ansys
origins lie and the set of tools available
reflects that wealth of knowledge and
experience. That said, the company has
1 The combination of clearly been looking at long standing
topology optimisation workflows and much of the R18 release
and the ability to work focusses on compression of existing
with both solid and
workflows and common processes, rather
mesh-based geometry
in SpaceClaim makes than adding new technology per se.
for a very powerful For instance, in the pre-processing
solution stage. While the company has SpaceClaim,
which does much of the heavy lifting
when it comes to study set-up, its often
a big old tool for more simple geometry
requirements. In the drop test field, a
good example is creating the geometry
for the floor. Now, rather than firing up
SpaceClaim to add in a simple plane for
the floor, Ansys R18 now includes basic
geometry creation tools to let you add it
in quickly without having to use another
system.
Another area connected to this is the
use of sub modelling. This is the process
whereby a large-scale coarse study is
conducted, areas of interest are found,
then a sub-model and study is carried
out at much finer detail. R17 brought
the ability to mix and match both solid
mesh and beam elements in sub-models,
but there were instances where joints
between the different section sizes gave
less accurate results. For R18, this has
been addressed to allow you to account for
the difference by setting the appropriate
stiffness behaviour (using axial offsets in
SpaceClaim).
Perhaps the biggest news for the pre
processing stages in R18 relates to mesh
generation something that will never
tire from a little clever thinking and a little
speed up here and there.
19/07/2017 17:59
 For R18, this focusses on iterative
meshing, with the user providing a target
mesh quality and the system working to
achieve that target. This saves time when
running multiple computes to get your
desired mesh.
Elsewhere, a greater use of mesh
patterning has been implemented. This
means you can chop up a model into
pattern-able chunks (typically most
useful with axial or radial patterns) and
work on that portion to get the best
result, then the system will pattern it to
create the full form (even if the study isnt
necessarily symmetric in nature).

TOPOLOGY OPTIMISATION
Perhaps the biggest news for all users
in terms of functionality upgrades is
that Ansys has finally brought topology
optimisation to its mechanical products.
This is a hot topic for many vendors as 2
they align themselves with the additive
manufacturing world (and to be fair, hype)
some do a good job of it, some dont. So many CAD integrated systems allow you geometry and much more. Whereas some 2 Ansys R18s

how does Ansys offering stack up?
The answer is that the solution is pretty
much as you would expect. Itll allow you
to define a design space/domain, loads
and constraints and work towards an
optimised solution.
But what Ansys does bring to the process
is the level of sophistication you can work
with. For example, rather than a single
study and load conditions, you can have
multiples, all of which influence the final
result.
There are a range of manufacturing
constraints, including min/max member
size, pull direction (useful for cast, forged
or machined components) as well as cyclic
and symmetric constraints. Also, while
to work with a single body, Ansys tools topology optimisation codes give you a topology optimisation
tools include cyclical
support linear bonded constraints. mesh and pretty much leave you to figure
symmetry, something
Of course, because these tools are built the rest out for yourself, this enables you thats not readily
into the workbench environment, that also to take advantage of it and integrate it available in other
means that the process can very quickly into more traditional forms of design, systems
be plugged into downstream activities, making downstream production much
whether thats validation or automated easier (here, Im specifically thinking (Over the page)
refinement. about machining additively manufactured 3 Ansys AIM gets
a comprehensive
Another ace that Ansys has up its metal parts, though its not just limited to
update for this
sleeve is SpaceClaim, which for a while, this process). release, with greater
has included tools to assist with mixing coverage of physics,
and matching mesh geometry and solid TEMPLATE DRIVEN SIMULATION interoperability with
geometry built using the Polygonica WITH ACT & AIM R18 other Ansys tools and
much more
technology from MachineWorks. The last major section I wanted to
This means that solid features can be highlight was the work done to help
integrated into the mesh form and the capture best practices, with a little
mesh itself can be skinned to its surface automation and, again, consolidation of

WORKFLOW: TOPOLOGY OPTIMISATION WITH ANSYS R18

1 To start, we apply our initial boundary conditions. In 2 We now define the setup under topology optimisation 3 As the solution progresses, we can dynamically see the
this case, constraints for rotation and translation, and then and can define our optimisation constraints, such as topology material density vary in the Mechanical window,
finally a force. optimisation region, response constraint and objective. useful to determine if the model has converged or not.

4 SpaceClaim has tools to fix, smooth and amend the STL.

5 Once we have the final CAD geometry, post optimisation
6 Finally, once we assign the original boundary conditions,
Here we create a cylinder to act as a cutter to give us a of the STL, we can move down the analysis tree and assign we can analyse the new design to ensure it meets the new
smooth surface to assign our boundary condition. original boundary conditions to validate the new design. performance criteria.

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 SOFTWARE REVIEW
workflows. Within Ansys Mechanical tools, there are
two approaches available.
The first is AIM, which was introduced a few years
ago and is a complete environment designed for just
this. It provides the user with a growing range of pre-
baked templates to guide you through the simulation
of specific studies.
While on launch, AIM featured the basics, the two
releases since have seen the tools coverage grow
hugely. Itll now cover basic fluids, structures, thermal
and electric conduction, through to fluid structure
interaction, magento-statics, polymer extrusion,
thermal transients as well as a range of tools to pass
data on for further work in full Ansys.
The focus for R18 has been around greater
sophistication of frequency response in magnetic
studies, magnetic thermal coupling, expanding the
set of boundary conditions for structural studies and
greater communication with Fluent.
While thats AIM, theres also another route to carry
out this type of work, using the Ansys Customisation
Toolkit (or ACT). Introduced back in R14, this allows
users to use a variety of programming languages in
a single environment to create bespoke templates
which can be rolled out across your company.
While there are a wide and growing range of
templates already available (some at cost), this is
proving useful to many organisations looking at lock
down simulation use and capturing their own best
practices whether thats using the integration to all
of Ansys application sets or integrating it into third
party or in-house codes.
IN CONCLUSION
The simplification of the Ansys product range is
perhaps a good indicator that adoption of advanced
simulation tools like this is finally starting to take
hold.
While its undoubtedly a more complex beast than
many have experienced, particularly in comparison to
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many CAD integrated tools, theres nothing here that
an engineer with a good solid knowledge of their field
or specialism couldnt take on.
Whats interesting is how the company is looking to
make that process easier (with the adoption of tools
like AIM and the elements of process and workflow
consolidation in R18) but also more scalable at the
enterprise level.
The ability to have a simulation specialist distill best
practices into more easily usable template-driven
workflows makes huge sense and makes broader
adoption of such tools more possible.
Topology optimisation, introduced into this release,
replaces the existing Shape Optimisation product
which was much less capable and didnt allow you
to work on downstream processes. While many
are exploring the potential for these tools, some
implementations are pretty rudimentary and bare
bones (more box ticking than anything else).
Thats not what weve come to expect from Ansys
and thankfully it has delivered a set of tools that
not only gives you the finer controls but has done so
in an environment thats perfect for integrating it
into other processes and workflows. Then, when the
results are finalised, it provides you with the CAD
related tools (courtesy of SpaceClaim) to progress
that new, optimised, part into production. Its also
worth noting that the topology optimisation tools are
also included in all levels of the product, from the
basics to the enterprise level.
Ansys is doing interesting things with its flagship
product these days and focussing on a much wider
remit and broader spectrum of potential users. That
said, theres still plenty of the more obscure and
specialist updates that weve not covered here.
Next month well be taking a quick look at what
the company has worked on for the R18 release in
relation to fluid dynamics and its Fluent focussed
products.
ansys.com
SIMULATION FOR
FUNCTIONAL SAFETY:
ANSYS & MEDINI ANALYZE
F
or some time now Ansys has
been acquiring an interesting
set of technology companies
to fulfill its own vision of
a complete environment in which
to simulate a product, from the
traditional structural and fluids
related simulation world, through
electronics, composites and also into
the systems level world.
One of its most interesting recent
acquisitions is the Berlin based company,
Medini, which specialises in functional
safety in primarily the automotive world
but which is also starting to see adoption
elsewhere (in fields likes shipping,
aerospace and medical).
Its solution, Medini Analyze, is focussed
on investigating where functional
errors (in both engineering, software
and systems) could result in threats to
passenger safety and to assist in finding
ways to counteract or negate them. The
tools are currently in use at a wide range
of Auto OEMs (Daimler, Audi, Toyota, Tesla,
VW, Renault, Ford, Nissan) aswell as tier
one suppliers (TRW, Continental).
With the ground swell of interest and
investment in autonomous vehicles, it
looks like a smart purchase.
19/07/2017 17:59
DriveWorks Ad.indd 1 19/07/2017 14:22
 HARDWARE REVIEW
Lenovo ThinkPad P71
The ThinkPad P71 is the next iteration of Lenovos newly rebirthed 17 mobile
workstation. Al Dean investigates whether it can help take VR on the road
T
Intel Xeon E3 1535 he rise of interest in Virtual
CPU Reality (VR) is currently at the
4x 16GB (64GB) beginning of a hype curve thats
DDR4-2400 Memory
going to last for the foreseeable
2x 512GB NVMe
future. The combination of consumer
PCI-E SSDs
focussed hardware and software along
Nvidia Quadro
P5000 GPU (2GB) with a rebirth of interest from the
17.3 4K (3840 x
professional community means that
2160) Anti-Glare IPS were on the cusp of such immersive
Microsoft Windows environments becoming usable for the
10 Pro 64-Bit majority rather than just the cash rich
416mm (w) x enterprises.
275.5mm (d) x 31.5 In the box on the opposite page we talk
mm (h) about how the Head Mounted Displays
3 years NBD onsite (HMDs), such as the HTC Vive and Oculus
Rift, are not only affordable but easy to set
5,099 + VAT (base up and configure. The time is ripe.
price from 1,830
Simultaneously, theres also a need for
thinkworkstations.com those of us with both budget and project
pressures to ensure that we adopt the
VR strategy that suits us best. Not every
organisation has the need or, indeed, the
room for a full scale environment set-up.
So is there a viable alternative thats not
permanent but could be portable?
This is where Lenovos brand spanking
60 JULY / AUGUST 2017 DEVELOP3D.COM
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new ThinkPad P71 comes into its own.
Those that follow the portable workstation
market will know that the 17 models are
few and far between and have traditionally
been restricted to the HP and Dells of
the world as well as a few smaller, more
specialist vendors. The P71 marks the
next iteration since last years P70, which
marked the first time Lenovo has produced
a 17 model in recent memory.
The reason for this requirement is
twofold and much of it relates to the
undoubtedly heavy graphics compute
requirements to drive VR. The ThinkPad
P71 can be configured with one of two
beasts either a Nvidia Quadro P4000 or
P5000. Our test unit was fitted with the
more powerful P5000.
These graphics boards, although in a
mobile unit, have some serious power
requirements (100W) and generate
substantial thermal output, so youre going
to need a bigger machine to effectively
cool them during use which, if youre
running professional applications (and
especially VR applications), youre most
certainly going to do.
THE MACHINE
Once youve got the machine set
up and running (see our note
on colour calibration on the
opposite page), youre struck
by the size of the machine,
though having spent the last
few years working with a
15 Macbook Pro, I was
initially surprised how
heavy the machine was
it weighs in at a shade
under 3.5 kg.
That said, after a
while you forget the size of the unit,
considering the specification here.
After all, were talking about a beast of
a display for a portable machine. With a
17.3 display running at 4K, youll notice
that youve got a lot of room to work and
quickly forget that its in fact a portable
machine.
As ever, the build quality of the Lenovo
ThinkPad machines are still just as you
remember. This is a mil-spec machine
(MIL-STD-961 for the standards geeks out
there). Its built like a tank and should
stand up to the rigours of the road
warrior.
And of course, theres the usual
keyboard arrangement that ThinkPads are
known for. Youve got a full-size keyboard
(including separate numerical input),
track-pad and your nubbin point in the
middle of the keyboard.
THE TEST UNIT
We received a specced out test unit
that weve been testing for the last few
months. As our focus has been VR, we
wanted to ensure that we could see how
far we could push a portable unit and
that is always going to mean some heavy
requirements.
With a Xeon R 1535 CPU (giving us four
cores or eight threads), RAM coming in at
64Gb (split over four 16Gb units) and dual
half terabyte SSD drives, this machine
was never going to be a slouch in even the
most demanding of applications.
In terms of connectivity, theres a lot of
options here. The machine has four USB
3.0 inputs/outputs, two Intel thunderbolt
3 ports on the rear, ethernet, bluetooth
and Wi-Fi for connecting to your network
and peripherals.
In terms of display connections, youve
got two options HDMI 1.4 or a mini
DisplayPort 1.2 so using the
machine alongside a
desktop monitor or
two isnt an issue at
all. And as youll see
from our guide to VR
set-up opposite, having two
outputs for display can also pay
dividends here as well.
IN CONCLUSION
The ThinkPad range is still as you
remember them essentially built to last
and considering the amount of travel that
our readership does, often into less than
19/07/2017 18:00
 THINKPAD P71 & VR:
SET-UP TIPS FOR
OCULUS RIFT

clean environments, having a mil-spec
machine whilst signing off first-off-tooling
on a shopfloor in China is always going to
be a wholly good thing. That means its not
only tested against, but passes military
tests for humidity, vibration, temperature
and mechanical shock.
Yes, its larger than many might be used
to, but with that size comes the benefit of
graphics processing to rival most office-
bound, full stack workstations.
Once set-up with our VR rig (see our
notes on the right), we found that it
handled everything we pushed at it.
Whether it was running the new tools in
KeyShot 7 (which combined progressive
rendering with HMD display), Autodesks
VRED (which pushes a machine to its
limits once you switch on anti-aliasing
in VR) or the other tools weve been
evaluating under NDA.
When it came to using the machine
without the VR kit plugged in, again, it
worked flawlessly. The clarity offered of
a large display running at 4K is very high
especially when using 3D design systems.
It was crisp, responsive and roomy.
So the machine performs well, its
well built and runs your VR applications
perfectly. What about the cost?
This isnt a cheap machine, particularly
with this spec. The base level price for
the P71 is 1,830, but our unit came in at
over twice that at 5,099. While the drive
capacity and RAM specs are higher, what
really drives up the price is the Quadro
P5000.
While its possible to spec the machine
with the lower specced P4000, if you
want to push things, the more graphics
compute the better. For those on a
budget and not so concerned with VR, the
machine can also be delivered with the
P3000 and M620M GPUs as well.
Ultimately, it comes down to the
experience and potential benefit you
can derive from a machine like this,
particularly if youre looking to go all out
for VR.
Heres huge potential to add to your
business by being able to arrive at a
clients site to discuss a project, quickly
rig up a VR headset and sensor package
and immerse your customers in the
product theyre looking to purchase or
commission you to build.
If you want to do that in an efficient way
then the ThinkPad P71 proves that this
is possible without having to lug around
a desktop unit. Pack it up, arrive, deploy
and get the order. Thats solid gold in
terms of return on investment.
thinkworkstations.com
lenovo.com
Over the last couple of months weve been looking at a range
of VR enabled tools for this issue (KeyShot 7) as well as
forthcoming issues and have been using the ThinkPad P71
and the Oculus Rift as our workhorse test system. During
that time, weve come up with a short guide to set-up for
this particular combination that should prove interesting
for anyone thats looking for either a portable VR solution,
whether to take to client visits or presentations or, indeed,
for something that can easily be packed away.
Connections are everything: When you set-up any VR rig
you need to ensure that your various sensors and HMDs are
plugged into the appropriate connections. With the HTC Vive
much of this is done wirelessly through a base unit, whereas the
Oculus Rift (particularly when youre using the Touch Sensors)
has some additional requirements.
We found that to get the transfer rates (key to accurate and
consistent tracking) you need to find out where the separate
USB bus connections are. As you have a need for USB for the
HDM, then one each for the two sensors, youll find yourself
working around the machine, with the set-up software running,
while you find the best combination. It might be more prudent
to invest in a good, high-speed USB 3 hub, but word is that the
Oculus set-up software is a little picky in this regard.
Collaboration with displays: One of the benefits of the new
breed of HMDs is that its entirely possible to have one person
using them, then others in the session looking at the screen to
see what theyre talking about. While the 17.3 display running
at 4K is good for a team of two, if you want to project it for a
large group, youll think youre immediately out of luck.
The good news is that you can use a standard, off the shelf
projector (we set-up with a BenQ W2000) and a converter for
the mini Displayport socket on the side of the machine.

DIALLING IN COLOUR: P71S INTEGRATED DISPLAY CALIBRATION

U
nless youve done a lot of work in
the high-end imagery field, you
might not be immediately aware
that your computers display
probably isnt, by default, showing
you a true representation of your colours.
While statistics are few and far between, there are
many phenomena that affect the accuracy of your
display whether thats manufacturing variance,
your software control or the age and temperature
of your hardware.
At DEVELOP3D, weve always advocated using
colour calibration tools when youre working
on high accuracy requirement imagery and
animations. Many tools, particularly in the
visualisation world, support the importing
calibration profiles (known as ICC files), so they
match perfectly with the requirements and
measurements of your displays. top will flash and eventually itll beep when done.
The thing is that it typically requires an Open it and youre done.
additional device to routinely measure and Of course, if you want to get serious about this,
calibrate your displays. There are a range of then youll need the ICC profiles. These arent
these available, but the best known are either immediately available from the
from X-rite or Datacolor. But additional cost is application. We
additional cost, right? managed to
So it was with some interest that we discovered track them
that the ThinkPad P71 includes colour and display down and
calibration. In fact, when you first boot up the they can be
machine it guides you through the process to found in the
nail your fancy 17 display from the word go. This Windows/
requires that you close the lid the sensor for the Spool/Drivers
calibration is built into device, just to the right of folder and then
the keyboard. This will run through a calibration loaded into
process using an application called Pantone Color your favourite
(developed by X-Rite). rendering and
As the process works, the red LED in the I on visualisation tool.

DEVELOP3D.COM JULY / AUGUST 2017 61

p60_61_D3D_JULYAUG17_LenovoP71.indd 61 19/07/2017 18:00

 SOFTWARE REVIEW
Autodesk FeatureCAM 2018
Following on from last months look at Autodesks updates to the advanced machining
capability in PowerMill, Al Dean turns his attention to FeatureCAM, which brings a
more production machining and turning oriented approach to the portfolio
A
longside the Delcam/
Autodesk products that have
addressed the, often unique,
demands of the mould and
die industry, theres also another
product, FeatureCAM, that automates
the CNC programming workflow.
Unlike PowerMill, which focusses
on the machining of complex forms
and surfaces, FeatureCAM instead
concentrates on the machining of
more prismatic, perhaps less complex,
components, where both time-to-
program and machining cycle times are
most important.
FeatureCAMs key focus is the extraction
of features from your CAD geometry with
associated operations, enabling you to
define best practice and allow for reuse as
often and as quickly as possible. Whether
that geometry is drawn using the tools
within the system or using data imported
from another system, the workflow is
similar.
While FeatureCAMs origins were as a
2.5 and 3-axis milling focussed system, it
quickly expanded to include turning, then
combined the two in the turn-mill centres
and, more recently, Swiss-type lathes.
These machines have gained increasing
adoption in the last few years and the
62 JULY / AUGUST 2017 DEVELOP3D.COM
p62_63_D3D_JULYAUG17_Autodesk_FeatureCAM_2018.indd 62
Product: more recent releases have also seen
FeatureCAM 2018 improvements of more complex, but
Supplier: Autodesk increasingly commonplace, machining from
Price: See text 3+2 to 5-axis simultaneous.
autodesk.com
So lets take a look at what the 2018
release brings and put it into the context of
the systems history and use model.
CONSISTENT USER EXPERIENCE
As we covered last month, Autodesk has
been through a program of refreshing
and reinventing the user experiences
for all of its products. As youd expect,
FeatureCAM has had the same treatment,
bringing its UI up to date with current
windows standards (in terms of workflow-
based ribbons) as well as making it more
consistent with other systems in the
Autodesk Manufacturing range.
In the case of FeatureCAM, which
already has a very process oriented
workflow, it makes perfect sense. Youll
1 FeatureCAM
2018 brings greater find just three ribbons available. The
capabilities for more first, Home, gives you all of your general
complex machine use tools for file control, display settings,
on prismatic parts set-up creation, basic geometry creation
such as 3+3 axis
and manipulation and job inspection.
machining
Then you dive into where the meat of the
2 FeatureCAM 2018
system lies.
adds greater control
over synchronised The Construct ribbon gives you a range
turn mill machines of geometry creation and editing tools,
from first principles sketching tools,
through creation of surfaces and solids.
When you consider that a lot of users
base their machining operations on 3D
geometry from clients or the design
department, this might seem strange, but
the reality is that many folks still work to
drawings (paper, PDF or, indeed, digital).
FeatureCAM allows you to work with what
youve got. If its a back of a fag packet
sketch, you can quickly sketch out the
geometry you want either staying with
2D entities or modelling it up into 3D. If
you receive a drawing, you can import
the lines, circles and arcs and work with
those. If you work off 3D geometry, then
you use that as your starting point.
Its worth a few notes on how the
system works with imported geometry.
As you might assume from the name,
FeatureCAM is focussed on finding
machinable features in your parts quickly.
Importing a set of CAD geometry will
kick off a wizard that steps you through
not only the set-up of your stock (which
can be by boundary, billet size or a more
complex stock model), but defines your
datum and then offers to run you through
Automatic Feature Recognition (AFR).
This will analyse your part and find any
machinable features. It then uses this
19/07/2017 18:00

to generate a starting list of operations, using your
defined set of standard tooling. Once youve got that
list of operations, you then work through the order
(which can be manual or automatic) and use feed-
rate optimisation to reduce the machining time to the
minimum to get your cycle time down.
When it comes to more complex forms of
machining, obviously the system requires more input
and youll need to work with the tools available to
define each operation individually.
The 2018 release brings the ability to automate
the selection of your axis when machining in 3+2
using your defined machine limits (in terms of axial
limitations). Itll choose either the standard or
alternative position to ensure your program is within
the travel limits of your machine tools capabilities.
The point is that FeatureCAM allows you to get 60
per cent of the way there by handling the simpler
use cases, giving you more time to focus on the more
complex cases.
When it comes to turning and mill turn, the nature
of the beast means that more complex programming
operations are needed but, again, the mix of
automation enhanced with the ability to dive in and
manually create more complex operations applies.
Once you have your operations defined, theres
also a wealth of simulation tools available to not
only show you the progress of your work-peice, but
also to conduct full machine simulation (which is key
for more complex machining operations). The visual
simulation tools have seen some work for this release
and are both more interactive and rearranged on
screen, providing a more heads-up approach to
interaction.
FUNCTIONAL UPDATES FOR 2018
While the UI changes are the big news for this
release, that doesnt mean that functionality hasnt
been added too. There are a couple of big ticket items
here that are worth a little discussion.
The first is the ability to create spiral face toolpaths
that use an inner boundary curve to constrain
your tool path to the region you want to machine.
p62_63_D3D_JULYAUG17_Autodesk_FeatureCAM_2018.indd 63
Previously these would have been applied across the
whole part, but can now be restricted to where you
need them.
Another update relates to mill turn operations and
superposition. This is where you have the machine
cutting a feature on both the main and sub-spindles
to create opposing features (think: end drilling)
simultaneously. You create the two operations, select
and superimpose them, which will force the system
to execute them at the same time on two separate
work-peices.
IN CONCLUSION
FeatureCAM is about getting a job done quickly.
That starts with preparing your part for machining.
Whether thats creating the part from a paper
drawing or the programming of operations based on
a 3D model. It has been developed to get your part
ready for the machine and so out the door in the
quickest time possible. Of course, this also depends
on cycle time and, again, this is a key focus for
FeatureCAM.
The system is geared up to strip as much time out
of a cycle as possible, whether thats a 2.5 axis basic
job or a more complex mill/turn job. When youre
dealing with larger batch numbers, cycle time is
everything. If you can take even seconds out of each
operation, over the course of 10,000 parts, youll
save minutes, if not hours. That time saving means
you can not only deliver on time, but also on cost,
without impacting the quality of the parts.
This release of FeatureCAM might not have a huge
amount of updates to its functionality, but the work
done for 2018 ensures that the system is clean, fresh
and more logically laid out than ever before.
As with all things Autodesk these days, the system
is also now sold on a subscription basis. While, for
existing customers this doesnt change anything,
for those new customers, the starting point is
FeatureCAM Standard which brings you 2.5-axis
milling and drilling, turning as well as 2 and 4-axis
wire EDM.
autodesk.com/manufacturing
2
WHAT ABOUT
PARTMAKER?
Alongside FeatureCAM, theres
also PartMaker. This was acquired
by Delcam some years ago and
addresses the often unique needs of
those programming for Swiss Lathe
type machines.
While the adoption of multi-tasking
lathes has been growing of late, the
Swiss Lathe takes the combining of
both mill and turn parts concurrently
to the extreme. Here, cycle time
is fundamental, particularly on
high-precision components such
as speciality fasteners and small
mechanical components (its name is
derived from early use in the watch
making industry).
PartMaker is still an active product
and receiving active development. In
fact, this release sees additions such
as support for laser machining, keyway
broaching (and, if youve not seen a
Swiss Lathe working with a laser, ten
minutes spent on Youtube is a good
investment of your time).
That said, due to increasing overlap
in capabilities, PartMaker has been
bundled with the high-end FeatureCAM
offering (FeatureCAM Ultimate).
It might also be worth assuming
that eventually all of the unique tools
in PartMaker will transition into
FeatureCAM.
DEVELOP3D.COM JULY / AUGUST 2017 63
19/07/2017 18:00
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 THE LAST WORD

A new trend is percolating through the

additive manufacturing world. Al Dean
considers how vendors are starting to
look into swapping large, costly
machines for cheaper ones and asks
if the dawn of the AM farm is upon us

T
ake a trip around any
large-scale 3D printing
service provider and youll
see banks of high-end 3D
print hardware. These are
organisations that thrive on volume
and throughput. Youll also typically
find that these are longer standing
organisations founded when 3D
printing was a secret known only to the
educated and experienced few.
Just this month Formlabs launched
FormCell, a series of its Form 2 SLA
machines combined with a fully automated
robotic arrangement to move completed
builds through its Wash and Cure stations.
Markforged, which is now in both
plastics and fibre as well as metals, has
also published its thoughts on the move to
lower-cost machines in multiples.
Its CEO Greg Mark commented in a
recent blog post (markforged.com/adam)
that, Todays metal 3D printers are the
mainframe computers of manufacturing.
They are large, slow and expensive ($500k the combination of low cost, internet produced can fit inside the volume of a Formlabs FormCell
1M). In the same way mainframes were connected sensors and some hard-core desktop machine? A good proportion Id five Form2 machines,
a Wash and Cure
disrupted by cloud data centres, large- data analytics. Just as with traditional bet.
station and a robotic
format metal printers will be replaced by manufacturing, theres a drive to provide a What might start to shift is that this gantry to automate
smaller, low cost machines working-in- more dynamic, live environment for factory large volume manufacturing can become the whole process
parallel-print-farms. automation and analytics. more accessible for a wider spectrum
Whether referred to as the Chinese of potential users. Consider the cost
SOFTWARE INFRASTRUCTURE IS KEY Factory 2025, the more European implications of running a third of a
Whats interesting, particularly with Industry 4.0 or Industry IoT, having a live million quids worth of sintering machine
the Formlabs and the Markforged production system is one thing, but when compared to having ten smaller scale
announcements, is the importance of the youve got rapid turnaround machines, machines at three grand a pop.
software aspects. If these machines are often building parts that could each be If one machine breaks, you can swap it
to be used in this manner, the success different, customised and adapted to each out probably for less than itll cost you
(or indeed failure) of the systems comes customer, itll be even more key. to get your honking big machine repaired,
down to the software, which ensures Heres where theres potential for a and the downtime will be shorter. Youll
these machines are running constantly. startup to come in and disrupt the work have scope to produce in different
Should errors occur, then they need to be already done by the longer term players in materials concurrently, or different
identified and resolved quickly. the field (whether thats PTC, Siemens or geometries on different machines.
Markforgeds Mark comments, We someone else). There will also be potential to rapidly
have spent the last four years building New kid on the block Tulip (tulip.co) scale up your capability quickly and
out a comprehensive cloud-based fleet is looking to do just this by providing efficiently. Prior knowledge is immediately
management solution called Eiger. There a specific set of tools for industrial applicable order the new machine, plug
are thousands of Markforged printers automation. In fact, Tulip has linked up it in and away you go.
churning out parts all over the world with Formlabs for the FormCell and I dont Theres a lot of potential to the idea so
all running with full telemetry, error imagine itll be the last. lets see where things head, eh?
monitoring, feedback, and analytics.
Meanwhile Formlabs has built print job WHAT OF THE BIG COSTLY MACHINES?
scheduling and error detection, remote The reality is that the large-scale AM GET IN TOUCH: Email Al on al@x3dmedia.com or say hello on
monitoring, and part and serial number machines arent going to disappear. After the twitter @alistardean He welcomes our robotic overlords. If
printing into its own environment. all, large parts will need a large volume someone could come up with an automated lawn strimmer, that
At the core of these solutions is machine but what percentage of parts would be ace. His two stroke beast is driving him batshit insane.

66 JULY / AUGUST 2017 DEVELOP3D.COM

p66_D3D_JULYAUG17_LastWord.indd 66 19/07/2017 18:00

 Fujitsu recommends Windows 10 Pro.

The
Evolution
of Going
Small
FUJITSU Workstations
CELSIUS W570 & J550/2

Previous generation CELSIUS W570 CELSIUS J550/2

W Series Desktop Workstation Small Form Factor Workstation
28 liter 21 liter up to NVIDIA Quadro P4000 10 liter up to NVIDIA Quadro P2000

Fujitsu Workstations Made for Innovators and Creators

The rst-ever desktop workstation in 1995 was a pioneer of its era, and Fujitsu has never stopped innovating and enhancing the products since.
FUJITSU CELSIUS workstations, featuring NVIDIA Quadro graphics, provide the ultimate in performance and reliability to increase application
efciency for CAD users, architects and engineers. All products are whisper quiet thanks to their excellent thermal management and are
optimized for use with a host of leading workstation applications, like Autodesk, Dassault Systmes, Siemens PLM or PTC.

More information around Virtual Reality:

www.fujitsu.com/global/products/computing/pc/vr/

Copyright 2017 Fujitsu Technology Solutions GmbH

Fujitsu, the Fujitsu logo and Fujitsu brand names are trademarks or registered trademarks of Fujitsu Limited in Japan and other
countries. Other company, product and service names may be trademarks or registered trademarks of their respective owners,
the use of which by third parties for their own purposes may infringe the rights of such owners. Technical data are subject to
modication and delivery subject to availability. Any liability that the data and illustrations are complete, actual or correct is
excluded. Designations may be trademarks and/or copyrights of the respective manufacturer, the use of which by third parties
for their own purposes may infringe the rights of such owner. All rights reserved.

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