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Roland monoFab P46 Siemens

Intel CoreNX
i7 7.0 P40 P55
vs Xeon Workstations P55

TECHNOLOGY FOR THE PRODUCT LIFECYCLE MARCH 2015 | £6 | € 7 | $10 | DEVELOP3D.COM

DEVEL
LIVE
M
OP3D

EVENarch 26
TP
pageREVIEW
32

FLOATING
ON AIR
Rotron engineers a lightweight drone
engine with phenomenal power

Test & simulation Spoon science Bluebird K7 project Trampolines


We chose the Stratasys uPrint machine
for functional prototype testing. This FDM technique
allows us to print plastic parts & attach motors.

Watch the video or call


to see how a professional 3D printer allows truly to discuss your application
functional prototypes to take flight at Aerialtronics: with our experts:

tiny.cc/drone-d3d +44 (0)1908 904367


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

W
DESIGN/PRODUCTION
Art Director
Rob Biddulph e have just over a month to go until DEVELOP3D
LIVE 2015 kicks off at Warwick Arts Centre. So, as
Design/Production you can imagine, it’s all hands on deck and to the
Greg Corke
greg@x3dmedia.com pumps (or something) as we head into that final
+44 (0)20 3355 7312 four weeks when things go right, things go wrong,
things get fixed and eventually, we’re joined by
ADVERTISING over 1,000 designers, engineers, educators, artists
and yup, a few software executives. Once the event
Advertising Director is underway, it all seems a bit of a blur, but in the
Tony Baksh run up we’re trying to ensure that you have a valuable day out in Warwick, meet
tony@x3dmedia.com
some new contacts, see some interesting technology and, of course, hear stories
+44 (0)20 3355 7313
from some amazing speakers.
Deputy Advertising Manager This year, we’ve got a curious mix of speakers — from rocket engines to the
Steve King wonderful world of artist and inventor Dominic Wilcox. I’ve seen Dominic present
steve@x3dmedia.com
on a number of occasions and I can promise it’ll be both entertaining and, more
+44 (0)20 3355 7314
importantly, inspirational.
US Sales Director We’ve also got a cracking exhibition running again this year. We’re excited
Denise Greaves to welcome back some DEVELOP3D LIVE regulars who will show what they’ve
denise@x3dmedia.com been working on in the past year, but we’ve also got a number of new companies
+1 857 400 7713 exhibiting for the first time with one in particular pushing itself to the limit to get
its first machine ready for the show.
SUBSCRIPTIONS Turn to page 32 for an extensive preview of what you’ll find on the day. We look
Circulation Manager
forward to seeing you there, for what promises to be our biggest and most exciting
Alan Cleveland event yet.
alan@x3dmedia.com You can get your free ticket at develop3dlive.com and stay tuned for more details
+44 (0)20 3355 7311 over the coming weeks!

ACCOUNTS
Accounts Manager
Charlotte Taibi
charlotte@x3dmedia.com
Financial Controller
Samantha Todescato-Rutland
sam@chalfen.com

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

Rooms 108 - 109, 4th Floor, 65 London Wall,


London, EC2M 5TU
T. +44 (0)20 3355 7310
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DEVELOP3D.COM MARCH 2015 3


26 March 2015
WarWick arts centre,
University of WarWick
RegistRation closes soon
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Learning-Zone-Advert-2014-A4.indd 1 10/06/2014 11:03


CONTENTS

MARCH 2015 ISSUE No. 66

8 NEWS
SolidWorks unveils Industrial design tool, Teradici offers
free trial of remote CAD software, Ansys sets the bar high
with Ansys 16.0 and Autodesk to scrap perpetual licences

Comment
16 Jeremy Pullin on setting up a 3D printing facility aimed at
engineering education for non-engineers

18 YOUR DEVELOP3D
Tell us what you think. This month: CEO deathmatch at
DEVELOP3D LIVE and SolidWorks World bingo

FEATURES
20 Visual design guide: Vuly Thunder Trampoline
22 Product design showcase: Spoons
26 COVER STORY UAV rotary engines from Rotron
32 DEVELOP3D LIVE 2015 preview
40 Simulation Workshop: #7 FEA + Testing
42 3D printed carbon fibre parts at Champion Motorsport
44 HyperMILL 5-axis machining helps the Bluebird sail again

REVIEWS
46 Roland MonoFab
55 Novatech E5-1620V3 workstation
57 Scan 3XS GW-HT20 workstation
58 Lenovo ThinkStation P900 workstation

60 DEVELOP3D SERVICES

61 DEVELOP3D JOBS

66 THE LAST WORD


This month Al Dean discovers while working in his workshop
that the pursuit of perfection isn’t the be all and end all

The wood used to produce this magazine


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

DEVELOP3D.COM MARCH 2015 7


NEWS
NEWS PRODUCT DEVELOPMENT NEWS

SOLIDWORKS INDUSTRIAL DESIGN CONCEPT


(SW-ID) LAUNCHED AT SOLIDWORKS WORLD
» Next generation SolidWorks tool is based on the 3DExperience platform of
parent company Dassault Systèmes (DS), rather than the standard SolidWorks

I
n front of 5,500 attendees at its
SolidWorks World user event in
Phoenix, new CEO Gian Paolo Bassi
heralded the arrival of SolidWorks
Industrial Design (SW-ID).
Representing the next generation
SolidWorks tool, SW-ID is based on the
3DExperience platform of parent company
Dassault Systèmes (DS), rather than the
standard SolidWorks.
Previewed at SolidWorks World 2014 as
Industrial Conceptual, SW-ID is billed as an
ideation enabler, aiming to equip mechanical
engineers with ‘product design’ tools, as well
as enabling cloud-based workflows.
SW-ID is able to produce organic shapes
and concepts by developing sketches,
freeform Sub-D 3D modelling, feature-
based and direct 3D modelling.
The big news is the cloud-based teamwork
abilities, which allow users to collaborate
through a web browser-based interface. with a focus on A-Surface development, The product will cost $190 per month Cloud-based teamwork
abilities allow users to
Designers can chat with other users, exterior surfaces still need to be turned (£145 suggested UK price) with a 12-month collaborate through a web
share models and annotate in real-time, into engineered components so models commitment when it launches in April. browser-based interface
using the cloud for model sharing and will need to be exported to traditional For standard SolidWorks, also announced
modifications (using save and refresh). SolidWorks for further development. was SolidWorks Model Based Definition (MBD)
With control locking, individual users can How design changes can be for streamlining the generation and use of
be assigned responsibility for updating the accommodated is, as yet, unclear. engineering documents using a 3D annotation
model. “The needs of the CAD user community (or Product Manufacturing Approach/PMI)
Also new are the pen-based sketch have been a beacon of technological approach that is typically found in higher-
controls. Product demos at SolidWorks World innovation and we are committed end, enterprise level systems.
showed SW-ID working with a Wacom Cintiq to developing tools that respond to MBD allows users to generate one
multi-touch, reproducing a pen and paper evolutions in the product design process, master document for all product and
environment for fast concept sketching. from a technical perspective as well as a manufacturing information, downstream
Sketch options come complete with collaborative one,” said Gian Paolo Bassi, processes, and compliance with regulations
Photoshop-style shortcuts - hitting the shift CEO, SolidWorks. and standards without having to produce
key to instantly straighten hand drawn lines, “With SolidWorks Industrial Design and maintain separate sets of 2D
and ‘alt’ to curve them. and our 3DExperience platform, we want engineering drawings.
Sketches look similar to Catia Natural engineers to be able to rely on powerful, Engineers can define, organise and
Sketch and Catia’s Imagine & Shape modules, accessible technologies that facilitate their publish product and manufacturing
working on 3D planes (front, top, side) that work and result in significant business information directly in 3D (and
can continue to be developed as 3D models advantages.” associatively to the 3D model) with a view
within the SW-ID 3D modelling tools. SW-ID is the second SolidWorks application to improving communication between
This model can be built out using the to be delivered on DS’ 3DExperience design and manufacturing teams and
3D modelling tools, including SolidWorks’ platform, after SolidWorks Mechanical reducing the risk of errors.
own proprietary Sub-D system. However, Conceptual was launched two years ago. solidworks.com

ANALYSIS - FIRST IMPRESSIONS OF SW-ID of Autodesk Fusion and


the soon to be unveiled
on different foundation
technologies).
SW-ID is the realisation automotive firms and understanding that tools Onshape shows that In terms of modelling
that the worlds of designer enterprises, for traditional for this new era of design momentum is growing. functionality, there appear
and engineer are fast SolidWorks customers it is are needed fast. Price has also raised to be many similarities
combining, but it’s a uncommon for it to exist in What has really grabbed some eyebrows, for what with Autodesk Fusion
shame that DS is still any rigid form. the headlines is the move is essentially an ‘add-on and Rhino. However, SW-
insisting that the two Every sound bite at SWW to the cloud using DS’ product’ that has limited ID is an expensive buy,
disciplines are distinct and was about the age of the 3DExperience platform. interoperability with especially when hitched to
separate. entrepreneur and enabling While cloud-based product the familiar desktop the standard SolidWorks
While a bifurcation fast, fluid, collaborative development tools are still SolidWorks (due to the product.
of roles may be true in design. Perhaps now DS is in their infancy, the launch two products being based Stephen Holmes & Al Dean

8 MARCH 2015 DEVELOP3D.COM


Muncaster ad.indd 1 18/02/2015 08:45
NEWS

TERADICI OFFERS FREE TRIAL Pro 3D graphics


OF REMOTE CAD SOFTWARE for rugged laptop

P
anasonic’s new Toughbook
54 is being pitched as the
thinnest and lightest semi-
rugged laptop in its class. It
is also the first rugged laptop
to feature CAD-focused 3D graphics —
thanks to an AMD FirePro M5100 GPU.
With a full magnesium alloy case with
handle and resistance to spills and drops,

T
the mobile workstation is designed for a
eradici is offering a free Teradici says set up takes under 5 mins — With Teradici's semi-harsh indoor or outdoor environment.
30-day free trial of its PCoIP users install the remoting software on the Workstation Access It features a 5th Generation Intel Core i5
Software you can
Workstation Access Software host workstation (Windows 7 or Windows vPro processor and 11 hours of battery life
run CAD software
that can be installed on any 8.1) and the client software on the local PC such as PTC Creo (18 hours with an optional hot-swappable
Windows workstation with (Windows XP / 7 / 8.1 or Mac OSX). A PCoIP from anywhere second battery).
Quadro K2000 graphics and higher. zero client can also be used. Panasonic is currently working with key
The software allows users to connect The free 30-day trial is available in North software developers for CAD certifications.
remotely to their 3D CAD applications over America, UK, Northern Europe, New Zealand panasonic.com
LAN or the Internet — providing there is a and Australia. The software costs around
low latency, high bandwidth connection. US $240.
Unlike the company’s PCIe host cards, Meanwhile, BOXX has become the second
which provide dedicated hardware for
compressing, encrypting and sending
workstation manufacturer to sell Teradici’s
PCoIP Workstation Access Software. Delcam updates
IP packets over a network, the new
Workstation Access Software does
The Austin-based firm joins Dell who has
been promoting the remote workstation inspection tool

D
everything in software. It is designed technology alongside its Precision Tower
specifically to work with 3D applications. workstations since late 2014. elcam has released the 2015
Teradici says it delivers outstanding image Teradici refers to this latest BOXX deal as version of its PowerInspect
quality and high performance 3D. Dynamic the next phase of its global rollout of PCoIP inspection system, the
quality adjustment and monitoring helps to Workstation Access Software. We expect to hardware-independent
maximise frame rate. see more manufacturers come on board in metrology software.
The software is targeted at small and the coming months. Delcam lists new features as automatic
mid-sized businesses in architecture, Meanwhile, to find out more about the collision avoidance, faster import of large
construction, engineering and technology, read our in-depth report CAD files, quicker preparation of longer
manufacturing with limited IT resources, tinyurl.com/tera-D3D inspection reports, and improved display of
and departmental deployments in Access the free trial at results from point-cloud data.
enterprises of any size. connect.teradici.com/30-day-trial delcam.com

DEVELOP3D.COM THE BEST FROM THE WEBSITE

Read Stephen Holmes' Dr Robert Langer wins Mastercam is looking Pixologic has launched the Version 4 of the Autodesk
SolidWorks World live blog the 2015 Queen Elizabeth to improve shop floor latest version of its ZBrush T-Splines plug-in for Rhino
for equal helpings of new Prize for Engineering, for productivity with CAM modeller, release 4R7, with includes integration for
technology, future visions controlled release large speed and automation in new modelling options and graphical algorithm editor
and dry humour molecule drug delivery its latest release — X8 Mill KeyShot 5 integration Grasshopper
tinyurl.com/D3D-SWW15 tinyurl.com/QEprizeBOB tinyurl.com/newX8Mill tinyurl.com/4r7-keyshot tinyurl.com/RhinoGrasshop

10 MARCH 2015 DEVELOP3D.COM


NEW

THE WORLD’S FIRST MOUSE


FOR CAD PROFESSIONALS

Right Mouse Button

Middle Mouse Button

Left Mouse Button

CadMouse
PRECISION ENGINEERING YOU CAN FEEL
The 3Dconnexion CadMouse is designed specifically for working in CAD. Say goodbye to repetitive mouse wheel clicking
and say hello to precision and comfort thanks to the advanced laser sensor and dedicated middle mouse button.
Stay in control with the Smart Scroll wheel and marvel at how you ever worked without QuickZoom that effortlessly
zooms to your point of interest with a single click.


3dconnexion.com facebook.com/3dconnexion
twitter.com/3dconnexion
 youtube.com/3dconnexion

3Dx_Ad_CadMouse_A4_EN_v1.indd 1 18.02.15 17:34


MSI Ad.indd 1 18/02/2015 08:46
NEWS

ROUND
DEVELOP3D LIVE UP
set to be biggest 3D Systems has been

event yet awarded two research


contracts worth over $1

T
million dollars to develop
he expanded exhibition at advanced aerospace
DEVELOP3D LIVE 2015 has sold and defense 3D printing
out weeks in advance of the manufacturing capabilities.
event with over 60 companies The contracts include the
set to showcase the very provision of flight-worthy
latest in CAD, 3D printing, simulation, with carbon fibre from Markforged — plus The DEVELOP3D composites and metal-
workstation, design visualisation and established technologies from Stratasys and LIVE conference and printed parts 
exhibition will take
manufacturing technology. 3D Systems and a range of bureau services. place at Warwick 3dsystems.com
The exhibition will feature all the major CAD There will also be a massive array of University on
software developers, many of which will be workstation technologies including the latest 26 March 2015
demonstrating how new cloud capabilities AMD FirePro GPUs, which can handle heavy 3D printing company
will, both now and in the future, improve duty 3D graphics and compute tasks on a Solidscape and specialist
on current tools. Onshape, founded by the single card, plus a whole number of new wireless product designer,
original SolidWorks team, will be giving first workstations based on Intel’s Xeon E5-2600 LSR, are combining high
public demonstrations of its new cloud- v3 series CPUs, including new machines from precision wax 3D printing
based modeller and offering a free install to HP, Lenovo, Fujitsu, Dell and Scan. with LSR’s mould making
delegates who bring a laptop. DEVELOP3D LIVE 2015 will be held at process. In the process, wax
There will also be an abundance of 3D Warwick University on March 26. Registration patterns are taken directly
printing technology including presentations is open now at develop3dlive.com to silicone tooling or to
from HP, low-cost sintering tech from cast metal parts without
Blueprinter, stereolithography from See p32 for the event preview, which includes traditional hand finishing
Formlabs, and 3D printed parts reinforced details of the exciting conference lineup. solid-scape.com

Stratasys has expanded

Ansys extends focus to Internet of Things its 3D printing material


options, with its FDM ASA

F
material now available in
rom simulating software and process and ensure users are following eight new colours. ASA, an
hardware interactions for the simulation best practices. all-purpose FDM material
Internet of Things, to better Ansys 16.0 can now simulate a wider that has a matte finish and
understanding the full spectrum range of materials including sheet metal, is UV resistant, now comes
of advanced structural composites and elastomers like rubber, in red, orange, dark grey,
materials, Ansys is setting the bar high often used in seals and vibration dampers. yellow, green, dark blue,
with Ansys 16.0, the latest release of its Complex fluid dynamics has also been white and light grey
Ansys 16 offers
flagship simulation platform. simplified with Ansys stating that simulation stratasys.com
the ability to
Ansys believes that the increased levels time for complex models in Ansys 16.0 has prepare designs
of connectivity needed for IoT require a been reduced by up to 40 per cent. for the Internet
higher standard for hardware and software Ansys 16.0 also provides enhanced of Things through Dell's new slimline 15.6-
reliability. In relation to this Ansys 16.0 capabilities for developers of systems and serious simulation inch mobile workstation,
work — including
features capabilities to verify electronics embedded software. Extended modelling the Dell Precision M3800,
electromagnetic
reliability and performance throughout the capabilities are said to enable hardware and disturbances like includes an optional 4K
design process and complex electronics software engineers to define the intricacies in this humble Ultra HD touch display, a
industry supply chains. The biggest of a system and its subsystems operations. domestic kitchen Thunderbolt 2 port and
introduction is the Ansys Electronics Also new is Ansys AIM, an immersive additional storage options.
Desktop, a single-window, integrated simulation environment designed to The touch display (3,840 x
interface that brings electromagnetic, lower the barrier to entry for multiphysics 2,160) is made with Corning
circuit and systems analysis into a single simulations. Gorilla Glass NBT and has
working environment to help simplify the ansys.com ten-finger multi-touch
dell.com

Granta targets additive manufacturing UberCloud has launched


new application containers

G
for CAD simulation
ranta Design's latest stores process parameters, extracts tools such as ANSYS
software tool, MI:Additive logged data for specific builds, links this Mechanical and LS-DYNA
Manufacturing, is designed information to supplier data on the batches and LS-PrePost, for CD-
to improve repeatability in of material used to make a part, and adapco STAR-CCM+. The
the additive manufacturing captures testing and inspection results. ‘containers’ are portable
industry by overcoming data challenges, This data can feed into statistical analyses between in-house and
such as logging materials and process that determine mechanical properties, cloud environments for on-
information. which can be exported to simulation codes demand access
The MI:Additive Manufacturing workflow and the results can be captured for use in theubercloud.com
begins by importing ‘logfiles’ directly from optimising part design and production.
3D printers. The system automatically grantadesign.com

DEVELOP3D.COM MARCH 2015 13


NEWS

AUTODESK TO SCRAP SINGLE New mouse for


PRODUCT PERPETUAL LICENCE pro CAD users
» Autodesk is embracing the cloud and fundamentally
changing the way companies buy and use its CAD tools

F
rom 2016 it will no longer

3
be possible to buy perpetual
licences of Autodesk’s Dconnexion has launched a
individual products as the classic style 2D mouse designed
company starts to move specifically for CAD users.
customers to a pure subscription The three-button CadMouse
service. It will, however, still be possible features a dedicated middle
to acquire perpetual licences of Suites button (for model pan / rotation or
for some time after. short cuts), a gesture button (to access
The bold decision to remove the option of favourite commands via an application
buying and owning individual products is or environment-specific radial menu) a
great news for Autodesk as it can cut down QuickZoom single click thumb button (for
on piracy, maintain the price and margins ‘effortlessly’ zooming in and out of your
around the world and claw back revenue geometry) and a Smart Scroll wheel, which is
given to its sales infrastructure of dealers notice to this transition and will offer said to deliver precise click-to-click zooming
and distributors. flexible terms to those who have individual in CAD applications or speedy scrolling with
However, customers that have stuck to perpetual licences, such as multi-year inertia effects in browsers and documents.
three year upgrade cycles may not be so subscription deals and no charge for 3dconnexion.co.uk
receptive. While Autodesk will hope to bring maintenance. The company will also offer
as many of these on board with desktop additional programs.
subscription pricing versus perpetual Having said that, Autodesk’s cloud
ownership with maintenance, those that are
used to upgrading at their own pace may
offerings and subscription roll out appear
to still be embryonic in many places and the Learn about CAD
not be so happy with this enforced change
and choose to seek out alternatives.
company has yet to find the right amount
of features when compared with the virtualisation

T
The company has already announced subscription fee to please the masses. In
subscription and term licensing and has the creative software industry, the speed of he writer of a thesis exploring
moved elements of product fulfilment to Autodesk's subscription transition is second cloud, remote graphics and
web delivery and added services to its only to Adobe's. virtualisation is calling for
offering within the subscription package. The changes to the dealer and professional CAD/CAM users to
Andrew Anagnost, Sr. VP, industry distribution channel will be interesting, participate in a short survey.
strategy and marketing at Autodesk, the as over time many of these have been The resulting data will help gain better
man behind the company’s evolving model, weaning themselves off boxed product insight into the adoption of these new
told DEVELOP3D that desktop subscription revenue and turned more to training and technologies. All participants will get a free
with cloud services provided a better offering services. copy of the report.
customer experience versus shipping just a Meanwhile, as of 13 March 2015, The thesis will focus on the latest
boxed product. Subscription Center, the online site where developments from Nvidia, Citrix and
It is easier to deploy software, simplifies Maintenance Subscription customers have VMware in the area of 3D capable high-end
upgrades and offers more flexible historically accessed their Subscription virtual desktops, as well as SaaS (Software
access to tools and new workflows. The benefits, will be retired. All customers as a Service) based CAD/CAM solutions,
company is also offering a range of new will be directed to Autodesk Account, a that will make high-end 3D applications
on-line ‘cloud’ services for collaboration, personalised portal where customers can available for designers at any location on
rendering and analysis. track and manage all of their Autodesk any device.
Autodesk is giving the market a year’s products and services in one place. surveymonkey.com/s/designerworkplace

THE BEST FROM DEVELOP3D.COM

Ansys has acquired NTI, The Leatherman Tread Ricoh Europe is now a Unilever is using a LightWave 3D has launched
an in-flight icing simulation multitool bracelet features reseller of the Leapfrog Stratasys Objet500 Connex its 2015 edition of its end-
software developer who 25 links that offer a range Creatr HS 3D printer and 3D printer to produce to-end production pipeline
supports a safety-critical of tools — small bottle will focus on customers in injection mould tools for with new updates for
aspect of aircraft design openers, screwdrivers etc. the education sector first consumer testing designs product design renders
tinyurl.com/D3D-icey tinyurl.com/D3D-Leatherman tinyurl.com/Leapfrog-Ricoh tinyurl.com/Unilever3D tinyurl.com/LightWave15

14 MARCH 2015 DEVELOP3D.COM


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Lenovo logo, For Those Who Do and ThinkStation. Microsoft  and Windows are registered trademarks of Microsoft Corporation. Other company, product
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COMMENT

A 3D printer can be a powerful


machine to have in an educational
workshop as long as that workshop
also contains other, non-additive,
means of manufacturing /
fabrication, writes Jeremy Pullin

R

ecently I have been
involved in discussions
The importance of being able to these costs may not be prohibitive, they do
not compare well to standard raw materials
about setting up actually make things should never such as pieces of wood or sheets of plastic.
a facility aimed at The next issue is time. 3D printers may well
engineering education
be underestimated. This is especially be the fastest solution for things that would
for non-engineers. The true when you are learning otherwise take several stages to produce
idea in brief is to set but when it takes 30 minutes to 3D print a
up a classroom next to  washer (assuming you already have a CAD file
a workshop containing a bunch of kit plastic turbo impeller using a 3D printer but and can’t use an off the shelf one) it does not
which can be used to make prototypes, cannot saw in a straight line with a hacksaw. compare well to the 2 minutes that it would
models etc. The importance of being able to actually have taken you to laser cut it or turn it on a
Amongst the kit planned to go into the make things should never be underestimated. lathe. A print time of a couple of hours is no
workshop are a few desktop 3D printers, This is especially true when you are learning. use to you if you are running a 1 hour class.
which got me thinking about the advantages A second advantage is the reduction in Another big disadvantage is the lack of
and disadvantages of 3D printers as learning time. The time required to become design for manufacture. DFM is crucially
educational tools for engineering. competent at operating a desktop 3D printer is important and can make or break the
The first thing to consider is what you are nothing compared to that which is required to viability of a design as a product. The idea of
trying to teach. If you are getting a bunch become competent at using the kit you would freeing designers from a world of constraints
of kids to design bodywork for remote have had to use if you didn’t have one. If you into a world of endless possibilities where
controlled cars, whistles or cup holders then are teaching on a finite time budget, this frees they are limited only by their imagination
it’s a great fit for banging out lumps of plastic up more time to cover other subject areas. is one created by the unconscionable and
in the appropriate shapes required. The versatility of a 3D printer is another perpetuated by the unknowledgeable.
If however you are teaching software big advantage. Its ability to produce a myriad Although design for 3D printing rules exist,
programming, forging or computational of forms means that it takes the place of they are different from design rules for more
fluid dynamics then it’s no use to you at multiple more specialised pieces of kit. This conventional production processes. The
all. The grey area comes when you start saves workshop space and means less pieces danger here is that parts progress from the
talking about the design of non-customised of kit to buy when setting the workshop up. virtual (i.e. CAD) world to the physical world
products, which are going to be produced in Another massive advantage of 3D printing without encountering the constraints of the
their thousands or more. Pupils from Watford compared with traditional fabrication is processes that will be used to make them if
The biggest advantage that 3D printing Grammar School for safety. There was a time not so long ago when they become non 3D printed products. It’s
brings in this case is the fact that it allows Girls being shown the schools did not have technicians to drill holes easy to see how this can ingrain bad design
non-engineers to actually make things by difference between a for the kids using the nasty scary pillar drill practices into the pupils.
consumer 3D printer
lowering the bar to the skills and knowledge thing, the kids did it themselves along with In conclusion, 3D printers are a great
and a professional
required. It’s no exaggeration to say that machine during a visit milling, turning, forging, casting etc. thing to have in an educational workshop as
there are people around who can produce a from LaserLines Now of course we live in a compensation long as that workshop also contains other,
culture where personal injury lawyers point non-additive, means of manufacturing /
the shotguns of blame at the rabbits of fabrication. For educational purposes they
employers and educational establishments as should never be used in isolation. The most
they dive for cover behind the grass mounds important lesson (by far) that should be
of health and safety. Technologies such as stressed is that just because your design can
3D printers and laser plotters offer a safe be 3D printed it doesn’t mean that it is correct
alternative meaning that things can be made for series production.
despite the ever prevalent health and safety
rules and regulations.
Jeremy Pullin is the rapid manufacturing
Of course as for just about everything in manager for Renishaw, having set up and
life, there are cons that go with the pros. The now in charge of its pioneering Rapid
most obvious one has to be expense. Desktop Manufacturing Centre. He can be found
tweeting as @jezpullin
machines are easy to get hold of and keep
getting cheaper and cheaper but running costs All views expressed here are Jeremy Pullin’s
do not come down at the same rate. While own and not necessarily those of his employer

16 MARCH 2015 DEVELOP3D.COM


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FEEDBACK

Your DEVELOP3D
» Your views on Autodesk dropping its perpetual licensing system, 3Dconnexion's
CADmouse, CEO deathmatch at DEVELOP3D LIVE, and SolidWorks World bingo
This is an interesting move and one I and collaboration performed: via standard
support, but on the face of it are Autodesk PLM application and conventional CAD
assuming that ALL users will have an concurrent engineering with one check-
unrestricted access to the internet? out at a time or can the cloud CAD enable
Corporates which require high level concurrent access of several designers to a
of security around internet access will same design live?
be less than willing to open up just to Philippe Pradoura, Schneider Electric
accommodate a CAD application. It’s often
impossible to get simple functions like When you run conventional CAD applications
software activation to work correctly with on Mainframe2, they behave the same way
high security measures in place, so I’d be as they would on a PC. Great thing about
interested to see how they expect to tackle it is that all apps will work without any
this. modifications: SolidWorks, Inventor, or
TimC Solid Edge. But it also means that you bring
your designs in the same way (checkouts
Editor's letter: Celebrity and all). Multiple users can collaborate on
CEO Deathmatch Mainframe2, but they will look at the same
DEVELOP3D FEBRUARY 2015 design.
Software executives in leotards and gimp Nikola Bozinovic, CEO, Mainframe2
masks is EXACTLY what we really want to see
in Warwick this spring. Robox desktop 3D printer
Please inform the editor of this mistake. upgrade for AutoMaker
Clive Bagley develop3d.com
I had a chance to play with the beta version
3DConnexion swaps hands and the UI is clearer to use and produced
with its new CADMouse great results with just the default settings.
DEVELOP3D.cOM The cloud import worked well and I quickly
That Sun infrared mouse brings back found a useful item to print.
memories! I remember being on placement Andy from Workshopshed
Got an opinion on Stephen Holmes and his working on IDEAS and thinking it was an
anything that has SolidWorks World Bingo amazing piece of tech, with the gridded Gian Paolo Bassi named new
(or has not) appeared
in DEVELOP3D? Let us
Twitter metal mousemat too. CEO of SolidWorks
know what you think I'm getting close to #SWWBingo. All I need Mike W develop3d.com
Greg Corke is a sighting of @gpbassi in Cowboy outfit Paraphrasing what he said “access to
greg@x3dmedia.com and I win! I’m just disappointed that it doesn’t feature information anywhere, anytime on any
Facebook @WillRadiganPE any of their 6D tech in it, which would have device” almost a direct quote from #Onshape
/develop3d been a *real* category changer! Devon Sowell
Twitter One of the funniest things I have seen in a Jonathan
@develop3d long time. Well done. Pet products: Frogs
Web @ajkelly Mainframe2: DEVELOP3D FEBruary 2015
develop3d.com CAD in the cloud "Ever wanted to keep a pet frog but never
Linked In Autodesk to scrap its DEVELOP3D DEC/Jan 2015 been sure what to put it in?" No, no I
DEVELOP3D group
perpetual licensing system If we run the standard CAD application in haven't! #NewEngineeringProblem
Letters may be edited DEVELOP3D.COM the cloud, how is the CAD data management Rachel Berry @rhbBSE

60 second Why did you become a designer? 
 What design would you have Is there anything that would a fascinating man — I need to know
interview To be honest, I don't see myself
as a designer. My professional
loved to have designed and why? 

Whatever I am working on at any
make your design process run
smoother? 
more about that punching a polar
bear in the face incident...look it
Lloyd background lies in production given time. It’s important to love I have a very small and brilliant up! My wife, children, father and Al
Pennington engineering and, following work what you are doing more than team, so for me, it is always more Dean (chuckle).
in this line, I was offered a design anything else. Even if in hindsight I brilliant people.
position. Unsatisfied and frustrated always feel that I could have done Lancashire born Lloyd Pennington has
with being employed (or vice better. What would you say is the been making things all of his life
versa?) I decided to follow a route biggest challenge facing as a result of his dad making things all of
of self-employment in the design Play-Doh, Meccano or Lego? designers? 
 his life. Making things is something Lloyd
engineering sector. Easily Lego, despite the fact that I I think it's solving manufacturing, possesses as an instinct. Having worked
need my teenage son to program human, finance, sustainability as both an employee and an employer in
Which designer or company do Mindstorms these days! issues etc....and maintaining the engineering and manufacturing sector
you most admire and why? 
 balance at the same time.  over the years, Lloyd now steers a
In my heart, my dad. The man was What are your weapons of choice? successful design and manufacturing
(and is) a genius at just cracking on Depends on the size of the victim. Can you predict any future company which he says is about to
and making things, out of anything. trends? revolutionise the machine tool industry.
If you really want me to name a What is missing from your toolset?  No....otherwise I would be a lot
company, then it’s Renishaw.   Funny you should ask. A high speed, richer than I am now. See Lloyd at DEVELOP3D LIVE on March
  high fidelity, cheap to run, easy to 26 on stand 64 (Muncaster Technologies)
What product couldn’t you live use, tool for making prototypes.... If you were hosting a dinner party
without? 
 would you like one ? [Ed - see who would you invite and why? 
 If you want to take part please
A computer. muncastertechnologies.com] Brian Blessed, who wouldn't? What contact tanya@x3dmedia.com

18 MARCH 2015 DEVELOP3D.COM


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Protolabs Ad.indd 1 16/02/2015 14:56


VISUAL DESIGN GUIDE Vuly is an Austra
Andon with the a
vuly thunder world. Seven yea

Brief
Vuly commissioned Australian industrial design
studio D3 Design to help it design Thunder. “The
brief was to design the best trampoline in the
world. A bold target and to achieve it we needed
to completely rethink what a trampoline was,”
says David Francis, D3’s creative director

Ease of use
Joe Andon’s mantra of simplicity and ease of
use meant that the designers were constantly
challenged to reduce the complexity and
number of parts. The end product consists
of only seven different components with no
fasteners needed for assembly

Safety
Safety was a key driver for the project. The
traditional hard steel frame, which can
cause head impact injury, was removed and
instead a mat support system was developed
which would give way under pressure

Leaf spring system


The leaf spring system was inspired by nature —
specifically a tree with its solid trunk and smaller
branches higher up. Similarly, each leaf spring
consists of three laminated leaf springs of different
lengths that become thinner and more flexible the
further they are from the base and closer they get to
the mat allowing for a good bounce

20 MARCH 2015 DEVELOP3D.COM


alian brand that was started by 25-year-old Joe BACK tO
aim of creating the best trampolines in the BASICS
ars later, its most recent offering is Thunder CUrVED
DISPLAyS
Curved screens? That’s just a gimmick
to sell more TVs, right?

In some ways, yes. As far as TVs go,


we’re not at all convinced, but we do
reckon there’s some mileage with
professional displays.

Well, go on. Please tell….


DeSign
proCeSS
With complex design and
Curved screens are supposed to offer
engineering challenges
an ‘immersive’ experience. But if you’re
involved, the project was a ten feet away on your bashed up sofa
sequence of think, sketch, watching Eastenders, you’re hardly going
draw up, prototype, test and
evaluate and then refine again to share a moment with Dot Cotton. You
need to be in a controlled environment.

Like in the Queen Vic when Peggy


Mitchell ruled the manor?

Not quite. We were thinking more like in


an office, sat at an ergonomic desk.

Ah, I’m starting to see where this is


going. So what are the benefits for CAD?

CuSHioneD With a 34-inch screen directly in front


Thunder has a soft-edge to of you, it’s possible to properly immerse
help cushion tumbles and spills
as the hard frame and coiled
yourself in your 3D designs. And with
springs of a typical trampoline an extra wide 3,440 x 1,440 resolution
have been removed screen you can also flank your modelling
window with supporting apps.

Sounds a lot like my dual screen CAD


workstation.

It is. But instead of having an annoying


BounCe gap between displays you get one
To deliver better bounce, continuous screen to do with as you wish.
the design team created a
progressive rebound system to
allow for plenty of air time and So what models are curved?
no lateral movement making it
kind on knees and joints
Check out the Dell UltraSharp 34
Monitor U3415W (pictured) or the HP
ENVY 34c (also called the Z34c).

Are there any downsides?


frame
The strong dual-frame
Some say curved screens and CAD
design is resistant to rust, geometry don’t mix. It could give you a
scratches and cracks distorted view of the world — a bit like
Ian Beale after spending a lifetime of
misery in Albert Square.

priCe
Available to purchase in
the UK for £899.99
vulytrampolines.co.uk
SPOON SWOON

W
hen baking we often need to Starting out with the Spudnik potato 3D printed some nylon spines that we
spoon and scrape in quick masher, today the üutensil product range over moulded with the silicone tool. We
succession. Instead of dirtying has grown to around 20 tools, which are then pretty much had a finished product
two utensils, now there is one that will do sold worldwide. without having to do any injection
both jobs. The Swoon is an offset spatula The Swoon design process began with a moulding.
spoon from London-based kitchen brand discussion between Reay, the design team “Obviously with the final product, the
üutensil. and the marketing director. From there, spine is injection moulded but doing it
“Swoon is part of a new hand tool range sketches were formed with one or two then this way helped speed up the process and
with each tool doing at least two jobs,” modelled in SolidWorks. meant we could start photographing and
explains Gavin Reay, founder of üutensil. The final design features an offset marketing the Swoon before production
“We are not trying to force two functions spoon head and a silicone edge that has was complete,” says Reay.
together, they are functions you would been bevelled for scraping along the side Swoon is part of üutensil’s hand tool
conceivably be using at the same time.” of a bowl or pan – Reay calls this the range along with the Flipp – a turner,
üutensil was formed in 2009 by Reay, an windscreen wiper effect. The soft non-slip drainer and grater in one – and the
industrial designer and director of London- handle also has a rest built in to prevent Pinch++ kitchen tongs. “These products
based consultancy And Design. With the spoon slipping down. form the back bone of the hand tool range
four children, he was inspired to create “With this product, once we had gone that we are going to bring out over the next
functional kitchen tools that reflect how past the CAD and 3D printing stage, couple of years,” says Reay.
people really live and cook. we went straight to a silicone tool. We üutensil.com

» Manufactured with advanced


materials, these hi-tech utensils would
be more than a match for spoon bending
guru Uri Geller, writes Tanya Weaver

PRODUCTDESIGN
SHOWCASESPOONS
PROFILE

The Swoon spoon has an offset


spoon head that allows for a
straight working edge down the
handle. When baking, the user can
scrape the bowl before spooning
the mixture into the tin

DEVELOP3D MONTH 200X 23


Spoon for all

W
ith its deeper cavity to hold
contents securely, the S’up is a
perfect spoon for shaky hands.
The project began as a design exercise
between Mark Penver, an intern at
Glasgow product design consultancy 4c
design (now a permanent member of staff)
and Grant Douglas, a man with cerebral
palsy, to create a one-off prototype.
From sketches, Penver moved quickly
into SolidWorks creating a range of spoon
heads and handles.
“We worked a lot on the curvature of the
handle. So when the spoon is on the table
there is a larger area to grip because it is
raised off the surface,” explains Penver.
When Douglas received his final
prototype, it transformed his eating habits.
With such positive feedback, 4c Design
decided to try and bring the S’up Spoon
to market in the hope that it could do the
same for other shaky hand sufferers.
To fund the aluminium tool for the
injection moulding process 4c Design
launched a Kickstarter campaign.
“We’re currently building a new business
plan around it and Grant is taking on a
huge part of that,” says Penver.
“We’ve also done a round of vacuum With its deeper cavity
cast prototypes so we can start doing to hold contents more
trials before we buy the expensive tooling securely and reduce
spillage, the sleek, matte
and build interest around the spoon,” black S’up Spoon offers
says Penver. a new perspective on the
supspoon.com traditional spoon

Outdoor spooning

W
hen camping, you don’t want to
lug loads of different utensils into
the great outdoors. So, the San
Francisco-based outdoor company Alite
alighted upon an innovative idea – a three-
in-one cooking utensil set, where a spoon
and spatula combine to form tongs.
In designing the Clover Cook Set, Alite
asked as many people as possible about
how utensils could make it fun and easy
to cook outdoors. The overwhelming
feedback indicated that most wanted
simple to use, yet multifunctional utensils
that were easy to transport and store.
“Armed with this information, we put
pen to paper and started sketching. Ideas
became a multitude of tape, cardboard
and wood prototypes,” explains Tae Kim,
Alite’s founder.
These rough designs were taken into
CAD (Alite uses Rhino and SolidWorks)
and the resulting models were 3D printed.
Having created two injection mould
tools, it was ready to go into production.
The Clover Cook Set, which is made of
BPA-free, food-safe Nylon 6, comes with
a lifetime guarantee. “Our key initiative
is if we could make the products last a
lifetime that would be more sustainable The three-in-one Clover Cook Set
than making something that would fall includes a big spoon for stirring
apart. We work with our vendors and and a spatula for flipping or for
cutting with its serrated edge. The
manufacturers to figure out the best two can then be joined together to
manufacturing process for that,” says Kim. form tongs. Simply reverse and it
alitedesigns.com nests for easy storage
24 MONTH 200X DEVELOP3D
25 D3D Ads.indd 1 18/02/2015 08:49
br
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the mall
Do Rol Briti
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cili AV Rot
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s to pu ha
see lsio s se
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ut d ea al o
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g th vis com
at its i ing
Exploded 3D CAD ts
model of the
Rotron RT600
Twin-Rotor Engine

26 MARCH 2015 DEVELOP3D.COM


rig
PROFILE

ht
ks DEVELOP3D.COM MARCH 2015 27
PROFILE

N
1

ecessity is the mother of Ambitious goal ●


1 Rotron’s
purpose-built
invention. This proverb is Rotron’s aim was to develop a rotary engine that could
engine production
certainly true in the case of deliver a higher power to weight ratio compared to any other facility encompasses
Gilo Cardozo, British aviation UAV specific engine while remaining small, lightweight, full design,
engineer and seasoned reliable and with almost zero vibration. manufacturing and
test capabilities
adventurer. In 2007 having “We came up with some unique patented ideas. For
created a paramotor (a foot- instance, the tip ceiling, which used to be a major problem
launched powered paraglider) with rotary engines, has been solved because of new
that could get him to the summit technologies and materials.
of Everest, he needed an engine “But the major issue is the heat build up in the centre of
to power it. Not being able to find anything up to the job, he the engine, which is hard to extract. So we developed several
set about designing his own four-stroke rotary engine. different unique ideas that extract energy from the centre of
Having achieved his Mission Everest goal (see box piece the engine allowing the engine to have longevity and more
on page 30), Cardozo decided to set up a rotary engine reliability,” comments Edmondson.
manufacturing brand within his paramotor business For instance, the Rotron Pressurised Cooling (RPC)
Parajet (see develop3d.com/profiles/it-gives-you-wings) called system offers cooling and lubrication to the engine and
Rotron Power in 2008, both of which are under the parent means it delivers a higher endurance lifecycle and is less
company Gilo Industries Group. prone to metal fatigue and component wear compared
This subsidiary has grown over the years and ironically with existing rotary engines.
no longer supplies Parajet with its engines. Rather, Rotron “We have developed this water cooled shaft which means
manufactures advanced rotary engines for Unmanned that water can be funneled through the centre of the shaft
Aeronautical Vehicle (UAV) applications. “Rotron is thereby cooling the shaft as it works, which then also has
our largest business within the group supplying high a cooling effect on the internals of the rotor — but also the
power to weight ratio engines for extreme applications, water goes round the external or gap in the housing so it
predominantly within the commercial aerospace sector,” cools from the outside and the inside and it’s had a massive
says Jim Edmondson, CEO of Gilo Industries Group. effect,” says Charlie Nicol, Rotron’s head of operations.

WHAT IS A rotary engine is


essentially an internal
gasoline engine, which
converts rotary motion
type of engine include
simplicity, smoothness,
and has often been
deemed impractical.
a very low lifespan.
“But in the aviation
A ROTARY combustion engine directly into driving compactness, high “They are plagued with world, as well as other
ENGINE? that can achieve four
strokes — intake,
force, in 1919.
As opposed to the
revolutions per minute
and a high power to
problems because if you
look at the tips of the
applications such
as motorcycles and
compression, common piston engine, weight ratio. rotor, when they spin outboards, what is
combustion and with its pistons all Over the years, round they wear quite important is a very high
exhaust — while changing direction, various companies have quickly,” explains Jim power to weight ratio
rotating. German in a rotary engine all improved on Wankel’s Edmondson, CEO of Gilo where the lifespan of an
engineer Felix Wankel parts rotate, moving engine design, however, Industries Group. “For engine isn’t as important
first had the idea in one direction. it has a number of that reason, people think as the weight impact,”
for this new type of Advantages of this inherent problems that rotary engines have he adds.

28 MARCH 2015 DEVELOP3D.COM


‘‘ What
we have
Work and play
The design and development work of these engines was
heavy fuel engines in the 20-60 HP engine category. As
a heavy fuel version of its gasoline RT300 (single rotor
carried out by Rotron engineers using predominantly engine) and RT600 (twin rotor engine) engines, Rotron
also done SolidWorks, of which it has ten seats in-house, making use claims to be the only manufacturer in the world producing
is work of the tool’s bolt ons including failure mode and effects a heavy fuel propulsion system within this engine category.
out how analysis (FMEA) and computational fluid dynamics (CFD). Until now, UAV manufacturers have not been able to
But Edmondson stresses that, as important as it is to offer heavy fuel engines within the Medium Altitude
to heat the have good tools, the company wants to instil a culture of Endurance (MALE) UAV market sector. This is largely due
fuel up to innovation by ensuring that its employees enjoy being at to the extreme power-to-weight ratios required in such
98 degrees work. “If you’re making inspiring technology, it should be propulsion systems; the size of the engine makes it difficult
Celsius an inspiring place to work as well,” he says. to propagate the flame and ignite heavy fuel.
So, activities that the company organises for all employees However, the UAV market, especially for use in defence and
before it includes Boot Camp, a bicycle ‘chain gang’ (a group cycle military applications, has coveted heavy fuel engines since
is actually ride after work), getting inspiring speakers to give a talk NATO’s announcement of the single fuel policy in 1997. This
injected (the most recent being James Holland, a World War Two policy states that one single fuel should be used across all
into the aviation historian) and a ‘Fly to Work’ programme where motorised military assets from chainsaws to UAVs by 2020.
they can get to fly a paramotor. The way in which a diesel engine, or a compression-
engine
’’ “If your employees are excited about coming to work on
a Monday morning, then you get the best out of them. It
ignition engine, works is that it uses the heat of
compression to initiate ignition and burn the fuel that
becomes an exciting environment and that is what it should has been injected into the combustion chamber. But a fair
be about, not this crazy mathematical problem that you amount of mass and energy is needed to make that happen
have to solve using SolidWorks,” comments Edmondson. and that is why diesel engines are quite big and so not
suitable for small applications such as UAVs.
Heavy fuel engines “You could use spark ignition, the same as with a petrol
All of this hard work and play has led to Rotron’s most engine, but that has inherent problems because diesel is
recent innovation, which it launched at the Farnborough so inert that you can take it on a plane in a flask and not be
Air Show 2014 last July — commercial off the shelf (COTS) stopped as you can’t light it with a match or flame. It has to
be heated up to 98 degrees Celsius to even start lighting it,”
says Edmondson.
2
Leading the way
With the challenge set, this small manufacturer began
work on its heavy fuel engine around three years ago. Its
goal was to lead the race in developing a solution that the
military could use in its UAV applications such as search
and rescue, anti-piracy and pipeline inspection.
The main innovation within the resulting engine is flame
propagation — making the flame burn smoothly across the
whole flank. Essentially, what Rotron has managed to do is
align the spark plugs so that the engine doesn’t have one or
two spark plugs, as in its petrol variant, but four.
“With four spark plugs, as the ignition starts at the
3 beginning of the rotor, it starts pushing it round, then the
second two fire almost instantaneously after with lighting
the back of the fuel. But what we have also done is work out
— I can’t go into too much detail — how to heat the fuel up
to 98 degrees Celsius before it is actually injected into the
engine,” explains Edmondson.
Rotron engineers relied heavily on computer modelling to
work this out. They weren’t only modelling flame direction,
but also using CFD to calculate property strengths and to
analyse where failures could occur.
This analysis work was carried out in conjunction with
physical trials. So, a part is first designed and analysed in


2 The Rotron’s charged cooling combined
with other proprietary cooling systems
delivers a reduced heat signature and
reduced component wear

3 Precision engineered single-rotor
eccentric shaft machined from a single billet

4 Close up of Rotron’s lightweight cast
rotor housing of an LCR engine

DEVELOP3D.COM MARCH 2015 29


PROFILE

the 3D world before it is built and physically tested. That


information is then correlated back to simulation. 5
Doing it this way means that not nearly as many prototype
rotors were destroyed, as they would have been if no
simulations had been carried out. And with it costing
£1,000 for each prototype built, a great deal of money was
saved in the process too.

Testing, testing
In November 2014, Rotron engineers prepared the RT600
heavy fuel engine for its first application-based test
programme. Having completed a complex installation into
the test mule at its facility, the team performed pre-testing
on all engine components and ancillaries to ensure optimal
configuration setup. Having received very positive first
results, future developmental testing will centre on the new
starter system that is currently being prototyped.
These test results will be supported by data collected
over an extensive pre-flight development program. For
this, Rotron has secured four launch partners who will be
working with the manufacturer to test the engine.
6
One of these is a helicopter manufacturer, which will use
the engines in unmanned helicopters to carry out power
line inspections. “As you can imagine, power lines going
across mountain ranges are very hard to track but these
helicopters can shoot along them and with special cameras
can pick up heat impacts from the transistors.
“With our engines being high power to weight and with
very little vibration they are ideal for such UAVs,” describes
Edmondson.
Although full production of the heavy fuel engines is only
scheduled for 2016, Rotron moved into its own facilities
in May 2014, which is right next door to the factory it used
to share with Parajet. Already some new investments have
been made to the shop floor including a DEA Coordinate
Measuring Machine (CMM) to deliver precise, accurate
manufactured components for the new rotary engines.
To further improve its processes, the design studio is also
in the process of implementing SolidWorks Enterprise
Product Data Management (EPDM), a data management
system that Rotron hopes will get its design data under ROTRON’S In early 2007 Rotron
founder and chief
The supercharger was
modified to be spun at up
control and improve the way it manages and collaborates
on product development.
HISTORY technology officer, Gilo
Cardozo, pursued a
childhood dream: to fly a
to 200,000rpm in order
to simulate sea level
atmospheric pressure of 1
“I think any company that has grown from five people five paramotor 30,000ft over bar at 30,000ft.
the summit of Everest. To eliminate the
years ago to +50 today, needs to have these processes put in Having teamed up with problem of icing, the
place. This tool from SolidWorks should be a huge help to friend and TV personality supercharger was placed
Bear Grylls, Cardozo had before the fuel delivery
us in terms of control and configuration,” says Edmondson. just seven months to build system. The heated and
When full production of the heavy fuel engines begins in two paramotors. supercharged air was
2016, 20 per cent of the engine will be made in-house with However, the most then sent through an
powerful paramotor intercooler before passing
the rest outsourced. But all suppliers will be sourced in engine available was the injector at an average
the UK as Rotron, and its parent company Gilo Industries, barely producing 30hp of 25 degrees Celsius.
passionately believe that design and manufacturing is and was far too heavy After four
to launch at the desired months of design,
critical to the future economic growth of British industry. altitude. So, he also set development, testing
rotronuav.com about building a four- and manufacturing, the
stroke rotary engine that engine was finally ready.
was more compact and With just two days before

5 With fewer moving ●
6 The Rotron ●
7 Target Drone
50 per cent lighter than a departure, the second
parts, the Rotron RT600HFE: Engine: suitable for piston engine equivalent. engine was completed.
engine offers easier suitable for UAVs Short-life UAVS & The basis of the Everest On 14 May 2007 the
maintenance requiring 56HP Aerial targets engine was a 294cc single two pilots took off and
rotor engine producing in a flight that lasted
40hp as a standard four hours they achieved
normally aspirated a paramotoring world
engine. record of 29,494 feet.
The engine included On completion of the
a miniature centrifugal expedition and building
supercharger fitted with on its success, Cardozo
a miniature intercooler continued to develop his
to ensure the air was rotary engine and looked
as cold and dense as for a commercial platform
7 possible when entering
the combustion chamber.
for the technology. Rotron
Power was born.

30 MARCH 2015 DEVELOP3D.COM


Adam-Hartles-Gilo-Edition-v1.pdf 1 16/02/2015 17:18:30
EVENT PREVIEW

dEVElOP3d liVE
2015 PREViEW
» With more exhibitors than ever before and a top drawer conference programme
DEVELOP3D LIVE on 26 March 2015 looks set to be our most exciting event yet
market, looking at funding, product
development and finding a route to market.
With talks from those who have managed to
pull it off with those who have helped along
the way.

EXhiBiTiON: On 26 March, Warwick Arts


Centre is going to be full with the most
varied and innovative exhibits. With over 60
stands and many new-to-market products
on show, there’s plenty to touch and see;
3D printers, modelling tools, design
visualisation technology, laser scanners,
document management, simulation tools,
workstations, and the latest in desktop
fabrication. There will also be hands on
training sessions with Autodesk Fusion
and the brand new Onshape Pro from the
original SolidWorks team.

d
www.develop3dlive.com/exhibitors
EVELOP3D LIVE is a PROdUcT dEVElOPMENT TEch:
globally unique product These are interesting times in the design WMG
design conference and software market, with many established The WMG is on-site at the Warwick
exhibition, featuring talks desktop products available we are beginning University campus and offers UK firms the
from leading designers, to see a number of new generation design opportunity to carry out research or assist
engineers, design tool tools come to market, offering innovative in solving design and production problems.
developers, hardware manufacturers and connected modelling tools with collaboration Tour places are limited to three groups of
rapid prototyping technologists. capabilities. Looking forward, how should 20 in the day, so be sure to book your slot
We have brand new products to see, free designers prepare for the next generation when you arrive on-site, at registration
training, graphics cards and workstation of tools? DEVELOP3D LIVE will feature
competition prizes. The conference a major launch of a new CAD system and accOMMOdaTiON
features four tracks of speakers, hand presentations on the next generation of tools. We realise that many of you travel great
picked by the DEVELOP3D editorial team, distances to attend the show. With
with multiple exhibition spaces, special PROdUcT dESiGN & ENGiNEERiNG registration opening at 8:00 am on
technology break out areas and tours of the This year we have doubled down on product Thursday 26 March and the event starting
Warwick Manufacturing Group’s (WMG’s) designers and engineers with two tracks promptly at 9.00 am, we are pleased to
impressive engineering facilities. The covering a wide range of specialist areas. offer quality affordable bed and breakfast
event is free to attend, we provide lunch and See pages 33 to 46 for the highlights and accommodation on-site on Wednesday 25
coffee/tea at regular intervals, and we hope check develop3dlive.com for the latest news. March. Cost is £66 inc VAT and includes
you enjoy celebrating the best in product a full English breakfast, free Wi-Fi and
design and engineering. MaKE aNd FaBRicaTiON parking. Book your room directly at
The revolution is now. It’s never been so tinyurl.com/D3D-accom (conference
cONFERENcE: Throughout the year we easy to bring your designs to life and we registration also required — see below).
meet and visit many innovative designers and have an array of designers and engineers
engage with all the key design tool developers. that want to share their experiences and
DEVELOP3D LIVE enables us to bring our workflows with their peers. Expect to hear
written stories to life for one day. With four some new stuff and get a peek into the
claiM YOUR FREE TicKET
develop3dlive.com/registration
simultaneous tracks, we have 34 speakers future of desktop manufacture.
talking on a wide variety of design-related We look forward to welcoming you to
topics: conceptual, automotive, aerospace, STaRT-UP: New for 2015, DEVELOP3D DEVELOP3D LIVE at Warwick Arts
product, analysis, virtual/augmented reality, LIVE features a track dedicated to those Centre, CV4 7AL on Thursday 26 March
design tools and professional 3D printing. who want to bring their inventions to

32 MARCH 2015 DEVELOP3D.COM


COURTESY OF LLOYD IMAGES / BEN AINSLIE RACING
aNdY claUGhTON America’s Cup winner, Sir Ben Ainslie,
with the long-term aim of challenging for
having been involved with the competition
since 1983. As Technical Director of Ben
BEN aiNSliE RaciNG Britain and bringing the America’s Cup Ainslie Racing, Andy will coordinate a
back home to where it all began in 1851. team of designers and engineers as they

B
en Ainslie Racing (BAR) was Britain’s Andy Claughton is one of design, build and test the prototype and
conceived in 2011 by four times the world’s most accomplished and final boats that will challenge for the 35th
Olympic gold medalist and 34th experienced America’s Cup designers, America’s Cup.

CARL BASS GIAN PAOLO BASSI


AUTODESK CEO SOLIDWORKS CEO

ThE FUTURE OF cad

W
ith embryonic ‘next generation’
modelling tools coming to market
and an increasing number of cloud-
based services and applications, designers
need to understand their implications on
JON HIRSCHTICK modelling, simulation and fabrication. As
CHAIRMAN
ONSHAPE these new products are introduced initially
as ‘companion’ seats, does this mean the
tools we have invested in and completely rely
on will soon be legacy systems?
DEVELOP3D LIVE will bring all the
major CAD tool developers under one roof
to explain how these new capabilities will,
both now and in the future, improve on
the current tools and how we can manage
this transition.
DAN STAPLES BRIAN THOMPSON
With a high-ranking line-up of executives,
SIEMENS PLM VP OF PRODUCT
MANAGEMENT, PTC expect to hear the latest on developments
concerning SolidWorks, PTC Creo,
Autodesk Inventor and Fusion, Siemens
Solid Edge and NX and more. We also
welcome Jon Hirschtick, founder of
SolidWorks, to launch a brand new cloud-
based modeller, Onshape.
CONFERENCE HIGHLIGHTS Skylon is an unpiloted,
reusable spaceplane
intended to provide reliable,
responsive and cost
effective access to space

Richard Varvill
REACTION ENGINES

R
eaction Engines conducts research
into space propulsion systems,
centred on the development of the
Skylon re-usable SSTO spaceplane, using
its own Sabre engine design.

The company has also developed the A2


passenger plane concept, capable of flying
non stop, halfway around the world at
hypersonic speed (Mach 5+).

Richard Varvill is Technical director and


head designer and is currently responsible
for the technical
aspects of Skylon and
the Sabre engine. He
is one of the founding
directors along with
Alan Bond and John
Scott-Scott.

DOMINIC WILCOX
Artist + inventor +
DESIGNER

D
ominic Wilcox works between the
worlds of art, design, craft and
technology to create innovative and
thought provoking objects.
Recent projects include the design of a
pair of shoes with inbuilt GPS to guide
the wearer home, a Binaudios device
to listen to the sounds of a city, a race
against a 3D printer at the V&A and a
stained glass driverless car of the future.
In 2009 he started a Webby award
nominated blog called Variations on
Normal where he shows his sketchbook
inventions and observations. He has
received commissions from a diverse
range of organisations such as Paul
Smith, Selfridges, The V&A museum,
BMW Mini and Jaffa Cakes.

34 MARCH 2015 DEVELOP3D.COM


Environment created in Autodesk® Maya® and rendered in Autodesk® VRED™ Professional
RELY ON THE POWER
OF AMD FIREPRO TM

Design engineers use AMD FirePro professional


graphics to accelerate their workflows.
Combining cutting-edge technologies, full ISV certification and optimizations
as well as professional-grade support, AMD FirePro graphics deliver unmatched
workflow performance, application experience and reliability across our entire
product range.

ALL AMD FirePro™ professional graphics cards are available from these selected partners.

Scan Computers Workstation Specialists Amari


www.scan.co.uk www.workstationspecialist.com www.armari.com
0871 472 4787 0800 180 4801 0192 322 5550

© Copyright 2015 Advanced Micro Devices, Inc. All rights reserved. AMD, the AMD Arrow logo, FirePro, and combinations thereof are trademarks of Advanced Micro Devices, Inc. OpenCL and the OpenCL logo are
trademarks of Apple Inc. used by permission by Khronos. Other names are for informational purposes only and may be trademarks of their respective owners.
Environment created in Autodesk® Maya® and rendered in Autodesk® VRED™ Professional

MA5832_AMD_d3d_A4_v2_0.indd 1 21/01/2015 12:21


CONFERENCE HIGHLIGHTS

RML Group

O
ne of the world’s most successful
and innovative motorsport
organisations, DEVELOP3D LIVE
is proud to have Arnaud Martin, Director
of Powertrain at RML (Ray Mallock Ltd)
talk at the conference.
RML Group engages in design,
development, build and operations of
race vehicles, performance road cars,
concept vehicles, advanced engines, EV
and Hybrid powertrain and electronics.

The Nissan ZEOD (Zero Emissions On


Demand) features ground breaking
hybrid powertrain solution including
multi award winning 3 cylinder engine.

A Fantastic lineup
Sarah Giblin
Riut (Revolution
in user thinking)

of SPEAKERS

A
s usual DEVELOP3D LIVE will have
a plethora of designers, engineers
and industry specialists. This year
we have three key areas: Product Design,
Make / Fabricate and Start-up.
We have doubled down on product
Frank Cooper
design with a wide range of innovative Jewellery Industry
Innovation Centre
practitioners telling us their experiences
with technology, fabrication and clients. Mona Hess
3DIMPact
Mark Sanders
Principal of MAS Design
Make/Fabricate is the track for those
interested in rapid prototyping, 3D
printing and taking design from art to
part. We have the guys from MakerCafe,
FBFX, Inition and Granger and Worrall
to name but a few, and also some exciting
exclusives from Autodesk and HP on its
3D printers.
We have two star designers making
a return to the stage: Mark Sanders of
MAS design (Strida folding bike, one
touch can opener) and Mark Shayler of Mark Shayler Hutch Hutchison
Ape, who doesn’t mince his words when Ape Head of Design, Vertu

it comes to eco-design. Chris Cheung


from the Foundry will be on hand to
divulge the latest in conceptual design.
We also have Hutch Hutchison from
Vertu designer phones, Aerialtronics
(drones), and presentations on jewellry
design, scanning and much more.
Check out develop3dlive.com/speakers
for more exciting announcements.
36 MARCH 2015 DEVELOP3D.COM
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Exhibition HIGHLIGHTS

Design visualisation

A
wide range of specialist design
visualisation and rendering
technologies will be demonstrated
including V-Ray from Chaos Group,
KeyShot from Luxion, iray+ from
Lightworks and HDR Light Studio.
For CAD-integrated design visualisation,
including real time rendering, check out
SolidWorks, Solid Edge, NX, PTC Creo,
Autodesk Fusion, Autodesk Inventor, Scene rendered in
Luxion KeyShot
solidThinking, and more.

Workstation TECH

T
here will be a massive array of
workstation technologies on show
including the latest AMD FirePro
GPUs, which can handle heavy duty
3D graphics and compute tasks on a
single card, plus a whole range of new
workstations based on Intel’s Xeon E5-
2600 v3 series CPUs.
HP will be highlighting its new Z
workstations including the HP ZBook
15u Workstation Ultrabook. Lenovo will
be showing off its shiny new ThinkStation
P Series desktops and ThinkPad mobile
workstations, while Fujitsu and Dell
will present their respective Celsius and
Precision workstation families.
Specialist manufacturer Scan will
demo its overclocked workstations while
3Dconnexion will present its CAD-focused
2D and 3D mice. HP Z640

The Mark One 3D


3D PRINTING printer can reinforce
parts with carbon fibre

D
EVELOP3D LIVE will play host
to its biggest ever range of 3D
printing technologies including
Blueprinter’s low-cost sintering tech,
Formlabs stereolithography machine,
and Markforged’s Mark One, which can
reinforce parts with carbon fibre.
Emco Education will highlight 3D
Systems’ range of printers. CDG will have
live demos of the ProJet 1200 micro-SLA
3D printer and other machines. Laser
Lines and Tri-Tech 3D will both showcase
the full range of Stratasys 3D printers.
Meanwhile, Hobs Studio, Malcolm
Nicholls Limited (MNL), Ogle Models
and Prototypes and Proto Labs will all be
on hand to promote a wide range of 3D
printing and prototyping services.
38 MARCH 2015 DEVELOP3D.COM
CaD/CaM

C
AD software will be in abundance
on the exhibition floor with
demonstrations of leading product
development software including Autodesk
Fusion, Siemens PLM Software NX and
Solid Edge, PTC Creo, and SolidWorks
Industrial Designer.
Onshape, a next generation, cloud-
based CAD tool, founded by the original
SolidWorks team, will also be given
plenty of floor time, as well as EPLAN for
electrical engineering, DriveWorks for
design automation, ITI TranscenData for
CAD data exchange and solidThinking
for industrial design and developing
structurally efficient concepts,
There will also be a wide range of
manufacturing technologies from Delcam,
Vero and Tebis, including tooling design,
reverse engineering, 5-axis machining, SolidWorks
wire EDM and others. Industrial Design

sIMulaTIoN

T
here will be a wide variety of
Finite Element Analysis (FEA),
Computational Fluid Dynamics
software (CFD) and multiphysics
simulation technologies on display.
Ansys, the specialist Computer Aided
Engineering (CAE) software developer
will be showcasing its latest release,
Ansys 16.0, while Autodesk, Siemens
PLM Software, PTC and SolidWorks will
be presenting a wide range of CAD-
integrated simulation technology.
FlowHD will be showing meshless
XFlow CFD technology, Strategic
Simulation & Analysis (SSA), a reseller
for the DS SIMULIA product range, will
be promoting its training and consulting
services, and NAFEMS the independent,
not-for-profit, CAE association, will be on
hand for best practice advice. DS Simulia Abaqus

MoRE ExCITING TECH Faro Focus3D


X330 Laser Scanner

F
or quality inspection and organic
modelling, CDG will have live
product demonstrations of Geomagic
Capture and Geomagic Sculpt.
Delcam’s PowerINSPECT will also be on
show for comparison of parts, prototypes
and tooling against CAD data.
Faro will exhibit its portable Faro Arm
Edge with LLP and Focus3D X330 Laser
Scanner, while Physical Digital will be
promoting its non-contact 3D scanning
technology.
For data management, CSI will be on
hand to discuss DesignDataManager
(DDM), while Kenesto will demo its cloud-
based, collaborative solution.
Mainframe2 will be showing how easy it
is to put CAD in the cloud.
DEVELOP3D.COM DECEMBER / JANUARY 2014 39
MARCH 2015

SIMULATION W
#7 FEA + TESTING
» FEA can tell us many things, but integrated test and simulation programs
are the only way to effectively develop products, writes Laurence Marks

I
thought I’d round off this series of the structure, how well our assessment of for good reason. It’s pretty important. But
articles with a piece on actually the restraints represents how the structure again, even if you follow all the best advice
making simulation work in is actually fixed, and how well we’ve on the subject, how do you know that you’re
reality. Too many people think interpreted the loads constraints nail it?
that simulation techniques are If we focus more closely on the springs Hopefully a picture is forming. A finite
about pushing an ‘improve my design’ we can learn a lot. Robert Hooke, the great element model is built up using a series of
button, but simulation software doesn’t unsung hero of English technology, said that descriptions – geometry, material, loads,
just radiate goodness like some form of the deflection of a spring was proportional to restraint, interfaces, physics etc, etc. And
information age fairy godmother. its stiffness and the load applied to it. And at each one required an understanding,
So far we’ve looked at various approaches a time when witches were still being burned interpretation or description of what was
and techniques, which can be used to at the stake, that was pretty impressive. But happening in the real world – or a lucky
represent what happens to components and many of the materials we engineer with guess at what was going on in the real
systems when they are used. And for all the simply don’t obey that law – not that world. Obviously some
incredible benefits, all these have one huge on-line material databases scenarios are easier to
shortcoming. They are only as good and interpret than others.
relevant as the input data, assumptions, But a series of intelligent
guesses and prejudices guesses at what could be
which are their very DNA. going on, is, after a good
In fact it has been said (well { fig.1} deal of number crunching,
I think it has been said, but transformed into what
as usual Google has failed are often staggeringly
to come up with the goods) impressive graphics. In
that the only function of a this respect CFD beats
numerical model is to reinforce FEA hands down. And
the prejudices of the person those graphics are often
that created it. pretty convincing, as well
We’ll concentrate on finite as being just pretty. And
element models for a while. at this stage you either
So the first useful thing we believe those results to be the single
can do is to try and visualise acknowledge version of the truth, or you chose the path of
what an FEA model that very often. In fact much cynicism. Only one makes sense if you think
actually is. { fig.1} shows in of the information is contradictory. about the inputs, but you’d be surprised how
conceptual terms what an FEA Use one piece of information and you’ll tough it is to convince some of our customers
model is all about. get one answer, use another piece and you’ll that the results are anything other than 100%
A continuous body is represented by a get a very different one. So you need enough definitive.
series of spring stiffnesses, and where these of a material definition to get a sufficiently So you need some form of stake in the
spring stiffnesses connect to each other we accurate answer, but you don’t want a PhD. ground, or reference point, to provide
can calculate deflections. These calculation But the 64 million dollar question is “how something to compare the simulation results
points are the only places in the model where do you know that your model is rigorous to. And that has to be the performance or
we can apply loads and fixings. We calculate enough?” We’ll leave that there for the behaviour of an actual thing. In the real
stresses by working out what has happened moment and move on. world. Measured and quantified. Which
to the small sub-regions bounded by the Anyone who read the Bob Johnson series means a good old fashioned test.
springs stiffnesses. of articles in DEVELOP3D will be aware The process of making the simulation
The effectiveness of the process is of the importance of decently defined model behave like the test is a real learning
governed by how well the springs represent restraints. He’s evangelical about it, and experience, and the way in which the

40 MARCH 2015 DEVELOP3D.COM


COMMENT

LAURENCE MARKS

WORKSHOP
‘‘’’
Too many people think that simulation techniques
are about pushing an ‘improve my design’ button, but
simulation software doesn’t just radiate goodness like
some form of information age fairy godmother

engineer and designer learns what really reality, are only that because they have built
makes the thing tick; what and what isn’t on years and years of test data already in the
important. It’s the IP of the design from a vault. We need to accept that, at the moment,
functionality point of view. Not surprising simulation delivers better testing of better
then that the NDA [Non Disclosure products, which we understand more. That
Agreement] is common currency at FEA has to be better than a simple “make it
consultancy companies. better button”.
I’d always thought about rounding off this
Laurence Marks is the managing
series with a piece on the Simulia Living director of Strategic Simulation and
Heart model. This is a seriously advanced Analysis Ltd, a company supplying the
model, which needs the power of both Simulia range of simulation software,
training, implementation as well as
Abaqus and a multiprocessor machine to consultancy services to a wide range
run. But the point is that for all its impressive of industries. ssanalysis.co.uk
behaviour the model only makes sense in the
context of a team of engineers and medics
working together.
Anyone who has ever worked in a team
which is made up of doctors and engineers
will appreciate that critical review and a focus
on delivering useful data is never far from
the top of the medical agenda. Doctors, in { fig.1} In conceptual
terms what an FEA model
my experience, seem largely immune to the is all about: a continuous
blinding effects of high-level graphics. body is represented
About 10 years ago I had an idea, which by a series of spring
stiffnesses, and where
I am now, depressingly, seeing being these spring stiffnesses
presented at conferences. Rapid prototyping connect to each other we
is revolutionising small batch production of can calculate deflections
parts. So why can’t RP techniques be used to { fig.2} Simulia Living
Heart model: for
accelerate product design by accelerating the
all its impressive
progress around the simulation test loop? behaviour the
Surely this is a critical way ahead – there are model only makes
many, many issues which need to be solved, sense in the
context of a team
but I’m pretty sure they can be, with the net of engineers and
result that product development cycles can be medics working
further reduced. together
So what’s my elevator pitch here? Simply
that simulation only makes sense in a world
where there is, or has been, sufficient testing.
Perhaps in some silver suited future, where
we can model every atom and molecule of
a structure, we won’t need testing, but now
integrated test and simulation programs
are the only way to develop products. And
before anybody else does I’ll mention the
no test programs, which, where they are a { fig.2}

DEVELOP3D.COM MARCH 2015 41


PROFILE

SMOOTH RIDE
1 2

3 4

» Champion Motorsport is putting its track prowess into road-going Porsches,


using 3D printing to smooth the airflow within its carbon fibre parts

T
urning a legacy of the outer diameter at factory halves, the disadvantage of a solution bath after the carbon
track victories into specifications. The result is better this being that the two halves fibre resin was cured.
successful road airflow through the duct, leading must be bonded together after This solution for the turbo inlet
going business is to improved engine performance. moulding, resulting in a part not ducts has also been transferred
historically the way to The new design is also lighter as strong as one with single-piece to a number of other tubes and
motoring success. From Ferrari than the original part, which construction. pipes for the Porsche engine
to McLaren, it’s a well-worn route further enhances performance. In both cases, a good surface — not only improving the
that has served many well. “Producing complex tubular finish is only obtained on one performance of the part, but the
Champion Motorsport’s racing composite components, such side of the part. production speed by providing a
legacy includes a win at the 24 as the turbo inlet duct, is very Over time, Champion tried reliable automated process.
Hours of Le Mans and five straight challenging,” says Chris Lyew, different methods for producing “We substantially improved the
American Le Mans Series LMP1 lead mechanical engineer, inlet ducts but was unable to quality of our carbon fibre turbo
championships: two as a private Champion Motorsport. attain a seam-free part with high inlet ducts and other aftermarket
team and three as an Audi Sport “The performance of the vehicle quality surface finish on both the parts by making them with FDM
North America factory team. depends on a smooth internal outer and inner surfaces. soluble cores,” says Lyew. “It’s
With the trophy cabinet suitably surface while the customer expects Already using a Fortus 3D now possible to mould the inlet
stocked, the team is now using its a beautiful external surface. The printer to make conceptual and duct in a single piece that is much
racetrack knowledge to develop part also needs to be very strong to functional FDM prototypes during stronger than parts produced by
and manufacture aftermarket last the life of the vehicle.” the design process, the idea struck bonding.
performance upgrade parts for Achieving a smooth interior to try using it to make soluble “Every FDM soluble core is
sports cars. and exterior surface finish with cores for moulds. After some exactly the same so it’s easy to
Producing the likes of exhausts, tubular composite components is tests, they perfected the technique; maintain the internal finish of
wheels and turbochargers, almost impossible using ●
1 Porsche 997 making its ducts in a the duct as well.”
boosting power levels and conventional tooling. Turbo with FDM- single piece by laying up By using 3D printing to produce
shaving off weight, the parts If the part is moulded in enabled components carbon fibre on an FDM the soluble cores, Champion
increase the car’s abilities. a single piece, the interior ● 2 FDM soluble core-
printed soluble core. has also opened up a new
enabled components
An example is Champion’s core can be trapped inside on an engine An excellent external world of design possibilities,
carbon fibre turbo inlet duct for the tube, unless it is made ● 3 Composite turbo surface finish was knocking away the barriers that
the Porsche 997 Turbo. of a material that can later inlet duct (black) achieved by combining have traditionally got in the way
By constructing the duct from be washed away like a made with FDM the soluble core with an of improving its design and
soluble core (white)
carbon fibre, Champion was able sacrificial sand core. external clamshell mould, manufacturing capabilities.
to increase the duct’s interior An alternative is to ●
4 Complex composite
ducts made from while the core can be stratasys.com
dimensions while keeping mould the tube in two FDM soluble cores easily dissolved away in championmotorsport.com

42 MARCH 2015 DEVELOP3D.COM


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43 D3D Ads.indd 1 18/02/2015 09:03


PROFILE

HELPING THE
BLUEBIRD
SAIL AGAIN
» The world water speed record breaking craft of Donald Campbell
is being resurrected, with MKW using 5-axis machining to produce
key components with the aid of HyperMILL

2 3

4 5

44 MARCH 2015 DEVELOP3D.COM



With high material costs and the overall value
of components after machining exceeding
£25,000, getting the job ‘right first time’ takes
on a new level of importance
1

O
n 4 January 1967 Donald sit on the underside of the Bluebird’s sponsons. emerge from the CNC machines as predicted.
Campbell took his Bluebird K7 At nearly 4m long, sponsons are the floating Other benefits for MKW are the time saving
to the water for the last time. wings on each side of the craft; that during features for the programmer, such as the
A turbo jet engine hydroplane, the final journey at 305mph were identified to one that lets them choose a feature on a part
the craft allowed Campbell to be continually bouncing off the water. such as a hole, and the software automatically
set seven world water speed records during Unfortunately when the sponsons bounced identifies all other holes with the parameters
the later half of the 1950s and the 1960s. past the maximum 5.5 degree pitch angle the and calculates the tool paths accordingly to
Its design and engineering was pioneering boat left the water resulting in the fatal crash. eliminate unnecessary tool changes.
when launched in January 1955, adding MKW more commonly works with clients This feature recognition has proved of major
nearly 100mph to the existing record, taking it in the defence, aerospace and oil and gas benefit on the sponsons manufactured for
to 276mph in 1964. industry, to produce complex components on the Bluebird K7 project. Each of the two 1.8m
His quest to break the 300mph speed record its seven 5-axis machines. long aluminium sponson parts has over 480
on the Cumbrian lake of Coniston took place With the capacity to machine jobs up to six holes of differing diameters and HyperMILL
in order to drum up interest and funding metres long by two and a half metres wide, reduces the tool changeovers and optimises
for another attempt to better the land speed the majority of work at MKW is aluminium, tool paths with its feature recognition cycle.
record he had held several times. stainless steels, duplex and titanium. MKW also acquired the HyperMAXX
One of the all time great thrillseekers, With high material costs and the overall roughing module, which helps avoid full
Campbell pushed the boat, designed with value of components after machining cutting, sharp corners and edges in the
speeds around 250mph in mind, to its limit. exceeding £25,000, getting the job ‘right first path, thereby preventing abrupt changes in
Out on the water the attempt ended in time’ takes on a new level of importance. direction that drastically reduce the federate.
disaster, the K7 flipping dramatically and Having invested over six million pounds in The Bluebird K7 project was the first to
tragically killing Britain’s most notorious new hardware, the company felt it needed to have the roughing module applied to it,
speed record breaker. upgrade its CAM package to ensure they could and despite the sponson parts primarily
Five years after the original craft was raised manage complex toolpaths needed across the consisting of holes and slots, the application
from the lakebed, a team of engineers ● 1 BlueBird K7 company’s twenty six CNC machines. of HyperMAXX shaved 20 per cent off the
and enthusiasts decided to rebuild it, replica with MKW adopted Open Mind’s four hour machining cycle time for each part.
enlisting the charitable support from sponsons HyperMILL, and with the new The sponsons are now attached to the rest
companies in the North East. ● 2 Mazak Turning
machines installed found new of the craft, although it is still to be fully
Centre producing oil
The full Bluebird K7 craft is & gas parts at MKW benefits, as programming times were completed by the engineering team.
being re-built around the original ●3 Typical satellite slashed in half, and machining times Upon its eventual completion in an
construction, although with many of jig manufactured being 30 per cent faster. estimated two years, the Bluebird K7 will sail
the components no longer available at MKW As well as physical gains, the ability on Lake Coniston and then be the centrepiece
the project is a painstaking process. ●
4 Programming of
to simulate part production before of a purpose built museum on the lakeside,
Bluebird sponson on
Tyneside-based tooling company right hand screen physical cutting, and post-processors a monument to pioneering engineering and
MKW Group provided its expertise to ● 5 Typical oil & gas for each individual machine, provided the man that pushed it to the limit.
manufacture critical components that component at MKW the confidence that the parts would openmind-tech.com | bluebirdproject.com/K7

DEVELOP3D.COM MARCH 2015 45


REVIEWS
Roland MonoFab
» Named after the Japanese concept of monozukuri (meaning: art, science and craft
of making things), Roland’s MonoFab combines 3D printing with CNC machining in two
matched devices. Al Dean puts Roland’s latest offering through its paces

ROLAND ARM-
10 3D PRINTER
TECH-SPECS
» Stereolithography
(SL) build process
using DLP projection
» 130 x 70 x 70 mm
build envelope
» 430 x 365 x 450mm
machine dimensions
» 10mm per hour
build speed
» 17kg
» 0.01mm+ layers
» UV curable resins
» Post processing and
finishing kit included
» 1 year on site
(guaranteed
telephone response
time and engineer
visit times) — 1
extensions available
at @ £734 per

I
» 8kg
doubt that there’s anyone that stereolithography 3D printer. to many other machines in its class, this
» Price €4,999 + VAT
really needs an introduction to For those that are unfamiliar with this builds from the bottom up. The projection
(inc. machine, finishing
kit, resin tray + 350g Roland and its range of hardware technology, it uses a small DLP chip from unit is in the base of the unit and projects
of resin) that supports design and Texas Instruments. These are commonly the light up, through a transparent build
engineering. If you’ve been through the found in today’s projectors and are tray to solidify a layer of material onto
UK’s design and engineering education compromised of a matrix of very small the build platform, which gradually
system, then the chances are that you’ll scale reflectors (up to 8 million of them) increments up in the Z axis.
ROLAND SRM- have come across its machines at some and a light source. These mirrors work to As a unit, it’s clear that you’re dealing
20 CNC MILL point. represent pixels on a screen. with the build quality that you’d expect
TECH-SPECS Roland’s history is, of course, in the In consumer units, visible light is used to from Roland. Getting the thing out of the
wide format printing game, which led display whatever you’re trying to project box is painless and it’s about ready to go
» 3 axis CNC machine the company to start to experiment with on a surface. In this case, the light source as soon as you’ve done it.
» 6mm cutter collect using the same technology to cut material, is UV light and this cures layers of resin About the size of an office desktop laser
» 203 x 152 x 60.5mm rather than just to print on sheets. held between a print tray and a build printer, it looks pretty slick. The orange
build volume Since then, the company has been, albeit platform. is, of course, predominant as it’s required
» 451 x 426 x 426mm quietly, providing 100,000s of units that Interestingly, while the term UV curable to block out any stray light that would
machine dimensions cover a range of capabilities. From CNC resin is commonplace, the pedants out otherwise cure the resin in the tray before
» 2kg workpiece mills of varying sizes to laser scanning there will know that most machines of this you’ve even printed anything.
weight
devices, and sometimes both combined class use violet light (rather than ultra In terms of initial set-up, Roland has
» Cutting speed 6 to into a single unit. violet) in the 405nm wavelength band. But an interesting set of software and online
1,800mm/min stepper
motor With this success, it was perhaps we’ll get onto the specifics of how it works support tools. All of the drivers can be
» Resolution —
perplexing that the company had, until shortly. downloaded by logging into its support
0.01mm (using RML-1) recently, avoided the 3D printing game. Alongside the ARM-10, the MonoFab tool. This lets you then download the
or 0.001mm (using After all, if you have that amount of range also includes a matched CNC software needed to set-up your print jobs.
NC code) customers, that amount of knowledge in machine. This takes Roland’s mastery of While we had a few glitches, these were
» 1 year return to base numerically controlled machines and that the desktop CNC game and packages it up quickly resolved and we were up and
warranty with £349
reputation, then it would make sense. into a nice little unit that matches the 3D running in about 20 minutes.
per year extension
option printer in terms of both size and styling. The machine connects using a standard
» 19.6kg Enter the MONOFAB So, in this review we’ll look at the two USB cable and the usual power adapter.
Despite this, it came as a surprise in machines separately, then wrap things It’s worth noting at this point that before
» Price £2,799 + VAT
the middle of 2014 when Roland finally up at the end to see what you get for you start printing, you need to ensure that
launched its first 3D printing device. What your money and where it can fit into your the workstation you have it plugged into
was interesting was that it didn’t just workflow. has the correct power settings.
release a 3D printer, but rather a brace of Essentially, the ARM-10 runs as a
devices — the MonoFab products. This is THE ARM-10 3D PRINTER secondary monitor. Because of this, you
comprised of two machines. The first, the As we’ve discussed, the ARM-10 uses need to ensure that any power savings or
ARM-10, is a Digital Light Processing (DLP) DLP driven stereolithography. Similarly monitor shut off settings are turned off in

46 MARCH 2015 DEVELOP3D.COM


HARDWARE REVIEW

your power settings. It’ll also only run on a


Windows box.
Once done, you’re about ready to get
set-up for your first print.
There are three key things to do before
you start printing. The first is to install the
build tray. You’ll notice that despite the
build envelope of 130x70x70mm, the resin
tray is in fact 130x130mm. We’ll get onto
why that’s interesting later.
You loosen off the finger clamps, slide
in the resin tray then lock it down again.
Interestingly, the machine includes a
protective shutter that only disengages
when you’ve installed the resin tray.
This will save that resin getting into the
projection gubbins and save you a lot
of grief (other machine manufacturers
should take note of this). You then add in 2
the resin from the supplied bottles. There
are handy marks on the side of the build
tray to make sure you don’t over fill it. platform on screen and you can then Once your parts are arranged, you then ●
1 (Previous page)

The final step is to calibrate the build adjust and position them, add supports add in the supports for the parts. Roland’s The Roland MonoFab
platform. You do this by loosening four and define the print parameters. support structures (compared to other machines — two
manufacturing or
bolts with an Allen key, hit Calibrate in the Now, it’s here that there are some SLA system software) appear heavy. And
prototyping methods
software and it’ll move into position. You curiousities. The software doesn’t give yes, they do use more materials, but the in a matched pair of
then need to push the print head down you any automated tools to assist with the results that we got with the machine devices
into tray so that it’s flush with the bottom correct orientation of your parts. In some indicated that heavier supports mean that ●
2 The Roland ARM-
of the tray. respects, this is good for those looking you’re less likely to have a failed build 10’s build method. UV
Now tighten up those bolts. Once done, to experiment and that have a working — and in the professional space, that’s light is projected from
you’re ready to rock and roll and get your knowledge of how these machines work. essential. beneath, through the
build tray to solidify
first print underway and, as ever, you need However, if you don’t, or you just want to You then define the build parameters for the model onto the
to jump into the supplied software to do it. get it working, you’re probably stumped. the print job. The ARM-10 is supplied with build platform above
The reason for this is that these machines just a single material. It’s a standard clear
SET-up software have some peculiarities centred on how resin as you can see in the above image.
Roland has always had interesting you need to orient the parts. Typically, What’s interesting is that Roland has
software and the supplied software with you need to have them at 45 degrees to exposed all of the settings for the process
the ARM-10 is equally as interesting. It the horizontal to avoid building heavy so while you can dive in and build parts,
steps through the workflow, beginning cross sections. It’s pretty trivial to do this you can also experiment with other resins
with import and healing of the STL manually, but some automation would be from the burgeoning market for such
data. It’ll place your parts into the build useful right at this point. materials.

workflow: SET-up AND BUILD WITH ROLAND’S ARM-10 SLA 3D PRINTER


1 The starting point is to import, scale (if needs be), heal ●
2 The ARM-10 builds using a bottom up, DLP approach. ●3 Once ready, you start the print process. The system
and then orient your parts. Roland's software doesn't have You need to position the resin tray, add your material, then them repeats the same process. The platform lowers into
automatic orientation tools, so you need to work the best calibrate the print platform — done by lowering the build the build platform, exposes a layer’s form, retracts, then
approach manually. Then generate the supports platform, then manually adjusting it to be flush with the tray lowers. Over and over again till the part is complete


4 Removing the build is simply a case of undoing a single ●
5 The supplied finishing kit gives you everything you need ●
6 Once rinsed and dried, you can then use the supplied
large knob and removing the platform from the machine. except rubber gloves and isopropyl alchohol (IPA) for cleaning tools to remove the parts from the support structure and
It’s worth noting that the machine will retract the build up the part. You use the scrap to remove the parts safely and start to clean them up ready for use. Any post curing is also
platform and notify you on screen when it’s ready cleanly then rinse in the IPA to remove any residual resin advisable at this stage

DEVELOP3D.COM MARCH 2015 47


48 D3D Ads.indd 1 18/02/2015 09:11
HARDWARE REVIEW

over your layer thickness, but it’s quoted


as running as fine as 0.01mm. Build times
will, of course, increase at that level, but a
balance can be struck between build time
and resolution as you see fit.
One thing we briefly mentioned was the
double size build tray. This is a curiousity
in this machine. While the build platform
(in terms of horizontal size) is 130x70, the
resin tray is in fact 130x130mm.
Why is that the case? I’m not entirely
sure, but what it does mean is that when
the PDMS layer on the resin tray starts to
cloud through exposure to the UV light,
which is inevitable on all similar machines,
you can take it out and rotate it 180
degrees and get another set of builds out
3 of the same tray.
As I mentioned, I’m not too sure why
Roland has done it. A full build platform
●3 The SRM-20’s When it’s ready, you hit go. The machine the part off with the supplied scraper, might have been more useful and would
build plate is usefully then sends the layer data to the machine and pop into a tub of isopropyl alcohol. give similar build capability as the Form
large and lets you
and starts to build. It runs very quietly as Give it a swirl around, then move the part 1+. It certainly gives you a little extra bang
rip through softer
materials. It won’t do the whole unit is pretty solid. There’s very to the second tub for a further rinse. It’s for the buck on consumable items.
metals, but almost little in the way of sheet metal (a problem tempting to remove the supports, but let
anything else is with the cheaper end of the spectrum the part rinse and get all the excess resin THE ROLAND SRM-20 CNC MILL
possible. It’s just a machines in this class) and because of the off before you start clean up. Alongside the 3D printer, the other half of
shame it doesn’t come build process, there are very few moving Next steps are that you can dive in and this rather impressive duo is the SRM-20.
with t-slots for better
workpiece holding parts, apart from the Z axis control for the break out your part (Roland’s supports This, as you’d expect from Roland, is a
build platform. break away nicely, even if they are a little smaller scale 3 axis CNC machine.
heavy). You’re supplied with a pair of flat The unit is a lot heavier than the 3D
RESULTS bladed snips, but I’m sure you’ve all got printer, but packed into a similarly sized
Once the build has completed, you’ll find your own personal set of tools for cleaning package. Again, the device is set-up and
a message on your workstation and see up 3D prints. installed using Roland’s support software.
your build platform up in the air inside Once done, the parts need a bit more Whereas the ARM-10 uses a single
the machine. To remove, it’s simply a case curing. We discussed the use of a UV application for set-up, with the SRM-20,
of flipping up the lid, undoing the large sterliser in our FormLabs Form 1+review you have a number of different options.
thumb wheel and removing the build back in October 2014 and the same stands The majority of work will be done
platform (don’t forget to remove the lid here. If you don’t want to go that route, through Roland’s ever present Modela
when that’s done). then a period in the sun will do the trick, Player application. This gives a backed
The ARM-10 is supplied with a nice just more slowly. in set of tools that allows you to import
finishing set-up. There’s an injection The resultant parts from the ARM-10 are part geometry, arrange it and then
moulded breakout tray with a pocket to just as you’d expect. The models are clean, program the tool-paths you need to cut
fit the build platform into. You then lever crisp and precise. You have full control the material.

WORKFLOW: USING THE ROLAND SRM-20 WITH AUTODESK FUSION 360 CAM

●1 Fusion allows CAM toolpaths to be programmed in ●2 Once you've switched to CAM mode, you begin by defining ●3 To create your first operation, put some work into
context, but if you’re looking to machine more than one per a set-up to represent your stock and datum alignment and defining your tooling in the tool library, so they can be
assembly, create a copy position reused — it’s worth including a model of the cutter holder

●4 Next step is to start to define the operations. HSM works ●


5 Once you've created and simulated your operations, you ●
6 Once you’re happy with your operations and have
includes adaptive roughing and clearing and these are a then need to post process. Handily, Fusion includes a Roland exported them using the appropriate post processor, you
good place to begin as they’ll remove material quickly post processor so will spit out the G-code you need can load them into Roland’s vPanel and get cutting

DEVELOP3D.COM MARCH 2015 49


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50 D3D Ads.indd 1 18/02/2015 09:14


HARDWARE REVIEW

The whole thing is geared up for the prototyping thumbscrews) to have a low-profile vice — and if they
process, supports the use of tabs (to retain don’t, they should. MONOFAB
components) and even steps into double sided cutting.
Alongside this, there are also a few other
If you’re looking to get into double or multi-sided
cutting, then the device is also supplied with small SHOPPING LIST
applications, that range from tools for designing pins that, with some tricks detailed in the manual (in
engraved forms from scratch to ClickMill, which lets fact, the subject has its own PDF manual), allow you UV tool steriliser (~£40): As we
you quickly define a toolpath and have it cut on the to locate and subsequently flip the workpiece into the discovered in previous tests, a UV tool
machine — ideal for facing off or trimming blank same position. steriliser, as used in beauty salons, is
material. Next up, it’s cutter time. The SRM-20 uses a 6mm an excellent option for post curing your
Another key component in the software stack is collet chuck that’s removable with a supplied spanner. models quickly.
the Controller application. This works just like your If you want to run smaller cutters, then there are also
Siemens or Heidenhain hardware controllers and is the 3, 4, 5 and 3.175mm collets available for £40 a piece. Ultrasonic Parts Washer (~£80): We
point where you load the G-code, set-up datums and Into this collet, you insert the cutter, set the depth discovered this one recently. A small
origins as well as have full real time manual control and tighten up with a small grub screw (and yes, they
scale ultrasonic parts washer, filled with
over spindle and feed rates. supply a couple of spares thankfully). You then screw
70/30 IPA/Water gives your parts a good
The latter is essential when you’re fine tuning the that into the spindle and nip up tight with a spanner.
best parameters for your cutters, the material and Here, it’s worth noting that there are two possible clean and helps with curing.
the machine. Ease the feed-rate off as you start, then positions for the spindle. One gives you full height,
ramp things up once confident you’re not going to but the other lets you drop the spindle (and hence the 405nm laser pointer(~£6): Whether
rip the machine apart at its, albeit well constructed, cutter) if you want to run things more tightly. you’re joining larger builds or fixing
seams. It would be nice if you could acquire spare collets parts in place, a decent method is to
What’s also interesting is that while the Roland to hold your eventual range of cutters, to save on use a UV laser pointer to cure a little
software tends to use its own proprietary RML-1 removing the whole shebang, setting the length and resin to solidify facts from support break
language, it’s also perfectly capable of running such. away.
‘standard’ G-code. This means that, given an
appropriate post processor, you can use pretty much First cut is the deepest
Isoprophyl Alcohol (~£5 per litre):
any CAM software you want or have access to. When that’s all done, you need to set the datum/
We did some trials with Autodesk’s Fusion 360 CAM origins for the toolpaths you want to run. This is done Used to dissolve any excess resin.
tools (see workflow on page 49). After a little bit of in the controller software and by moving the spindle Get hold of 5 litres as a start. Keep it
tinkering with origins and ensuring they matched up in to the correct X and Y positions, then also setting the Z clean and you’ll get nice clean prints as
both the CAM system and in the controller software, it origin separately. a result.
worked a treat. The benefit we found was that you end You then load in the G-code (you can batch load
up with much more intelligence and efficiency in your these, assuming you’re running multiples with the Microfibre cloths: These are essential
toolpaths (meaning quicker cycles), and have more same cutter) and set the machine running. Again, for cleaning the base of the resin tray to
control over collision checking (assuming you have put just as with the ARM-10, you need to ensure that your keep your builds nice and crisp.
the work into the tooling libraries). workstation is running without those pesky power
saving options — as it’s streaming in the G-code as it
Non-powdered gloves: Get them, wear
stock set-up cuts.
Once you have your tool-paths ready, you then need The cutting speeds and feeds are completely them.
to set-up the machine. This, of course, is a two step dependent on the material you’re working with and
process — the material on the table and the cutter in your cutter. Henry the Vacuum Cleaner (~ £99):
the chuck. You’ll also need to bear in mind step down when He’s cheerful, he’s reliable and he’s got
The SRM-20 features a pretty good sized table and you’re working with hard materials. With foam and a face on him. He’ll also work unlike the
you have a number of options for fixing your material softer materials, you can really let this thing rip and dust buster type product we initially
to it. The machine comes with double sided adhesive you can see your part emerging from the swarf and used.
tape and this works for most materials, assuming that dust as it removes material.
you’re not running it too hard. I’m sure someone will Once your first set of tool-paths is complete, it’s
adapt the steel table (which fixes in place with four then time to switch your cutter. You need to go

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DEVELOP3D.COM MARCH 2015 51


HARDWARE REVIEW

through the same set-up process. Assuming that on its own. includes the spindle unit) every 2,000 hour of
you’re running with the same origins, it’s essential On the 3D printing front, it really is odd that this cutting and they come in at around £270 for the
that you get the cutter lengths correct. isn’t possible, particularly when you consider that lot.
the system is essentially flashing a series of PNG We’ve also included a handy shopping list on
CONCLUSION or similar files through a projector. That said, the page 51 to give you an idea of costs and ancillaries
It’s hard to find fault with this pair of Roland computing requirements aren’t too heavy, so an that might be useful.
machines. They’re built like tanks, they’re reliable older standard PC should do the trick for both. Ultimately, it seems strange to look at two very
and they work perfectly once you’ve, as with all In terms of costs, we’re looking at around £7,998 different production methods in one review —
machines, learned the ins and outs of the process. for both. As you’d expect, that’s comparable after all, you wouldn’t want the machines running
With the ARM-10 3D printer, this is always down to buying similar devices separately. In terms alongside each other. Seriously, the dust, while
to ensuring that you’ve got adequate support for of costs, on the 3D print side, you’re looking at contained in the SRM-20, is a pain to clean out and
your parts — the rest is pretty reliable. With the resins and built trays. They come in at £64.99 you don’t want that anywhere near the 3D printer.
SRM-20 CNC, it’s down to good tool-paths and for 350g of the resin and £99 for the resin trays But when you consider the nature of many design
matching your cutting settings with the material. (remember, you get two bites at that particular offices’ prototyping requirements, it makes
Once done, both will give you good results. cherry by flipping it around). perfect sense. Many are currently debating 3D
If I had criticisms of both, it would be the simple On the CNC side, you’re looking at materials print vs. CNC.
fact that they need to be attached to a computer (which can vary) and, of course, cutters. The What if you could have both, running off one
that’s permanently on while the machines are machine is supplied with a 3mm ball nose, but machine in the corner of your office. Considering
running. In the case of the SRM-20 CNC this is you’ll soon find your collection growing. that you’re looking at two key prototype
understandable — as you’d need to have control The spindle unit, while rated for 1,000 hours, production methods, which vary greatly, but cover
over the machine while it’s running at first. That will eventually need replacing. The Spindle motor all those bases, for just a shade under £8,000,
said, once you’ve got the hang of things, it’d be is rated for 2,000 hours, so you’ll need to plan they represent a solid investment.
nice to be able to disconnect and have it running on one spindle unit and one spindle motor (which rolanddg.co.uk

DESKTOP FACTORY: WHAT’S OUT THERE AND WHAT’S COMING?

Machine: Form1+ Machine: ProJet 1200 Machine: XFAB Machine: Autodesk


Supplier: FormLabs Supplier: 3D Systems Supplier: DWS Systems Supplier: Ember
Price: $3,299 Price: $4,900 Price: Around $5,000 Price: $5,995

Funded through Kickstarter, but heavily VC Considering it invented the DWS or Digital Wax Systems has made Based on a DLP projection build process,
backed, FormLabs reignited the interest stereolithography process, 3D Systems a name for itself by building ultra high Autodesk’s Ember printer is at the beta
in stereolithography. When we looked at has been slow to release a lower cost resolution machines for specialised test stage as units roll out to users that
the Form 1+, we came away impressed by unit. The ProJet 1200 is a compact unit, industries, from jewellery to medical, have paid up in advance. Featuring 25
the build results, the reliability and the built initially for the jewellery and small wherever resolution is key. Its master of micron build layers and a fast build
affordability. Expect this company to do intricate component markets, where materials also shows in the forthcoming process, it’s looking good for Autodesk’s
very interesting things in the coming years investment casting is common. New XFAB machine, aimed at the desktop first foray into 3D printing hardware.
— killer machine and killer usability with a materials options have also opened up its market. Working area will be DEVELOP3D has an early build unit and will
decent sized build platform. Exactly what a use potential. Let’s hope we see more from 180×180mm and the results look be reporting in the coming months on how
design office needs. 3D Systems in this vein. impeccable. things are progressing
■ formlabs.com ■ 3Dsystems.com ■ dwslab.com ■ spark.autodesk.com/ember

Machine: OtherMill Machine: Carvey Machine: ShopBot Desktop Machine: Muncaster S6


Supplier: OtherMachine Co. Supplier: Inventables Supplier: Shopbot Supplier: Muncaster Technologies
Price: $2,199 Price: $1,999 Price: $5,799 Price: To be confirmed

Funded through Kickstarter, Other With the experience Inventables has Favourites of the larger MakerSpace or While the other machines are definitely
Machine Co’s OtherMill is a small scale CNC gained from its ShapeOko machines, the hackerSpace, Shopbot has built a name at the desktop, Muncaster technology
machine (140 x 114 x 31mm). It’s controlled company has launched the Carvey on for itself as a provider of larger format is a new entrant into the market aiming
using cloud-based programming (powered Kickstarter. It gained a lot of exposure CNC routers over the last few years. between the desktop machines and
by Autodesk’s HSMworks code) and will — like that typically associated with a 3D The smallest product in its range is the entry level, full scale, CNC machines. Its
handle a variety of materials including printer. With a larger build volume (300 ShopBot Desktop. Offering a 610 x 460 x products can be placed in the office or
some non-ferrous metals (they’re aiming x 200 x 70mm), its styling was done by 89mm build volume, it’s a smaller form workshop environment with some serious
it at prototyping PCB boards). Priced at Minimal, though how it’ll look covered factor machine that could be useful in the machining capability, including automatic
$2,199, it’s a small, portable machine that in model board dust is another matter. prototyping process. tool changers, 5 axis options. It’s launching
might just fit your workflow. Pricing again around the $1,999 mark. at DEVELOP3D Live 2015 too!
■ othermachine.co ■ inventables.com ■shopbottools.com ■ muncastertechnologies.com

52 MARCH 2015 DEVELOP3D.COM


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develop3d-2015-02-12-renda-microsoft.pdf 1 13/02/2015 14:56:36

Overclockers Ad.indd 1 18/02/2015 09:16


HARDWARE REVIEW

Novatech E5-1620V3
» With its Xeon CPU, ECC RAM and flexible storage this CAD-
class desktop also shows potential for CAE, writes Greg Corke

P
» Intel Xeon E5- ortsmouth-based Novatech which is also available in larger capacities
1620V3 (3.5GHz up to makes its DEVELOP3D should 120GB be too small (we only had
3.6GHz) (Quad Core) debut with a mainstream, 20GB free after installing our test suite).
processor
CAD-focused quad core Those working with memory intensive
» 16GB (2 x 8GB) workstation. But rather than applications may also benefit from using
Samsung 2,133MHz
DDR4 ECC memory using a popular Core i7 chip, the Novatech four DIMM slots instead of two, enabling
E5-1620V3 Workstation is based on the the Xeon’s quad channel architecture to
» 120GB Intel 520
SSD + 3TB Seagate Xeon CPU of the same name. deliver more memory bandwidth. 1
Barracuda HDD Intel Xeon means Error Correcting All of the components are housed in a
» Nvidia Quadro Code (ECC) memory as standard, which, matt black chassis, which is nicely laid out
K4200 (4GB GDDR5) on paper, means fewer crashes. While with 2 x USB 3.0 and 1 x USB 2.0 on the
GPU (341.21 driver)
we’ve never had any problems running top. Directly behind these is a neat HDD
» Supermicro X10SRI-F CAD on Core i7 workstations, Intel / SSD docking station where you can plug
motherboard a
certainly considers ECC to be essential for in a 2.5-inch or 3.5-inch drive, much like
» Microsoft Windows 7
Professional 64-bit
professional workstations. If you carry a Nintendo games cartridge. It’s a great
out complex FEA or CFD studies that take idea, particularly for those that want their
» 490mm (H) x 200mm b
(W) x 493mm (D) hours, even days, ECC memory can help data to move with them, but can be a little
» One year return
reduce the chance of losing data half way fiddly to guide drives into position.
to base warranty through and having to start again. Additional accessible storage can be
included. For 3 years That’s not to say our test machine is really found behind a push and click door at the c
add £80 and 3 years geared up for simulation. With four CPU front of the machine that features two hot
on site add £321. More
options available
cores running at 3.5GHz, a Quadro K4200 swap drive bays, so you can plug-in and
d
GPU for graphics and 16GB of DDR4 ECC remove drives without powering down.
memory, this mid-sized workstation has Five internal 3.5-inch bays round out the
2
£1,654 + VAT
mainstream CAD written all over it — and extensive storage options, populated in
novatech.co.uk
this is backed up by solid scores in our our test machine with the Intel SSD and
» CPU benchmarks Creo, SolidWorks and single run PowerMill 3TB Seagate HDD.
(secs - smaller is better) benchmarks. However, with the option of Overall, the Novatech E5-1620V3 is an
CAM (Delcam PowerMill) 6, 8, 10 or 14 core Xeon CPUs and up to interesting proposition for CAD users who
1) 164 2) 246 3) 345
Rendering (3ds Max
256GB RAM, the Novatech E5-1620V3 can want the added security of ECC memory. 3
Design 2015) - 243 be turned into a powerful machine for Easy access storage is a big plus, but the
simulation. This is not really possible with a machine is let down by the disappointing
» Graphics benchmarks
(bigger is better) Core i7-based workstation. Novatech makes SSD. But perhaps its greatest appeal
CAD (SolidWorks 2013
- SPECapc graphics
customisation easy at time of purchase comes from its potential. With up to 14 3
through an intuitive online configurator. CPU cores, 256GB of ECC memory and
composite) - 8.30
CAD (Creo 2.0 - SPECapc
And it could benefit from a few tweaks. eight drives there’s plenty to interest
graphics composite) - 8.35 The 120GB Intel 520 SSD, quoted as ‘end simulation specialists who want a powerful
of life’ on Intel.com, was disappointing. desktop for complex studies but don’t ●1 The bottom two panels on the Novatech
Eclipse chassis push open to reveal two hot-
Sequential write speeds were well below have budget for a dual CPU machine.
swappable drive bays
par and CAD software took noticeably Finally, the machine comes with a one
longer to install than other machines we’ve year return-to-base warranty, significantly ●2 Workstation interior ●
a ●b eight DIMM slots
for up to 256GB RAM ● c hard drive cage can hold
seen recently (reading and writing from less than the 3 years offered by most up to five 3.5” drives ●
d Hot swappable, front
the same drive). However, Novatech offers workstation manufacturers, but this can access drive bays with blind mate connectors
a big choice of higher performing drives, be extended all the way up to fives years, ●
3 HDD / SSD docking station where you can
including the excellent Samsung SS 850 Pro, including on site support (see box left). plug in a 2.5-inch or 3.5-inch drive

INTEL CORE i7 vs INTEL XEON CPUs highly. The Intel Xeon E5-1620
v3 goes up to 68 GB/s thanks to
its quad channel DDR4 memory
Xeons support Error Correcting
Code (ECC) memory, whereas
Core i7 chips do not.
preferred workstation-class cores running at a nominal clock architecture while the Core ECC memory is designed to
processor, the Xeon? speed of 3.5GHz. i7-4770K only reaches 25.6 GB/s reduce the chance of a memory
The obvious answer is if you Setting aside the important fact with dual channel DDR3. error occurring. This shouldn’t
want access to more CPU cores. that specialist system builders be an issue for mainstream CAD
The Xeon E5-2600 v3 series, can readily overclock the Intel Memory capacity is also users but when you’re running
which is supported in some single Core i7-4770K to 4.4GHz — which dramatically different, which a two day FEA simulation you
processor machines including the makes CAD software fly — the is crucial if you want to work want to do everything you can to
Novatech E5-1620V3, goes all the main difference between the two with complex datasets. The Core ensure it doesn’t crash half way
Most of the single processor way up to 18 cores. CPUs comes down to memory. i7-4770K peaks at 32GB, while through. While it is still highly
workstations we review at But when you start comparing the Xeon E5-1620 v3 can (in unlikely a workstation with Non-
DEVELOP3D feature Intel Core Core i7 to the dedicated single Memory bandwidth can be theory) go right up to 768GB. ECC memory will crash due to a
i7 CPUs. While these desktop socket Xeon E5-1600 v3 Series, important for memory intensive With current machines 128GB or memory error, ECC memory does
chips are considered ‘consumer- the differences are more subtle. applications, such as Finite 256GB is more common. gives you a bit more re-assurance.
grade’, we have found them to be Take the Intel Xeon E5-1620 v3 Element Analysis (FEA) or However, it should be noted that
perfectly adequate for professional CPU for example. Just like the Computational Fluid Dynamics Memory reliability is perhaps ECC is a bit slower than non-ECC
CAD work. So why invest in Intel’s Intel Core i7-4770K it has four (CFD) and here Xeon scores the biggest differentiator. All memory and also costs a bit more.

DEVELOP3D.COM MARCH 2015 55


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PNY Ad.indd 1 18/02/2015 09:17


HARDWARE REVIEW

Scan 3XS GW-HT20


» With eight CPU cores running at a whopping 4.2GHz, this single CPU workstation from
Scan offers an exciting proposition for design viz users on a budget, writes Greg Corke

D
» Intel Core i7 5960X ual CPU workstations have which means all four memory modules can a media card reader and DVD drive.
Extreme Edition long been essential for those be accessed at the same time (the Core i7 However, it can be pain to have to leave the
(overclocked to
serious about rendering. And 4790K has two channels). door half open to access these. There are
4.2GHz) (Eight Core)
processor with the latest Intel Xeon E5- With 4 x 2,666MHz 4GB DDR4 memory more USB ports at the rear of the machine.
» 16GB (4 x 4GB) 2600 v3 CPUs delivering 8, 10 DIMMs the Scan 3XS GW-HT20 is set up At 495mm x 210mm x 484mm it’s a
Corsair Vengeance or 12 cores at decent clock speeds, there is to make the most of the quad channel little bulky compared to similar machines
LPX DDR4 2,666MHz plenty here to excite hardcore users. architecture. However, it does mean the from Lenovo (ThinkStation P500), Dell
memory But, with high-end Xeons like the ten core are no spare slots for upgrades so choose (Precision Tower 5810) and HP (Z440),
» 256GB Samsung SSD E5-2687W v3 (3.1GHz, Turbo to 3.6GHz) wisely when deciding on a spec. but the spacious interior makes for easy
850 Pro + 2TB Seagate
Barracuda HDD
costing the best part of £1,500, those Drawing 140W at peak the Extreme servicing. Swapping out hard drives
dreaming of lightning fast renders soon get Edition processor demands some serious does require both side panels to be
» Nvidia Quadro
K4200 (4GB GDDR5) a dose of reality when budgets are set. cooling, and to unscrewed and popped off, but it’s a pretty
GPU (341.05 driver) The good news is there is some middle ensure it straightforward operation.
» Asus X99-S ground here and Scan’s latest 3XS GW-HT20 Our test machine has a familiar two-
motherboard workstation is leading the charge. With drive setup: a 256GB Samsung 850 PRO
» Microsoft Windows 7 Intel’s Extreme Edition Core i7 5960X SSD for Windows 7 Professional 64-bit and
Professional 64-bit processor at its heart, the Bolton-based applications and a 2TB Seagate Barracuda
» 495mm (H) x 210mm manufacturer has put together a single SATA HDD for data. The 850 PRO is a
(W) x 484mm (D) CPU machine with a substantial eight firm favourite at DEVELOP3D — both
» 3 year warranty – 1st cores. And, unlike Intel’s Xeon CPUs, for performance and endurance, as it is
Year Onsite, 2nd and
3rd Year return to
which are locked to their base speed, backed up with a 10-year limited warranty
base (Parts & Labour) the 3.0GHz chip has been clocked up to based on a 40GB daily write workload.
a whopping 4.2GHz. Graphics comes courtesy of an Nvidia
£2,247 + VAT This is familiar territory for Scan who Quadro K4200 (4GB), an excellent choice
3xs.scan.co.uk has an enviable pedigree in overclocked for high-end CAD that packs a real
machines. But while we are used to seeing punch. Buoyed by the 4.2GHz processor,
» CPU benchmarks its Quad Core workstations cut through it delivered some excellent scores in our
(secs - smaller is better)
our single threaded CAD benchmarks, SolidWorks and Creo tests. And while
CAM (Delcam PowerMill)
1) 138 2) 153 3) 180 the 3XS GW-HT20 also delivers in multi- the Quadro K4200 should be a good
Rendering (3ds Max threaded visualisation software. The 111 fit for most CAD users, a £850 upgrade
Design 2015) - 111 seconds it took to cut through our 3ds Max to a Quadro K5200 (8GB) should boost
» Graphics benchmarks ray trace render might not rival the dual performance in visually intensive apps
(bigger is better) CPU monster that is the Lenovo ThinkStation remains like 3ds Max.
CAD (SolidWorks 2013 P900 (66 secs), but it stands head and within its thermal We’ve seen more than our fair share of
- SPECapc graphics
composite) - 9.60 shoulders above any other single CPU limits, and fan noise is kept to a minimum, single CPU workstations over the years,
CAD (Creo 2.0 - SPECapc workstation we’ve seen at DEVELOP3D. Scan has employed a custom Corsair H100 but none have packed such a punch for ray
graphics composite) - 8.73 In addition to having access to more watercooling system. This compact, sealed trace rendering. With eight cores running
CPU cores, the other advantage of the unit clamps straight onto the CPU and at 4.2GHz the Scan 3XS certainly offers an
Extreme Edition Core i7 5960X processor is exchanges heat with a radiator. Two low exciting proposition for CAD users who also
higher memory bandwidth, which should duty fans push out hot air through vents at need quick turnaround of photorealistic
speed up some CPU operations. While the top of the Corsair Carbide 330R chassis. stills and animations.
mainstream chips like the Core i7 4790K This matt black case has become a There’s also plenty to interest users of
peak at 25.6GB/s, the Core i7 5960X takes mainstay of Scan’s 3XS workstations over simulation software though CAE specialists
this all the way up to 68GB/s. This is thanks the years and is solid and well built. Two may feel more comfortable with a Xeon-
to support for faster DDR4 memory (the USB 3.0 ports at the front are nicely located based workstation, backed with ECC (Error
Core i7 4790K supports DDR3) as well as at the top of the machine. Two more can be Correcting Code) memory to protect against
the quad channel memory architecture, found behind the front door panel, alongside potential crashes on long FEA or CFD runs.

●1 The 140W CPU


is cooled with a
custom Corsair H100
1 2 3
watercooling system
●2 To add or remove
drives, both side panels
need to come off. Drive
trays can take 3.5-inch
drives and 2.5-inch
drives with an adapter.
●3 The solid, matt black
Corsair Carbide 330R
chassis is sizeable
but benefits from a
spacious interior

DEVELOP3D.COM MARCH 2015 57


HARDWARE REVIEW

Lenovo ThinkStation P900


» This dual CPU powerhouse may come with a serious price tag, but for CAE specialists
who seek true design optimisation it should be money well spent, writes Greg Corke

T
» 2 x Intel Xeon E5- here are desktop workstations There’s a big choice of SATA SSDs, SATA intensive 3ds Max and Delcam PowerMill
2687W v3 (3.1GHz, and then there are behemoths HDDs, SAS HDDs and hybrid drives to tests. However, it’s interesting to note
Turbo to 3.6GHz) (Ten like the ThinkStation P900. suit all requirements. RAID 0, 1, 5, and that the HP Z640 we reviewed last month
Core) processors
And Lenovo’s flagship P-Series 10 is supported on the motherboard for (tinyurl.com/HPZ640-D3D), which featured
» 128GB (16 x 8GB) workstation is a beast, with performance, fault tolerance or data two eight core, 3.2GHz Intel Xeon E5-2667
DDR4 2,133MHz ECC
RDIMM memory performance to support the most demanding redundancy. SAS drives require an optional v3 CPUs, still came out slightly on top in
» 512GB M.2 SSD + product development workflows and HDD controller. these tests. It’s not what we would have
512GB SATA SSD overflowing with expansion options. While most users will be content with the predicted.
» Nvidia Quadro Fully loaded it can hold two high-end standard drive bays, there are some other The ThinkStation P900 certainly benefits
K5200 (8GB GDDR5) Xeon E5-2600 v3 Series CPUs, 512GB DDR4 interesting options. from its high-end Quadro K5200 GPU,
GPU (347.25 driver) memory, three double width GPUs (for Two additional drives can be added to the which delivered a strong performance in
» Microsoft Windows graphics or compute) and 14 storage devices. FLEX Bays at the front of the machine. This our SolidWorks and Creo tests and will
7 Professional 64-bit If you need a workstation that can deliver could be of particular interest to those who be a good match for those pushing the
(pre-installed through
downgrade rights in the compute performance and I/O that ultra frequently swap drives — perhaps to store boundaries in design viz applications like
Windows 8.1 Pro 64) high-end Computer Aided Engineering (CAE) overnight in a safe — as access is possible 3ds Max. Those focused on simulation,
» 446mm (H) x 200mm or design viz demands this is it. without having to remove the side panel. rather than visualisation, may consider
(W) x 620mm (D) The chassis is substantial but its solid For those that want PCIe storage, and the cutting back here to a Quadro K2200 or
» Three-year limited metal frame oozes quality. Weighing in at bandwidth advantages it has over SATA, K4200, and perhaps adding one or more
warranty with on-site, around 30kg — the best part of a business there’s room for up to four 512GB M.2 compute boards like the Nvidia Tesla K20 or
next business-day flight luggage allowance — and with SSDs. One or two of these tiny drives can Xeon Phi 3120A. Of course, this depends on
service for parts and
labour dimensions of 200mm (W) x 620mm (D) be housed on a bespoke small footprint budget and application support.
x 446mm (H) you’ll need a spacious and FLEX Connector card, a technology unique With 128GB (16 x 8GB) of DDR4 system
£12,213 ($18,686) sturdy work environment. to Lenovo that provides a way to expand memory the ThinkStation P900 is set up
lenovo.com Hauling it into position is made easier storage (as well as future I/O technologies to handle some hugely complex datasets.
thanks to two handles at the front and one like Thunderbolt 2) without taking up a full It laughed in the face of our attempts to
» CPU benchmarks at the back. They are totally integrated into sized PCIe slot. stress it, delivering the results from four
(secs - smaller is better) the main body of the chassis, making for an concurrent toolpath calculations in almost
CAM (Delcam PowerMill)
1) 165 2) 167 3) 172
elegant and robust design. THE TEST MACHINE the time it took to do one. To put this
Rendering (3ds Max The biggest innovations are inside The Lenovo ThinkStation P900 certainly in perspective, a quad core, single CPU
Design 2015) - 66 the box, where Lenovo has made every takes first prize for most expensive workstation, would typically take around
» Graphics benchmarks component eminently serviceable. Red workstation we’ve seen at DEVELOP3D. four times as long.
(bigger is better) touch points draw the eye to those that With two top-end Intel Xeon CPUs, 128GB Indeed, with 20 CPU cores and 128GB
CAD (SolidWorks 2013 can be removed and replaced without a DDR4 memory, fast PCIe and SATA SSD DDR4 memory to play with there’s plenty of
- SPECapc graphics
composite) - 9.37
screwdriver. This not only includes drives storage and a high-end Quadro K5200 GPU scope for running multiple compute tasks at
CAD (Creo 2.0 - SPECapc and PCIe cards, but the Power Supply Unit our test machine will set you back just the same time. This should be of particular
graphics composite) - 8.62 (PSU), fans and even the motherboard are over £12,000 ($18,500). interest to users of Finite Element Analysis
tool-less by design. The Xeon E5-2687W v3 CPU is Intel’s (FEA) or Computational Fluid Dynamics
The drive trays are a particular delight. ‘workstation’-specific Xeon chip. With ten (CFD) software looking to get quick
Simply pull out a tray, clip in the drive(s) cores running at 3.10GHz it is designed performance feedback on different design
and push back in. Thanks to a blind connect to offer the best balance of CPU cores options in an iterative workflow.
backplane, there are no cables to worry against clock speed — which is good While 128GB RAM seems an incredible
about as drives automatically connect to news for both single threaded CAD tools amount for a desktop workstation, the
power and data. and multithreaded ray trace rendering, machine can actually go all the way up to
There are four trays in total: two at the simulation and CAM applications. 512GB. This should be of particular interest
bottom and two at the top of the spacious The benchmark figures speak for to those really pushing the boundaries of
interior. Each is designed to house one themselves with the ThinkStation P900 desktop simulation, though would add a
3.5-inch drive and one 2.5-inch drive. delivering excellent scores in our CPU cool $11,000 onto the price of the machine.

1 2 3

58 MARCH 2015 DEVELOP3D.COM


Of course, having buckets of processing
power and memory is no good without fast
storage to back it up. And with a 512GB M.2
SSD and 512 SATA SSD our test machine
scores highly.
Running over the PCIe bus the 512GB
M.2 SSD boasts two to three times the
bandwidth of SATA, which is great for
reading and writing huge datasets very
quickly. And with a 512GB SATA SSD for
support there’s scope to share the load
between drives. With space for 12 more
drives it is possible to build some complex,
high performance disk arrays.
With only 1TB in total, the obvious omission
from this machine is capacity; not a problem
if you connect direct into a server or NAS,
but adding a couple of 4TB SATA drives
will hardly break the bank — presuming, of
course, it isn’t broken already.
And this brings us nicely back to the topic
of price and our closing thoughts. No doubt
there will be designers and engineers that
baulk at the idea of buying a workstation
that costs as much as a family hatchback.
And if you run CAD, with a little bit of
simulation or rendering, then by all means
get a £2,000 single CPU workhorse and bag
7
yourself a Ford Fiesta out of the change.
But if you’re heavily into design
visualisation — and particularly simulation
— then the ThinkStation P900 is certainly
one to watch. Optimise the hell out of your
design / simulate / iterate workflows and
you could pay for the machine in one project.
Of course, there are less expensive
configurations — Lenovo showed us a base
model starting at £1,700 — but this kind of

1 The internals are neatly laid out with four drive bays ●
6 The M.2 SSD is housed on a FLEX Connector, a bespoke,
misses the point. The ThinkStation P900 located along the right for easy access small footprint PCIe card. The P900 includes two FLEX
is all about delivering ultimate power and Connector ports: the second can be used to accommodate

2 Each drive tray can house 1 x 2.5-inch drive and 1 x 3.5-
add-on technologies such as RAID cards and additional
expandability. Settling for an entry-level inch drive. Both clip in easily.
model would be a bit like buying a Ferrari I/O - including Thunderbolt or card readers

2 A blind connect backplane at the rear of the drive bay
with a Ford Fiesta engine. means drives automatically connect to power and data ●
7 The solid chassis features integrated handles top and
bottom and four nicely spaced USB 3.0 ports. One USB
● The Power Supply Unit pulls out for easy servicing
4
port is always on so you can charge your smartphone
To read more about the customisation ●
5 Fans feature blind connectors for easy replacement when the machine is off. Another can be used for
features of the ThinkStation P900, check out or cleaning. Fan noise was noticeable when idle but diagnostics - an error log can be downloaded to an
our preview (tinyurl.com/D3D-Think) remained at the same level even under heavy loading Android or Windows phone or tablet or a USB stick

4 5 6

DEVELOP3D.COM MARCH 2015 59


DEVELOP3DSERVICES
To advertise YOUR services here contact STEVE KING
STEVE@X3DMEDIA.com | +44 (0) 20 3355 7314 | +44 (0)7850 507362

Welcome to DEVELOP3D’s professional


services section for product development
+PIO&XBOT%FTJHO
professionals.
*OEVTUSJBM%FTJHO
To see your service advertised here,
please contact Steve King. .FDIBOJDBM&OHJOFFSJOH
steve@x3dmedia.com 3BQJE1SPUPUZQJOH
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4PVSDJOH

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Product
Design

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60 MARCH 2015 DEVELOP3D.COM


DEVELOP3DJOBS
Welcome to DEVELOP3D’s jobs section.
Every issue we will bring you the latest product development
jobs to help you kick start your career.

In partnership with CADjobhunter.com we also have a dynamic


jobs website where you can find your dream job by searching by location,
keyword or CAD/CAM/CAE software.
Alternatively upload your CV to help your future employer find you.
Register your details at

jobs.develop3d.com
To advertise on the website or
inside the magazine contact
Matt Wells
matt@x3dmedia.com
+44 (0) 7990 573624

Technical-Sales-2015-Half-Page-Develop3D_v1.pdf 1 15/01/2015 11:27:47

To advertise Contact Matt Wells | matt@x3dmedia.com | +44 (0) 7990 573624 JOBS.DEVELOP3D.COM MARCH 2015 61
JOBS.DEVELOP3D.COM

Mechanical Design
Engineer
Twickenham, United Kingdom

The National Physical Laboratory (NPL) is one of the UK’s leading science facilities and research centres. It is a world-leading
centre of excellence in developing and applying the most accurate standards, science and technology.

The Opportunity
We have an exciting opportunity to join our team of engineers work alongside scientist to create unique pieces of
equipment and machinery to help aid their discovery or projects. Sometimes working to tight time scales, technical
precision or budgets while keeping an impeccably high standard.

The Person
t Served a mechanical engineering apprenticeship in the manufacture of precision parts, tooling making or similar
t Has knowledge and understanding of the manufacturing techniques for precision parts in the one-off/low volume
environment
t Has minimum qualification at HNC/HND level in mechanical engineering, preferably educated to degree standard in
Mechanical Engineering
t Minimum of 5 years design experience in a relevant field, i.e. design of; bespoke machinery, mechanical assemblies,
mechanical equipment or instruments, bespoke complex assemblies
t Experienced with CATIA V5 or SolidWork to design on machinery for one off builds

www.npl.co.uk
For more information please contact
Thalia Jones on 02089436105 or email thalia.jones@npl.co.uk

More deTails aT hTTp://goo.gl/iKs76u

More deTails aT hTTp://goo.gl/udQFpp


62 MARCH 2015 JOBS.DEVELOP3D.COM To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 7990 573624
JOBS.DEVELOP3D.COM

Make JCB
your future.
ALIAS Industrial Designer
Staff position - JCB World Headquarters - Staffordshire, UK

Closing date : 13th March 2015

MORE DETAILS AT http://goo.gl/uNHmn9


Alias ad.indd 1 18/02/2015 11:12
To advertise Contact Matt Wells | matt@x3dmedia.com | +44 (0) 7990 573624 JOBS.DEVELOP3D.COM MARCH 2015 63
JOBS.DEVELOP3D.COM

Where next?
Wherever you take us.

DESIGN, MECHANICAL AND RESEARCH ENGINEERS


£COMPETITIVE | WILTSHIRE, UK

What’s next for Dyson? You tell us. Actually, you won’t just tell us, you’ll show us. Because we’ll give you
the freedom to invent, to pursue your ideas and to push technological boundaries.
Great things are happening here. Not only are we working on some incredible new projects, but we’re
continuing to invest heavily in our UK Research, Design and Development (RDD) centre. Which tells you
two things. Firstly, that we’re doing fantastically well as a global business. Secondly, just how vitally
important engineers are to us. In many ways, engineers are Dyson. That’s why we’re looking for more
like minds to join us and create the technology of the future.
So if you’re unafraid to take risks and ready to turn conventional thinking on its head, we need to hear
from you. Your background could be mechanical engineering, technology, science.... we’re open to
ideas. Find out more at www.careers.dyson.com

MORE DETAILS AT http://goo.gl/aKWU82


64 MARCH 2015 JOBS.DEVELOP3D.COM To advertise Contact Matt Wells | matt@x3dmedia.com | +44 (0) 7990 573624
JOBS.DEVELOP3D.COM

SHARE IDEAS TO CREATE


MEANINGFUL INNOVATIONS
THROUGH 3D PRINTING

To adverTise ConTaCT MaTT Wells | MaTT@x3dMedia.CoM | +44 (0) 7990 573624 JOBS.DEVELOP3D.COM MARCH 2015 65
THE LAST WORD

Prototyping is a curious process. It’s part


experimentation, part black art and part
luck. Al Dean has been pondering the
tools we have available to us today
and discovers that the pursuit of
perfection isn’t the be all and end all

I
’ve been lucky enough to be able on the chilly side). Using Meshmixer to
to spend time with a whole range generate the supports (see Figure 2), I found
of different prototyping methods that I was running things rather tight to the
over the last few months, as build envelope of the machine — but on I
you’ll have seen from the last few soldiered.
issues (and there’s more to come). I’ve The machine was calibrated and set
been in the workshop with not only a running. It’s here that I came up against
range of 3D printers, but also a small the problem with working in a workshop in
scale CNC machine from Roland. That’s the British winter time. Light curable resins
meant a lot of experimentation and operate best at temperatures somewhere in
small scale projects to enable me to the region on 18 degrees and above. 1
realistically complete them during the Of course, when trying to get a job
loan period. done and the heater is taking its time,
One such project is a mounting bracket for the temperature is often way below that.
my daughter’s wheelchair in the back of the What happens is the viscosity of the resin
car. Anyone that’s cared for someone in a increases and this, in combination with
wheelchair (or indeed, has one themselves) localised heat build up in the parts (where
will know that these things are massive and they’re cured), results in failed parts.
tend to take up a lot of space — and when All of this is well known. Except I forgot
running a smaller vehicle, you’re pretty and cracked on anyway.
much left with no usable space. Failed builds are par for the course with
Handily, the current car has a set of any 3D printer, but it’s easy to forget even
luggage mounting bars that run down the the most basic of these things when you’re 2
sides of the luggage space. They’ve also got in the middle of a project.
some nifty little clips for hanging items on. The end result was a half complete
One quick look at these and it’s evident that component. Luckily, the machine works
they’re ripe for a quick redesign to make quickly, but still it was an annoying
something a little more suitable to hold the occurrence, particularly when you know it’s
wheelchair out of the way and free up some a simple mistake that could have easily been
of that boot space. avoided.
After pulling the existing clips out, a quick
inspection showed that this was indeed the ALL IS NOT LOST
case, so I set about modelling something up. But what I noticed with these half built parts
Of course, unless you’re ultra precise with is that they gave me just enough to try out
measurements, you’re never going to get an the geometry I’d put together, in terms of
exact match for the production part, but it fit around those luggage racks as well as
seemed close enough. So, the next step was holding the webbing straps that would hold 3
knocking up a quick prototype. the wheelchair in place.
As anyone that’s dealt with 3D printers will That struck me as an interesting thing
know, the words “prototype” and “quick” and something that I’d experienced, but not that now allows it to print at 200 microns. ●1 Part quickly

aren’t particularly well matched. Handily, really formalised before. Prototypes are As with all layer based processes, layer knocked up in Fusion
and exported as an STL
I’ve just taken delivery of one of the early meant to be rough and ready, particularly thickness is one of the key drivers to speed.
units from Autodesk’s Ember Explorer during those early stages of the design Autodesk is also working on a resin for its ●2 Pushing the limits
of the Ember’s build
program. This is essentially a beta test unit process, where you’re trying ideas and Ember printer that will allow similar build tray
for those who got in early and will help checking fit and function. parameters and speed.
Autodesk work through some issues and The 3D print industry’s obsession with This is all incredibly exciting but
●3 FormLabs now
supports 200 micron
build up the Spark platform to assist with all resolution is all well and good, but perhaps sometimes I wonder if what we really need is lasers, reducing the
the prep work involved in 3D printing. we should be focussing on getting a model the digital equivalent of a block of blue foam build times for most
At the moment, the workflow is a little out of these machines more quickly, rather and ten minutes on a bandsaw, rather than parts, giving you a
fractured, but it works and works well than slowly at a ridiculous resolution. something that will give us ultra fine detail. quicker cycle time
once you’ve learned the ins and outs of the It would also seem some of the vendors
machine and the resin you’re running (pro agree. FormLabs recently announced an Al is now thinking that a bandsaw might be a
tip: always check the operating temperature update to the software for its Form 1+ good idea. His fingers? Not so much.
range if your office or workshop is a little machine and a new variant of its resin al@x3dmedia.com

66 MARCH 2015 DEVELOP3D.COM


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