Alessandra – re:3D | Life-Sized Affordable 3D Printing

2023 Gigaprize

Brookwood in Georgetown

And that is a wrap folks! Gigaprize 2023 is in the books, but our winner, Brookwood in Georgetown, is just getting started on their 3D printing journey! Brookwood in Georgetown is excited to use their Gigabot 4 to aid in producing ceramic molds and training for their vocational community that provides meaning work for adults with functional disabilities. Their final products the find their way onto the shelves at their award winning giftshop in Georgetown, TX.

GIGAPRIZE FINALISTS

We had many amazing applicants this year and it was an incredibly tight judging process, with our final 5 contestants (I Want That Leg, Re-Inventa, Sew-Printed, Centro de Aprendizaje Educarte and Brookwood in Georgetown) being separated by less than a point. A huge thank you goes out to our wonderful judges – Khaalid McMillan, Sabine Berendse, Kameco de los Santos, Sonakshi Senthil, Josh Pridmore, Scott Austin Key, Jason Kessler, Sakshi Shah, Dr. Andrea Santos, Ama Fofie, Erik Hausmann, Lillian Ferrell & Lindsay Shwartz for bringing their expertise and industry experience to our judging process.

AMERICA MAKES

As a bonus, our Partner Organization AmericaMakes, will provide America Makes Education and Workforce development portfolio assets and training to the selected organization, meaning Brookwood in Georgetown will be onboarded into the AMNation! To learn more about America Makes, please visit their website at www.americamakes.us!

A MESSAGE FROM BIG, 2023 GIGAPRIZE WINNER:

BiG has a vision of an inclusive, empowering world for adults with special needs. This marks a paradigm shift in the way that society typically views these individuals. We provide training and support for our Citizens to succeed in modified job tasks, allowing them to experience the dignity and satisfaction of accomplishing real work. Winning the Gigabot will allow us to dream and create in new and innovative ways for our Citizens to succeed. From making molds for our clay enterprise to creating adaptive tools for our Citizens to participate in our pie making kitchen—the sky is the limit! We are beyond grateful!

Debbie Guinn from BiG

I am so thankful to have been a part of this journey, and cannot wait to see what amazing things Brookwood in Georgetown will do with our Gigabot! I hope that the runner up will continue to follow re:3D and apply for our next Gigaprize!

Ryan Murray

Supply Chain & Engagement Consultant

re:3D® kicks off their 2023 Gigaprize Campaign, giving away an industrial 3D Printer to someone committed to uplifting their community.

FOR IMMEDIATE RELEASE

HOUSTON, June 1, 2023 — re:3D, Inc. is pleased to announce the kickoff of their 2023 Gigaprize campaign. For every 100 printers sold, re:3D donates a Gigabot 4* large-format, industrial 3D printer to an individual or organization committed to doing good in their community and/or society. Past Gigaprize winners include, among others, Magic Wheelchair out of Portland, OR, who provides 3D printed Halloween costumes for kids in wheelchairs, and Tunapanda Institute, incorporating region-specific 3D printing educational curriculum and opportunities to serve community needs in Kenya. The application for Gigaprize is live as of June 1st, 2023 via the re:3D website (www.re3d.org/gigaprize). Submissions will be accepted until June 30th, 2023 at 11:59PM CDT. Applicants will need to produce and upload a short 3-minute video explaining how a Gigabot 4* would help in furthering their mission and fill out a short questionnaire. Judging will take place during the first two weeks of July, and the winner will be announced mid-July. To remain impartial, re:3D will bring in external judges with a wide range of experience and expertise. All contestant videos will be uploaded to the official re:3D Youtube channel and a small percentage of the final score will be based on the number of “likes” each video receives.

*Gigabot 4 or equivalent store credit towards another 3D printer.

ABOUT re:3D

re:3D® Inc. consists of a group of explorers committed to decimating the cost & scale barriers to industrial 3D printing. Having pioneered the world’s first and most affordable, human-scale industrial 3D printer, re:3D likewise is creating large scale, affordable 3D printers printing from pellets, regrind, and flake plastic waste. Beyond creating 3D printers for customers in over 50 countries, re:3D offers 3D printing contract services, consulting, design and education services. For more information on re:3D, visit www.re3d.org.

Contact:

Ryan Murray

gigaprize@re3d.org

+1 (512)730-0033

Gigalab

Gigalab is re:3D’s next evolution in large-scale 3D printing & services. Each climate-controlled Gigalab contains the printers, tools, and supplies to innovate on-site with the option for a generator or off-grid energy power. We look forward to customizing your Gigalab to meet your needs.

We look forward to sharing success and failures with you! You can sign up for updates, or receive a quote for your Gigalab below!

A unique space to create, collaborate and innovate. Crisis-affected communities engage in creative problem-solving, adapting resources and processes to address challenges and create opportunities.

Gigalab offers unique tools and opportunities to repurpose discarded materials and create new items.

The first generator powered Gigalab is currently being outfitted for the Puerto Rican Science & Research Trust to process & 3D print with water bottles and manufacturing waste in Puerto Rico.

Thanks to an AFWERX SBIR Phase II award, two containers powered by wind will be installed at the United States Air Force Academy in 2022. These containers will contain all of the tools to process & 3D print with plastic waste from the dining hall, as well as discarded 3D prints used in their education.

Full-Scale Additively Manufactured Training Aids for DOD

Executive Summary

This award was designed to fulfill requests from two Air Force Education and Training Command (AETC) organizations who presented the need to produce full-scale training aids for Augmented Reality (AR) and Virtual Reality (VR) training. The inert aids, however, were too heavy and inaccessible, and traditional production methods can be time and cost intensive. Existing Additive Manufacturing (AM) hardware that could produce training aids at high fidelity were too small, requiring the aids to be made in multiple small pieces and then assembled. re:3D explored how a digitally driven workflow could drastically reduce these time, cost, scale, and quality factors. re:3D also provided fully custom AM machinery (i.e. 3D printers) capable of producing single-piece, full-scale training aids at high quality. By implementing 3D scanning and a custom large-scale 3D printer, dubbed “Exabot” by re:3D, these groups were enabled to produce full-scale training aids on-demand at a 74% reduction in turnaround time and approximately 90% reduction in costs.

Client Snapshot

The 149th Fighter Wing, stationed on Joint Base San Antonio-Lackland, Texas is a part of the Air National Guard. As an F-16 training unit, its mission is to produce the finest airmen for global engagements and domestic operations while supporting its families and serving its communities. It’s sister unit is the 147th Attack Wing, at Ellington Field Houston, where they fly combat support missions with the MQ-9 Reaper.

Needs and Challenges

For the AETC, there was a need to train Air Force (AF) technicians and operators in the precise assembly of GBU and JDAM kits. Technologies like AR/VR could have greatly increased training efficacy, but such a process still required the use of full-scale training articles. There were, however, certain drawbacks to using them. First, existing training aids were extremely heavy, requiring special rigging or equipment to transport. Second, traditional manufacturing methods for training aids were costly with respect to time, materials, and money spent. This could have been overcome by utilizing AM, but there were no existing AM platforms that could produce high precision parts at the scale of training aids being used. Even then, operators required a thorough knowledge of 3D printing for the greatest return on investment.

Solution

re:3D focuses on affordable, industrial scale AM, offering a much lower barrier of entry with respect to build volume and feature set as compared to industrial competitors (Fig. 1). All re:3D 3D printers are also designed for modularity and customizability, so older units always have the potential to upgrade. Through a Phase II Open Topic SBIR grant awarded by AFWERX, re:3D was able to work with the 149th FW and 147th ATKW to reverse engineer and produce full-size training aids from AM thermoplastic.

During this process, re:3D explored the potential for savings in cost, time, and materials through the fabrication of training aids via digital fabrication tools. Specifically, a Creaform HandySCAN Black Elite 3D scanner was used to capture high resolution 3D geometry for multiple Guided Bomb Unit(GBU) and Joint Direct Attack Munition (JDAM) kits (Fig. 2). The scans were post-processed in Creaform VXmodel and Dassault Systemes SolidWorks for ease of 3D printing and assembly. From there, several test prints were produced (Fig. 3) on re:3D’s print farm, a collection of in-house Gigabot and Terabot 3D printers(Fig. 4), to optimize the printing parameters for best quality.

After exploring the workflow and implied cost savings of using 3D scanning and AM to produce training aids, re:3D designed a custom 3D printer catered specifically towards GBU and JDAM production (Fig. 5). This included an extension of the flagship products’ maximum printing height from 3 feet to 6 feet, allowing for printing entire GBU/JDAM models in a single piece. Training was provided to the customer to minimize the learning curve and achieve reliable, successful 3D prints faster. The development process began on a touchscreen add-on, which will provide a more intuitive and accessible control interface.

Results

The first half of the work with the 149th FW and 147th ATKW consisted of the 3D scanning and print optimization work. With the 3D scanner, re:3D was able to capture and reverse engineer fully featured 3D models of multiple GBU/JDAM kits (Fig. 6). The test printing yielded multiple full-scale printed training aids delivered to both the 149th FW and 147th ATKW for their assessment. After this process, re:3D compiled a digital package consisting of post-processed 3D models, optimized printing profiles, and ready-to-print .gcode files (Fig. 7).

A fully AM GBU38B weighed 33 lbs (Fig. 8), with its real-world equivalent weighing in at over 600 lbs. This amounts to a weight reduction of over 90% by switching to an AM training aid that still maintains the same geometric features as the genuine article. There are also implied safety and logistical benefits as a result of the drastic weight reduction. Transportation and handling of the training aids would require less staff and equipment and be easier, safer, and cheaper as a result.

Using traditional sourcing, for the 147th ATKW to acquire one of their GBU/JDAM units would cost $10,000. A spool of high quality PLA plastic filament for AM will typically cost $20 per pound. At roughly 30 lbs, a fully AM GBU/JDAM kit only uses about $600 in materials to produce (Fig. 9). This equates to a 94% cost reduction when comparing just the materials. Extra associated costs include electricity usage, printing set up and post processing (when necessary), but these do not nearly make up for the drastic cost difference. Primarily, the main cost advantage comes in the fact that the parts can be printed with minimal setup or supervision.

Instead of acquiring engineering drawings of each and every piece of equipment and recreating the models in CAD, re:3D used a 3D scanner to quickly capture 3D geometry for the kits the 147th ATKW and 149th FW were interested in using. Each scanning session took approximately 2 hours, followed by a few hours of post processing for each model in order to fix any scanning artifacts or to modify geometry for ease of printing or assembly. From there, each model was ready to print as desired. The typical turnaround time for the 147th to acquire one of their traditional training aids can be around 3 weeks. On the other hand, one of these kits can be printed in its full scale in 130 uninterrupted hours. This equates to a 74% reduction in time to complete a fully 3D printed training aid.

After the completion of the custom 3D printer, dubbed the “Exabot”, it was delivered directly to the 149th FW. With a build volume of 3 feet by 2 feet by 6 feet (Fig. 10), Exabot is perfectly suited for printing full-sized GBU/JDAM kits, or any other parts that fit within the build volume as the end users see fit. Compared to a typical re:3D Gigabot 3+, Exabot also sports a stationary bed, a gantry which moves in the X, Y, and Z directions, a heavy duty frame with leveling casters, and a counterweighted filament delivery tube for consistent quality no matter how tall the print (Fig. 11).

After the Exabot delivery, re:3D provided training to the 149th FW (Fig. 12). While the crew at the 149th FW were already very familiar with 3D printing, re:3D was prepared to train operators at all levels of experience. This included education in machine calibration, maintenance, and operation as well as Simplify3D software set up. At the conclusion of the training, the 149th FW crewmen felt comfortable with operating Exabot and excited at their new ability to 3D print full scale parts.

Continuous Improvement

re:3D values continuous improvement for their products and is committed to building an upgrade path for all standard machines. For example, an early Gigabot 2 can be upgraded to the latest Gigabot 3+, affordably preserving common components from unnecessary disposal while improving the machine’s functionality. re:3D approaches Exabot with the same commitment, leveraging feedback from the 149th FW to inform improvements that all Exabot users will benefit from.

Improved Filament Feeding

One challenge of large scale 3D printing is managing the filament feed path. The first iteration of Exabot used counterweighted filament tubes, with a constant length of tubing that moved in and out of the frame depending on the height of the gantry (Fig. 13). After some use, however, the operators gave re:3D feedback about shortcomings with this design.

The 149th FW Exabot was updated with a frame holding the filament spools directly above the gantry (Fig. 14). This stores all filament inside the frame, minimizing the overall footprint. There was also a 70% reduction in the filament path, for more reliable feeding and less chances of grinding through filament, and more economical use of filament spools.

Upgraded Build Volume

While the original bed size was driven by the size of the training aids used by the 149th FW, the gantry of Exabot could actually accommodate a slightly larger bed plate. A simple and straightforward improvement was to install a new bed assembly that was large enough to fit the full stroke of travel of the X and Y axes. The original bed plate was 24” x 30” while the new plate is 30.7” x 30.7”, for a 31% increase in build volume.

Continued Engagement

re:3D continues to engage with the 149th FW for regular service and maintenance needs, and also to better understand their 3D printing workflow and collect valuable feedback. This information will inform the next generation of re:3D’s large scale 3D printing products.

Call to Action

This grant opportunity awarded by the AFWERX open topic solicitation enabled active investigation of Air Force needs and resulted in an innovative solution that was immediately commercialized with global interest, which include requests for even larger custom form factors. As mentioned above, many areas were identified and addressed for cost reduction. re:3D has had subsequent conversations with DOD stakeholders, identifying further needs that may be addressed through large scale 3D printing, whether through the flagship Gigabot, and now Exabot, or a collaborative, custom solution.

If your organization is interested in an Exabot of your own, it is available for purchase via GSA (https://bit.ly/3eFLpa0). If your organization is interested in collaborating on a future SBIR grant opportunity, feel free to email info@re3d.org with your vision to #dreambigprinthuge. re:3D is happy to consider any SBIR Phase 1, Direct to Phase 2 and eventually even beyond into Phase 3 opportunities. If you are interested in purchasing one of re:3D’s standard 3D printers or service offerings, please send a message to sales@re3d.org.

Specialty Pellets & Flake

Specialty pellets and flake are unique materials created for specific use cases. Sometimes, common materials like PLA or ABS cannot meet the demands of a specific application and a dedicated material is needed. Specialty materials have been created for casting, smooth surface finishes, flexible parts, high clarity, and improved material strength. Due to the wide range of different applications, specialty materials are not easily classified into other common material categories. The chemical makeup of specialty materials is diverse as well, making each specialty material truly special. If you have a very specific demand for a material, there may be a specialty material to help you out!

Applications for specialty pellets and flake are almost entirely driven on the material’s design. Unlike common materials, specialty materials are often created for a specific application. Some of the most common specialty material use cases are given, but specialty materials exist for a wide variety of different applications.

The sustainability of specialty pellets and flake varies widely, though often they are not easily recycled at commercial centers. Some specialty pellets are formulated to redirect a specific kind of waste into a pellet form for reuse. Safety data sheets of a specialty material can provide insight into ways to dispose of it properly.

rPC Flake

rPC Polycarbonate (PC) is a high performance material intended for use in engineering and industrial settings. As suggested by its name,

Brookwood in Georgetown

GIGAPRIZE FINALISTS

AMERICA MAKES

A MESSAGE FROM BIG, 2023 GIGAPRIZE WINNER:

Ryan Murray

ABOUT re:3D

Gigalab

Designed Around re:3D Large Scale 3D Printers

Have any questions?

*Disclaimer: This article’s contents do not express or imply an endorsement by the Department of Defense, the Air Force, or the United States government

Executive Summary

Client Snapshot

Needs and Challenges

Solution

FIGURE 1 - re:3D’S FLAGSHIP PRODUCT, GIGABOT 3+. LEARN MORE AT https://re3d.org/gigabot/

FIGURE 2 - SCANNING A GBU BODY WITH THE HANDYSCAN BLACK ELITE

FIGURE 3 - FULL-SCALE 3D PRINTED VERSION OF GBU BODY AND THE ASSEMBLED FULL-SCALE 3D PRINTED GBU12, RESPECTIVELY

FIGURE 4 - THE re:3D SHOWROOM IN HOUSTON, TX, WHICH HOUSES A PORTION OF THE COMPANY’S PRINT FARM

FIGURE 5 - EXABOT, FULLY ASSEMBLED PRIOR TO INSTALLATION AT THE 149th FW

Results

FIGURE 6 - GBU12 BODY BEING PROCESSED IN CREAFORM VXMODEL SCANNING SOFTWARE

FIGURE 7 - PREPARING THE GBU12 BODY FOR PRINTING WITH SIMPLIFY3D 3D PRINTING SOFTWARE

FIGURE 8 - FINISHED AND ASSEMBLED GBU38B. THE FULL LENGTH IS 94 INCHES OR ROUGHLY 2.4 METERS

FIGURE 9 - SPOOL OF PLA FILAMENT, SIMILAR TO WHAT WAS USED TO MANUFACTURE THE FULL-SCALE TRAINING AIDS

FIGURE 10 - SIZE COMPARISON OF TWO EXABOT FRAMES VERSUS ONE GIGABOT 3+

FIGURE 11 - EXABOT AFTER DELIVERY AT THE 149TH FW AND A COMPLETED 16 HOUR 3D PRINT OF A MODEL ROCKET

FIGURE 12 - ONSITE TRAINING WITH THE 149TH FW

Continuous Improvement

Improved Filament Feeding

FIGURE 13 - EXABOT WITH COUNTERWEIGHTED FILAMENT TUBES

FIGURE 14 - EXABOT WITH THE FILAMENT SPOOL FRAME

Upgraded Build Volume

FIGURE 15 - NEW BED PLATE SUPERIMPOSED OVER THE OLD BED PLATE AS A VISUAL COMPARISON OF SIZE DIFFERENCE

Continued Engagement

Call to Action

Specialty

Explore other Materials

Want to validate your material?

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GigabotX 2 XLT

Three Zone Independently Controlled Barrel Heaters

5/8" Extruder Screw with a16:1 L/D Ratio and a0.4,0.8, 1.75 or 3mm nozzle

4 Point Bed Leveling

NEMA 17 & 23 Stepper Motors

0.5" Aluminum Heated Bed with PRINTinZ

Leveling Caster Wheels

Full Color 10" LCD Touchscreen with Mainsail for Klipper interface

Linear Rails on X & Y Axis

7.8 kg Hopper Capable of 24h of Printing Between Refills

32bit ArchiMajor Control Board

Technology

Build Volume

Extruder

Materials

Granule Size

Layer Resolution

Printing Speed

Nozzle Diameter

Design

Construction

Build Plate

Stepper Motor

Bot Control

Connectivity

File Transfer Method

Open Source

Upload File Type

Printing Workflow

Power

Extruder Temperature

Build Surface Temperature

Explore other Solutions

Have any questions?

All-metal dual extruder

NEMA 23 stepper motors

Heated bed with PRINTinZ

Prints up to 1.83 meter tall

Leveling caster wheels

Exabot

Technology

Three Zone Independently
Controlled Barrel Heaters

5/8" Extruder Screw with a
16:1 L/D Ratio and a0.4,
0.8, 1.75 or 3mm nozzle

NEMA 17 & 23
Stepper Motors

0.5" Aluminum Heated
Bed with PRINTinZ

Full Color 10"
LCD Touchscreen
with Mainsail for
Klipper interface

7.8 kg Hopper Capable
of 24h of Printing
Between Refills

32bit ArchiMajor
Control Board

Three Zone Independently
Controlled Barrel Heaters

5/8" Extruder Screw with a
16:1 L/D Ratio and a0.4,
0.8, 1.75 or 3mm nozzle

NEMA 17 & 23
Stepper Motors

0.5" Aluminum Heated Bed
with PRINTinZ

Full Color 10"
LCD Touchscreen
with Mainsail for
Klipper interface

Optional Enclosure with
Removable Panels

7.8 kg Hopper Capable
of 24h of Printing
Between Refills

32bit ArchiMajor
Control Board