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TerabotX 2 3D Printers

Fulfill your large-format FGF 3D printing needs with TerabotX 2, expanding the size of your build volume to 879 x 908 x 830mm. This direct-drive pellet extrusion based 3D Printer can print from virgin or recycled pellets, flake, or regrind – and bring us even closer to the dream of a circular economy.

A ⅝” extruder screw with a 16:1 L/D ratio powered by a NEMA 23 motor enables 3D printing with 3-5mm plastic granules with melting temperatures below 270ºC. With a larger 0.4, 0.8, 1.75 or 3mm nozzle, TerabotX 2 3D printer reduces the dependence on printing with filament while supporting plastic granule mixing, increasing printing speed and cost savings.

Your open-source industrial 3D printer is powered by a 32bit Ultimachine ArchiMajor control board and Klipper firmware run on a Raspberry Pi. Access TerabotX 2 controls via the Mainsail interface on either the 10” LCD touchscreen or a desktop or mobile web browser.

Hand-crafted in Texas by team re:3D to highly precise standards, your TerabotX 2 3D printer is modular, upgradable and backed by Lifetime Customer Support.

Image of Gigabot 4 and GigabotX 2 3D printers side by side

image of the simplify3D software slicing a 3D model for 3D printing

Image of a hand tightening a screw on a 3D printer print head

Image of different Gigabot 3D printer replacement parts arranged on top of a white background

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Revolutionizing Chair Manufacturing: A Journey with Rhodes and re:3D’s Gigabot

Leia em português

Have you ever considered how the chair you are sitting on right now was made? It’s a question that often goes overlooked in our daily lives, yet the answer reveals a world of innovation and creativity shaping the furniture industry. One of the notable players in this space is Brazilian manufacturer, Rhodes. Founded in 1964, Rhodes has been at the forefront of chair component manufacturing, producing around 5 million components annually for various seating solutions, from office chairs to public seating in airports and stadiums.

Rhodes plays a vital role in providing essential elements for operative chair lines. Key products include bases, columns, and mechanisms, which maintain Rhode’s strong presence as a component supplier. Despite market challenges, especially during Brazil’s economic crisis in 2013-2014, Rhodes has excelled. During the COVID-19 Pandemic, Rhodes expanded into the ready-made chair market, adapting to the growing need for home offices. Currently, Rhodes is a major manufacturer of chairs and chair components in Brazil and exports its products to other Latin American countries, the United States, and some parts of Europe.

Rhodes’ integration of 3D printing played a crucial role in streamlining their manufacturing process and achieving global success. Initially, Rhodes outsourced their 3D printing needs. They would create a computer-aided design (CAD) file for their chair component prototypes, send it to a partner company in Italy, and wait for the 3D printed component to come back. The cost and time constraints prompted Rhodes to explore other alternatives. After a Google search led Rhodes to re:3D, the size and affordability of re:3D’s Gigabot cemented their purchase as Rhodes first in-house 3D printer for prototyping and design iterations. A decade later, Rhodes’ workhorse Gigabot 2 is still going strong, being used to 3D prototype every plastic component of their furniture lines.

"The Gigabot has paid for itself many times over. Having the capability in-house eliminates development constraints. For instance, I've even created a chair base prototype where each of the five legs was distinct, allowing me to assess the best aesthetic for the product within a single piece."

Júlio Reis - Senior Product Designer at Rhodes

re3D blog - Rhodes chair manufacturing 3D printed part

re3D blog - Rhodes chair manufacturing Prototype 2

Gigabot’s robustness and versatility has allowed Rhodes to seamlessly integrate 3D printing into their development processes. From mitigating design flaws to producing quick 3D prototypes for assessment, Gigabot has been a reliable companion, functioning almost continuously for a decade. But it wasn’t always that easy. It took Júlio a full year of experimenting and learning before getting quality prints from Gigabot, since he had no prior 3D printing experience when Rhodes decided to test the technology. Julio had to determine which material to print with and find a reliable national supplier. He ended up choosing ABS because of its durability, which was key to testing the prototypes before finalizing their design. Júlio built an enclosure for the machine to overcome temperature differences during different seasons and ensure ABS would print year-round. He has also tested every type of glue on the market, including hairspray, to make the prints adhere to the print bed, as re:3D’s original Gigabot 2 did not come with PrintinZ.

"I need to have a prototype to ensure assembly and reliability, especially for the design of the piece. [Gigabot] allowed me to try new fastening technologies, something that wasn't possible some time ago, as I required a mold to create the geometry I needed."

Júlio Reis - Senior Product Designer at Rhodes

Júlio started small, prototyping components of chairs such as caster bases, columns, mechanisms, seats, and backrests. Rhodes also began to use Gigabot to print replacement parts for machines in their factory and has been contracted by their vendors to CAD other non-chair-related products. Because of their success with Gigabot 2, Rhodes purchased a Gigabot 4, which will be an upgrade from their current, single-extruder workhorse. Júlio anticipates enhanced ease of use and agility, allowing for increased prototyping and quicker project timelines. Júlio believes that 3D printing’s strength and effectiveness is well-established and expects the technology to continue influencing the furniture industry.

"[Gigabot] allows you to design things you wouldn't if you didn't have it; it enables you to take more risks, to take more shots. It gives you more bullets to hit the target."

Júlio Reis - Senior Product Designer at Rhodes

The integration of Gigabot at Rhodes exemplifies how innovative technologies can revolutionize traditional industries. Júlio’s insights showcase the profound impact of 3D printing on Rhodes’ development processes, fostering creativity, and enabling the exploration of new design possibilities. Looking towards the future, Rhodes is poised to take its manufacturing capabilities to new heights with the upcoming addition of the Gigabot 4. With its dual-extrusion print head, this advanced 3D printer will enable Rhodes to produce larger, more intricate 3D prototypes, pushing the boundaries of design creation even further. Moreover, by doubling their printing capacity with two Gigabots, Rhodes aims to accelerate their prototyping process, allowing for quicker iteration and refinement of their chair designs. As Rhodes continues to leverage Gigabot’s capabilities, it exemplifies a story of adaptation and innovation in the furniture manufacturing industry that is not slowing down.

Revolucionando a Fabricação de Cadeiras: Uma Jornada com a Rhodes e a Gigabot da re:3D

Você já parou para pensar em como a cadeira em que você está sentado agora foi feita? É uma pergunta que muitas vezes passa despercebida em nossas vidas diárias, mas a resposta revela um mundo de inovação e criatividade que está moldando a indústria de móveis. Um dos nomes mais fortes nesse espaço é a fabricante brasileira Rhodes. Fundada em 1964, a Rhodes tem estado na vanguarda da fabricação de componentes para cadeiras, produzindo cerca de 5 milhões de componentes anualmente para várias soluções de assentos, desde cadeiras de escritório até assentos públicos em aeroportos e estádios.

A Rhodes desempenha um papel vital no fornecimento de elementos essenciais para linhas de cadeiras operativas. Os principais produtos incluem bases, colunas e mecanismos, o que mantêm a forte presença da Rhodes como fornecedora de componentes. Apesar dos desafios do mercado, especialmente durante a crise econômica do Brasil em 2013-2014, a Rhodes se destacou. Durante a pandemia de COVID-19, a empresa expandiu seu portfólio para o mercado de cadeiras prontas, adaptando-se à crescente necessidade do home office. Atualmente, a Rhodes é uma das principais fabricantes de cadeiras e componentes para cadeiras no Brasil, além de exportar seus produtos para outros países da América Latina, Estados Unidos e algumas partes da Europa.

A integração da impressão 3D pela Rhodes desempenhou um papel crucial na otimização do seu processo de fabricação e no alcance do sucesso global. Inicialmente, a Rhodes terceirizava suas necessidades de impressão 3D. Eles criavam um arquivo de design assistido por computador (CAD) para os protótipos de componentes das cadeiras, enviavam para uma empresa parceira na Itália e aguardavam o retorno do componente impresso em 3D. Os custos e as restrições de tempo levaram a Rhodes a explorar outras alternativas. Após uma pesquisa no Google levar a Rhodes à re:3D, o tamanho e a acessibilidade do Gigabot da re:3D consolidaram a compra como a primeira impressora 3D interna da Rhodes para prototipagem e iterações de design. Uma década depois, a robusta Gigabot 2 da Rhodes ainda está em plena atividade, sendo usada para prototipar todos os componentes plásticos de suas linhas de móveis.

"A Gigabot se pagou muitas vezes. Ter essa capacidade internamente elimina as limitações de desenvolvimento. Por exemplo, já criei um protótipo de base de cadeira onde cada uma das cinco patas eram diferentes, permitindo-me avaliar a melhor estética para o produto em uma única peça."

Júlio Reis - Designer de Produto Sênior da Rhodes

A robustez e a versatilidade do Gigabot permitiram à Rhodes integrar perfeitamente a impressão 3D em seus processos de desenvolvimento. Desde mitigar falhas de design até produzir protótipos rápidos para avaliação, a Gigabot tem sido uma companheira confiável, funcionando quase que continuamente por uma década. Mas nem sempre foi tão fácil. Júlio levou um ano inteiro de experimentação e aprendizado antes de conseguir impressões de qualidade com a Gigabot, já que ele não tinha experiência prévia com impressão 3D quando a Rhodes decidiu testar a tecnologia. Júlio teve que determinar qual material usar para impressão e encontrar um fornecedor nacional confiável. Ele acabou escolhendo ABS por causa de sua durabilidade, o que foi crucial para testar os protótipos antes de finalizar o design. Júlio construiu uma caixa de proteção para a máquina para superar as diferenças de temperatura durante as diferentes estações, garantindo que o ABS fosse impresso durante todo o ano. Ele também testou todos os tipos de cola no mercado, incluindo spray de cabelo, para fazer as impressões aderirem à mesa de impressão, já que o Gigabot 2 original da re:3D não vinha com a tecnologia PrintinZ.

"Preciso ter um protótipo para garantir a montagem e a confiabilidade, especialmente para o design da peça. [A Gigabot] me permitiu experimentar novas tecnologias de fixação, algo que não era possível há algum tempo, pois eu precisava de um molde para criar a geometria necessária."

Júlio Reis - Designer de Produto Sênior da Rhodes

Júlio começou pequeno, prototipando componentes de cadeiras, como bases de rodízios, colunas, mecanismos, assentos e encostos. A Rhodes também começou a usar o Gigabot para imprimir peças de reposição para máquinas em sua fábrica e foi contratada por seus fornecedores para criar em CAD outros produtos não relacionados a cadeiras. Devido ao sucesso da Gigabot 2, a Rhodes comprou uma Gigabot 4, que será uma atualização em relação ao seu robusto equipamento atual de extrusora única. Júlio prevê maior facilidade de uso e agilidade, permitindo mãos projetos de prototipagem e prazos mais curtos. Júlio acredita que a força e a eficácia da impressão 3D estão bem estabelecidas e espera que a tecnologia continue influenciando a indústria de móveis.

"[A Gigabot] permite que você projete coisas que não projetaria se não a tivesse; permite que você corra mais riscos, faça mais tentativas. Ele te dá mais munição para acertar o alvo."

Júlio Reis - Designer de Produto Sênior da Rhodes

A integração da Gigabot na Rhodes exemplifica como tecnologias inovadoras podem revolucionar indústrias tradicionais. As percepções de Júlio mostram o profundo impacto da impressão 3D nos processos de desenvolvimento da Rhodes, promovendo a criatividade e possibilitando a exploração de novas possibilidades de design. Olhando para o futuro, a Rhodes está pronta para levar suas capacidades de fabricação a novos patamares com a próxima adição da Gigabot 4. Com sua cabeça de impressão de dupla extrusão, esta avançada impressora 3D permitirá que a Rhodes produza protótipos maiores e mais intrincados, expandindo ainda mais os limites da criação de design. Além disso, ao dobrar sua capacidade de impressão com duas Gigabots, a Rhodes visa acelerar seu processo de prototipagem, permitindo uma iteração e refinamento mais rápidos dos designs de suas cadeiras. À medida que a Rhodes continua a aproveitar as capacidades da Gigabot, a empresa reforça uma história de adaptação e inovação na indústria de fabricação de móveis que não está desacelerando.

Jennifer Dennington

Blog Post Author

Engineering Update – April 2024

It’s been a while since we’ve shared the progress being made by re:3D’s engineering team – June 2023, to be precise. But with the move of our headquarters from Houston to Austin (Texas) underway, it seems like a good time to take stock of where we are and where we’re going in the figurative sense as well.

The Gigabot FFF (Filament) Platform

re:3D took an intense look at reports of “filament grinding” submitted by our Gigabot user community, taking input from all the spheres within our company. It turns out that “filament grinding” means different things to different people, so our first step was to agree on a common lexicon and definition. We landed on a concise problem statement: “Customers experience poor extrusion performance due to the extruder gear removing material from the filament, “ which captures multiple causes and failure modes or symptoms. The engineering team evaluated, modeled and tested printer components all along the filament path – beginning at the spindle holding the filament spool down to the exit of the extruder nozzle. While recognizing that every user can encounter unique challenges and edge cases, this exercise ranked potential root causes and recommended optimizations in printer slicing parameters and specific improvements in the extruder manufacturing process. We expect these internal improvements and updated slicer profiles to improve overall reliability and print quality.

During check-ins with our customers, we also receive a lot of interest in “automatic bed leveling” – another phrase that can have multiple meanings. We have incorporated an inductive sensor into the Gigabot’s extruder assembly and integrated the necessary software to allow the sensor to quickly map variations in the print bed surface and compensate the z-axis in real time to maintain a uniform nozzle-to-bed distance. This “bed mesh compensation” approach can yield exceptional first-layer results, even on a warped or non-trammed print bed. Our software team is working with the sensor manufacturer to improve the interface and provide a quality user-experience within the Klipper environment. After we finish mesh compensation development on our R&D and internal production printers, we’ll invite the user community to apply to beta test this new feature.

Our user community has also expressed a desire for a 1.75mm diameter filament option for re:3D’s Gigabot printers (where our extruders are designed for 2.85mm diameter filament.) In response, we have designed and are testing a conversion assembly to accommodate the smaller filament. The design has been tested for over 300 hours using a variety of filament materials – including flexible filament. It will soon be released as a kit which can be installed by users in the field.

The GigabotX FGF Platform

Specific to re:3D’s FGF platforms, the engineering team has focused on improving the performance and reliability of the extruder assembly. The standard ⅝” compression screw has remained unchanged, but the active feeding mechanism (i.e., the ‘crammer’) is getting a full overhaul. Feedstock with poor flowability such as coarse or lightweight plastic regrind and some TPU/TPE resin pellets can have difficulty flowing from the hopper to the extruder via gravity. The crammer provides an auxiliary auger to force these materials into the extruder body. The new design allows for higher and more uniform throughput, and increases reliability by using a stainless steel auger and machined components. Photos and design details, as well as a link to apply to be a beta-tester, are posted here on our User Forum.

In conjunction with the new crammer design, we have been testing an “autoloading” system to supply feedstock from a floor-mounted hopper rather than our normal top-mounted hopper. This system uses compressed air to drive an eductor which pulls and pushes the feedstock into the printer’s extruder via flexible tubing. A detection unit is mounted at the extruder which detects when the feedstock needs replenishing and triggers the compressed air to transport additional flake or pellets. The autoloader is currently being tested on a TerabotX which will be delivered in one of our Gigalab projects. It can operate as a stand-alone system or interface with the Archimajor control board and Klipper firmware to automatically pause printing if a feedstock delivery error is detected.

Other efforts underway include designing a more robust coupling mechanism between the extruder motor and the extrusion screw, installing a fourth heating zone to better control the nozzle/die temperature, and a deep-dive investigation into part-cooling for the GigabotX.

Software/Firmware

We are pleased to announce the upcoming release of Klipper Stack v0.5.0. This update represents a significant commitment to enhancing backend operations and ensuring our technology aligns with the latest developments within the Klipper community. Our focus on these upgrades positions us well for the introduction of innovative features in the future.

In pursuit of refining the user experience, we have streamlined the machinery setup process, enabling more rapid and efficient configurations. Enhancements include the introduction of prompt menus for various commands and adjustments to the location and visibility of the emergency stop button to reduce the risk of accidental activation. Furthermore, we have addressed and fixed specific issues such as the omission of certain characters and the disappearance of the virtual keyboard on touch-screen devices after each keystroke, ensuring a smoother and more reliable interaction.

This version also introduces a suite of new features and configuration adjustments. Highlights include the introduction of the ‘exclude objects’ module, which offers the flexibility to remove specific models from multi-model prints directly from the gcode mid-print. The ‘gcode arcs’ module expands movement options beyond the basic G1 move, incorporating G2 and G3 moves for enhanced precision. Furthermore, we have eliminated the homing sequence prior to resuming prints, addressing the issue of potential layer shifts on models.

These enhancements and fixes are part of our ongoing commitment to providing a robust and user-friendly platform, setting a solid foundation for future developments. The update is scheduled to release within a month.

Internal Processes

Internally, the engineering team is implementing processes reflecting re:3D’s ethos of being responsive and transparent to our community. Our engineering change and design processes are maturing to better engage internal and external stakeholders from the beginning of problem identification and requirements definition through operational release and ongoing support. These changes will help focus our resources on those efforts which will have the greatest impact on customer success and map the work against product roadmaps which have been developed to guide the engineering team over the next 12-18 months and beyond. And as an open-source hardware company and proponents of open science, we will be increasing our efforts to share as much of our learnings with the additive community as possible. This includes making our material testing protocols more robust and aligned with industry best practices and hosting an international, monthly FGF Users Group virtual meetup open to anyone interested in printing with pellets or flake.

And More…

Other activities have included improving the printers’ electrical systems and enclosure design. The team also continues to optimize printer software profiles and investigate additional slicing programs available for filament and pellet printing. Finally, additional variants of re:3D’s Gigalab will be presently fielded for evaluations – demonstrating that it is possible to turn waste plastic into usable parts at the point of need through additive manufacturing.

Look for release schedules and more details on all of these engineering initiatives in the coming months. We’ll be sharing via our mailing list, through blog posts and on the re:3D Community Forum.

Stay tuned, and Happy Printing!

Patrick Ferrell

Senior Engineer

re:3D’s HQ is Moving to Austin TX!

re:3D is proud to announce that we bought our own headquarters space in Austin. We will use the space to scale, grow our ability to experiment with Gigalabs in a large outdoor space, and expand our networks in Texas!

The new facility is located in East Austin, known for being a mecca that actively convenes creatives & organizations committed to social impact. This location also allows re:3D to scale locally with University of Texas and Austin Community College initiatives focused on additive manufacturing, while increasing our global presence.

We’re still working out the details, but welcome your feedback at info@re3d.org as we are committed to ensuring a seamless transition.

Below are some FAQs our team has assembled, and will be updated weekly based on your inputs.

You can witness the final move out logistics live on Wednesday May 29th from 10am-7pm. The Houston team would love to high five any visitors as we share memories and plans for the future! More information is located on our Eventbrite here.

re:3D’s new headquarters is located at 1201 Old Bastrop Highway, Austin Texas 78742 (formally the High Sign Brewery). The building can be accessed just off of the frontage road near the 183 and 71 intersection, so if you are looking for something to do before your next flight from the Austin airport, we would love to see you!

Our current Houston headquarters’ and Austin Office lease end May 31, 2024. For this reason we are trying to batch equipment and inventory moves each week to minimize disruptions to our operations. All headquarter operations will be established in Austin beginning June 1 2024.

re:3D has maintained a presence in parallel with Houston since 2013. We are indebted to the Clear Lake community for supporting our founding but are struggling to scale & maintain insurance for manufacturing operations in a hurricane vulnerable area. As Austin offers more opportunities for recruitment, reduced overhead, and active support from local organizations that support our social mission, we decided to move our operations, while still maintaining a footprint in Houston.

Both Charlotte, who is a Co-PI for our NSF Covergence grant, and Patrick who leads our Army Gigalabs grant as well as two NASA awards will remain in Houston. Where they will be working from is yet to be determined, and we welcome your suggestions!

While some of the Houston crew is moving to Austin (so far- Cheyena, Justin, Will, Mitchell, Jordan, and Annabelle), several teammates will be transitioning to their next adventure and welcome suggestions/introductions on where they should be applying!

Orders are being accepted, however there may be delays in for orders placed in May when we transition from Houston to Austin. For this reason, we recommend stocking up on parts prior to April 30th:)

Tours in Houston and Austin can be arranged by emailing discover@re3d.org.

Email info@re3d.org and we will do our best to transparently reply within 24 hours!

A Journey of 3D Printing Innovation & Collaboration with YLAI Fellows

re:3D was first introduced to the US Department of State’s Young Leaders of the Americas Initiative (YLAI) in 2017. YLAI’s vision is to create a vibrant network of entrepreneurs across the Western Hemisphere. A key way this is achieved is through a Fellowship Placement with a business in the United States for four weeks. The Fellowship Placement is an opportunity for YLAI Fellows to experience the U.S. work culture and connect with key players in their industry. The YLAI Fellowship offers hands-on experience in exchange for using their skills and network to contribute to U.S. businesses and organizations. The Fellowship not only provides business insight and network for the Fellows but also provides their placement companies with cross-cultural understanding. Businesses form long-term relationships with their Fellows, extending the Fellowship well past the initial four-week placement.

Since 2017, re:3D has hosted three YLAI Fellows, the most recent being Juliana Martinelli from Brasília, Brazil in May of 2023. Samantha Snabes, re:3D’s Co-Founder and Catalyst and Juliana met over video to ensure that re:3D would be a good match for her fellowship. Juliana’s company, InovaHouse3D, 3D prints with cement and has a mission to print affordable houses in Brazil. Even though re:3D prints with plastic, we also have a social responsibility aspect to our work and admire InovaHouse3D’s goals!

Frame of the Ayla 130, InovaHouse 3D's Cement Printer

Extruder of the Ayla 130, InovaHouse 3D's Cement Printer

Juliana worked on three different projects during her Fellowship. The largest project she undertook was completing a customer outreach campaign to re:3D’s customers who spoke Spanish and Portuguese. Juliana individually contacted forty-four customers in Central and South America. She successfully heard back from twenty-five customers via email and set up in-depth phone calls with them. During these conversations, Juliana learned what each customer used their Gigabot for and the current state of their Gigabot. Juliana provided the customers with re:3D resources and connected them with other members of the re:3D team. re:3D values the relationships with our customers and the outreach Juliana did have a positive impact in connecting with customers we don’t normally get the chance to talk to. Additionally, this outreach campaign connected Juliana with more players in the Additive Manufacturing space in Latin America.

Because of Juliana’s background in Electrical Engineering, she was able to problem-solve grounding issues with Gigabot’s electrical box. This was incredibly helpful as re:3D was building up its engineering team. The final project Juliana worked on was a personal project. She wanted to pitch InoveHouse3D to a few American Investors to get their valuable feedback. Juliana was able to meet with two different Investors and strengthen her InovaHouse3D deck.

By the end of Juliana’s Fellowship, a strong connection had formed between her and the re:3D team. YLAI had let re:3D, and the other businesses hosting fellows, know that there would be an opportunity for an Outbound Exchange program. In this exchange, someone from re:3D would go to Brazil for two weeks and work with Juliana’s company. Jennifer Dennington, re:3D’s Account Manager, applied for the Outbound Exchange Program and was awarded the grant! Jennifer left for the exchange in early January 2024 to amplify the future of Additive Manufacturing in Brazil.

One of the main projects Juliana and Jennifer worked on was creating a storytelling blog post and video on re:3D’s customer Rhodes. Rhodes produces around 5 million components per year to assemble various models of office, school, and training chairs and public seats in airports, theaters, cinemas, and football stadiums. The blog article and video about how Rhodes uses its Gigabot will be published soon, so stay on the lookout for that.

Another project Jennifer and Juliana collaborated on was creating Additive Manufacturing lessons for Brazil. Jennifer’s background is in Special Education, she has a passion for making education fun and accessible to all people. Juliana teaches lessons to schoolchildren at the Planetário de Brasília (Brasília’s Planetarium) and has connections with public schools in Brasília. Before coming to Brazil, Jennifer knew she would share re:3D’s Introduction to Autodesk’s TinkerCAD lesson where Juliana would teach students how to make 3D models on their computers. However, after speaking with Juliana, Jennifer learned that many students do not have access to technology at school. Jennifer shifted gears and decided the first lesson she needed to create was an Introduction to 3D Printing lesson for students with limited to no knowledge of 3D printing and limited access to technology.

Jennifer modeled this lesson after the 5E Model of Instruction where students engage, explore, explain, elaborate, and evaluate 3D printing. She only included resources that Juliana had readily available to be used in the lesson. For example, because of Juliana’s partnership with the University of Brasília’s LAB, Juliana could bring 3D printed examples to show the students on top of having the Google Slides presentation. Click here to view and download the Introduction to 3D Printing Google Slides and here to view and download the full lesson plan.

After Jennifer finished the Introduction to 3D Printing lesson, she went back to the Introduction to TinkerCAD lesson because it is a personal favorite of re:3Ds. TinkerCAD is a fantastic resource for teachers because you don’t have to have a 3D printer to do incredible and engaging lessons with your students. Teachers will have students they do not expect to interact with this lesson get really into it and become incredible 3D designers. Not only can students make 3D designs with TinkerCAD, but also they can create circuit boards and learn how to write code, all for free! TinkerCAD puts out challenges each month for students to compete in and educators post lessons they have created on TinkerCAD as well. Click here to view and download the Introduction to TinkerCAD Google Slides and here to view and download the full lesson plan and other additional resources. These lessons can be replicated and customized to fit different cultural contexts, educational settings, and learner demographics, thereby extending the reach and impact of 3D printing education. Jennifer hopes her lessons contribute to building a future workforce equipped with valuable science, technology, engineering, art, and math (STEAM) knowledge and competencies, thus promoting innovation and economic development in the long run.

Juliana took Jennifer on a tour of Programando o Futuro, an electronic waste (e-waste) recycling center with a broader mission of providing free technology education to the community. Their hands-on courses in robotics, 3D printing, computer repair, and marketing aim to equip people with tech skills, boasting a 55% job placement rate. With a commitment to inclusivity and sustainability, Programando o Futuro engages in extensive plastic recycling, collaborating with companies like HP to transform shredded plastic into new products or filament for their 3D printing lab. Programando o Futuro has repaired and donated over 3,000 computers and aims to recycle 1,100 tons of material this year. They want to partner with Juliana and the University of Brasília to get a spectrometer, which will help them rapidly and accurately identify the types of plastic that are donated. Additionally, Juliana wishes to use her partnership with Programando o Futuro to apply for re:3D’s Gigaprize program or apply for a grant to purchase a GigabotX 2 for their organizations.

A bonus meeting happened with Bryan Murphy, Associate Chief Engineer for the International Space Station (ISS), at Boeing to bring ISS Mini-Mimics to Brazil. The ISS MIMIC is a 1:100 scale articulating model of the International Space Station (ISS) that runs off of live data streaming from the real ISS. re:3D has had the joy of helping the ISS Mimic team by 3D printing solar arrays and participating in the 11 Freeman Library Community Builds of the ISS Mimic. If you would like to learn more about the ISS Mimic, check out this article written by re:3D. Jennifer and Juliana’s meeting with Bryan was successful because they secured three ISS Mini-Mimics for educational institutions in Brasília. The goal is that after Juliana completes the ISS Mini-Mimic with students, she will then apply for grants to fund an ISS Mimic community build at the Planetarium! She is also hoping to get support from Brazil’s only astronaut, Marcos Pontes, who is currently a Senator for São Paulo, in this endeavor. Bringing the ISS Mimic to Brazil has the potential to foster a lasting interest in space exploration and STEAM fields to all who encounter it.

A final fortuitous event happened at the end of Jennifer’s time in Brazil when she was able to meet with the 2024 Class of Brazilian YLAI Fellows. Jennifer was in Brasília at the same time as their orientation for YLAI. Juliana and Jennifer went and spoke about their YLAI experience with the Fellows for an hour and a half. The Fellows Jennifer met were awe-inspiring entrepreneurs. They have built up their business and are incredibly hard workers. When they come to the US they are paired with businesses and are partnered with anyone from the CEO of the company to an Account Manager. YLAI is not only about the Fellows coming in and learning from an American company but also about them sharing their knowledge and passion with the company they are paired with. If you are interested in hosting a YLAI Fellow, please email info@re3d.org, and Jennifer will put you in touch with the proper contacts. re:3D hopes to continue partnering with YLAI for as long as we are around.

Jennifer Dennington

Blog Post Author

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

Blog Post Author

3d printing award Free 3D Printer Gigaprize giveaway

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

Ryan Murray

Blog Post Author

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!

Gigabot 3D Printer Portfolio Pellets, Flake and Filament

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 3D printing Pellets and flake materials

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.

TerabotX 2

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

9 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 All 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 FGF 3D Printing Solutions

Have any questions?

Revolucionando a Fabricação de Cadeiras: Uma Jornada com a Rhodes e a Gigabot da re:3D

The Gigabot FFF (Filament) Platform

The GigabotX FGF Platform

Software/Firmware

Internal Processes

And More…

Brookwood in Georgetown

GIGAPRIZE FINALISTS

AMERICA MAKES

A MESSAGE FROM BIG, 2023 GIGAPRIZE WINNER:

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?

Have any questions?

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