The Fire Station Gigabot

Chuck Grant wasn’t with the Magnolia Fire Department in 2011 when the Riley Road Fire happened,  but the effects of the massive blaze on the department he now works for as Assistant Fire Chief and Chief of Technology are still visible.

The fire took 10 days to contain and burned nearly 19,000 acres in Magnolia, Texas, northeast of Houston.

“The fire was in such a size that it knocked out cell service in a lot of areas,” Chuck recalls. This meant that the department’s typical public alert methods using Facebook, Twitter, and other cellular-dependent mediums were off the table. They had no easy way to communicate with the community they were trying to help.

What the firefighters found is that when residents didn’t know where to go or what to do, they came directly to the fire station to try to get information. But in a large-scale disaster like this one, that was a problem. “There was no one in the fire stations because they were all dealing with the emergency,” Chuck explains. The fire exposed a serious communication problem they realized they needed to remedy.

When Chuck joined the team, he began working with the Fire Chief to devise a solution to this problem.

What they came up with was something akin to a tool that many businesses use for public messaging: LED signs. The signs would be out front of each of Magnolia’s nine fire stations to display updates and actions during large emergency events, with the ability to change the information quickly and from the field.

The next order of business was aesthetic – they wanted to add a symbol of the fire service to the signs to make them their own, something that would look good for the community.

When they settled on the idea of a large fire hydrant statue on either side of each station’s sign – two at each location meant 18 in total – the next challenge became how to get them made. They started investigating options like fiberglass and bronze casting, but quickly realized that everything was far out of their budget.

That’s when they found Gigabot.

The sign project in conjunction with other potential uses for 3D printing at the station made getting their own Gigabot and fabricating the decorative hydrants themselves the most cost-effective option. Chuck already had a background in 3D modeling, so designing the hydrants was no problem. “It was just a matter of scaling something up from, say, an inch tall to 99 inches,” he said. “And the Gigabot was able to do that for us.”

The build volume of Gigabot was the original draw for their sign project, but in order to make the purchase financially worthwhile to them, they wanted the bot to have a second, longer-term use. This is where the RFID tags enter the story.

Fire stations operate under a system of strict regulations: a truck must have a certain amount of equipment before it can respond to emergencies, and this equipment has a variety of imposed lifetimes that need to be tracked. Chuck explains, “When I started 35 years ago in the fire service, no ax had an expiration date on it – either it worked or it didn’t. And now that’s all kind of changed. So the need for technology has really, really ramped up.”

On top of this, equipment must cycle in and out of the repair room as it’s damaged. A tiny crack to a mask takes that mask out of service until it’s fixed. Keeping track of what equipment is damaged, what needs to be replaced on trucks, where damaged equipment is in the repair process – they’re all more processes that need to be tracked.

All of these components add up to quite the logistical headache for fire stations: monitor the ticking clocks on your equipment to make sure active tools are not outside their expiration dates and take things out of circulation when they are, keep track of damaged items in for repair, and ensure your trucks have all the equipment they need to be ready to respond to a call at a moment’s notice.

It’s quite the operational feat for organizations whose main function is to save lives and battle fires.

In the interest of allowing firefighters to do what they do best, stations are looking for ways to manage all their equipment tracking in the most efficient way possible. Magnolia Fire found a solution in RFID tags from Silent Partner Technologies. The small radio frequency identification devices have an adhesive on one side to affix them to objects and they can be scanned from a distance and tracked via software on a computer. Chuck explains, “It very quickly gives the firefighters the chance to scan the truck and know that the vehicle is ready for them to respond to a call the minute they come into work.”

The problem was, Magnolia quickly realized that the harsh firefighting environment in conjunction with the wide variety of materials they had to tag was proving to be too much for the adhesive tags. “Because the fire service is a tough place to be a little tag, the adhesive strips on the back don’t hold up as well as they would in another application,” he explained. Heat from fires, water from hoses, and the general physical battery that the firefighting tools endure took their toll, and the department found themselves returning from events sans many of their RFID tags.

A solution, they realized, lay in 3D printing.

Using Gigabot, Chuck has been printing small compartments for the RFID tags to fit into which they can then mechanically fasten to their tools. 3D printing the tag holders provides a uniform material to which the adhesive can adhere, while also tucking the tags away where they can’t get bumped off. And they can do this all without altering the form and function of their well-designed equipment.

“All of our items have been well-designed, they’re well-engineered, and so for us to just take something and stick it on the side of it isn’t really a great option,” Chuck explains. What they’re doing is replicating a certain component of an object and building a pocket into it where they can hide a tag. The clip of a flashlight, for example, is replaced with its 3D printed clone, plus one RFID tag that you wouldn’t know is there. This becomes infinitely important when when you’re in a smokey room with thick gloves on, where a foreign part on a familiar tool can lead to dangerous confusion.

If the sign project was what led Magnolia Fire Department to Gigabot in the first place, creating custom RFID tag holders for their equipment is what kept them coming back. It’s proven to be the long-term justification they wanted in order to get their own 3D printer on-site.

“We certainly had this sign project that’s important…it’s going to be the thing that people notice the most because it’s going to be out in front of the building,” Chuck says. “But long-term, to get the most out of our investment, we need that secondary…task for the Gigabot to do.” The ongoing RFID project checks that box.

Gigabot has also proven itself as a problem-solver for issues that weren’t necessarily originally on Magnolia’s 3D printing radar, as the department now has the ability to produce any sort of custom-made pieces they desire. “Instead of going into the marketplace and kind of having to mold to what is available, we can meet our own needs by drawing our own parts and printing them,” Chuck explains.

An example of one such piece is an ingenious yet simple part to hang the firefighters’ masks inside the trucks, keeping them off the seats and floor where they’re more likely to get damaged, and hanging them in a way that doesn’t put stress on the facepieces. The clever design fits into the masks where the firefighters’ air tanks connect; with one twist they lock onto the piece so they can’t fly off en route.

The station’s service room is lined with equipment in for repair, including a table full of dinged masks. Much of the damage was due to them being tossed around inside trucks or hung in a way that puts undue stress on the temples of the masks, causing them to crack over time. This new piece, they explain, solves these problems and was infinitely simple for them to manufacture.

Clessie Hazelwood, Battalion Chief at Magnolia Fire Department, originally saw the design 20 years ago at a different fire department. Chuck prodded him to talk about how much effort that department had to go through to produce one. Clessie sighed, “Oh…they had to do machining, set up dies and everything.” It was a long, costly process.

When Magnolia got their Gigabot, Clessie came to Chuck to see if the part was something he could print for them. Chuck chimed back in, “From the time you told me about it ’til the time you held it in your hand, how long did it take?” Clessie paused.

“Less than a week.”

Morgan Hamel

Blog Post Author

3D Printing Products for Refugees

The Gigaprize is a competition we run for every 100 bots we sell to donate a Gigabot to an organization that will use it for good. Scott Key originally saw the call for contest entries on Instagram.

He and his business partner, Sam Brisendine, thought the odds of them actually winning were pretty slim, but they decided to give it a shot anyway. That decision ended up paying off handsomely.

The winners of the 400th Gigabot are Good Works Studio, a Houston-based design firm specializing in products for refugees.

Sam and Scott met as students at the Rice University School of Architecture, where they developed a sort of Swiss Army Knife crate of supplies for refugees as a class project. The crate itself broke down and transformed into a floor, and as time went on, they came to realize that the most valuable part of the whole package was not the cache of supplies inside but the box itself. Emergency Floor was born.

Thus a school project gave birth to Good Works Studio, the company that the two cofounded specifically to develop products for the refugee space. Their first product, Emergency Floor, is a modular flooring system for refugee camps that can be quickly installed and configured to the varied layouts and sizes of different shelters.

Flooring for these refugee camps provides families with something more than just comfort: safety. The flooring acts as a thermal break between the cold nighttime temperature swings of places like Iraq and Lebanon, as well as a means to combat the higher rates of diarrhea and parasitic infections that come from living in the dirt.

Emergency Floor is just the first product that Scott and Sam have released to tackle problems faced by millions of refugees around the world, and they’ve got more in the works. However, the design and prototyping process that goes into developing products like these is not cheap, and Good Works Studio is a young, cash-strapped, two-man company whose founders work separate full-time jobs to pay the bills. They ran a crowdfunding campaign to get Emergency Floor off the ground, but they knew that the money and time needed to take future ideas from paper to product would be prohibitive.

Traditional manufacturing and tooling isn’t the most forgiving when it comes to the design process. Get a mold made and then decide you want to tweak something in your design, and you’ve just gotten yourself a $15,000 paperweight. Perfecting the design before moving on to manufacturing was imperative.

“Previously we had outsourced 3D printing and other prototyping methods,” Scott explained, but, as he went on, “It was just going to be an impossibility to do the amount of iterations we needed to get a product to where it needed to be.”

Having an in-house 3D printer was the dream.

For Scott and Sam, Gigabot is an enabler. Having a 3D printer of their own means getting well-designed products into the hands of people who need them more efficiently and effectively. They can send a design file to print in the morning, have a prototype in their hands by the afternoon, and start printing a modified version before they leave at the end of the day. This ability to iterate their designs quickly and in-house allows them to move through the prototyping process much faster and less expensively than any other avenue.

The overarching vision that drives Sam and Scott is a desire to help those in need around the world through design. The next product they’re working on is a device that can be installed into any shelter to act as an air conditioner – sans electricity – using the Venturi effect.

Our aim with Gigabot is to enable others to create products that make this world a better place, and the Gigaprize is our way of making this technology even more accessible to people who will do just that.

As Sam put it, “Design can do good for those who can’t afford it.” We couldn’t agree with him more.

Learn more about Good Works Studio and their first product, Emergency Floor: 
Twitter: @EmergencyFloor
Instagram: @EmergencyFloor
Facebook: https://www.facebook.com/emergencyfloor/

Morgan Hamel

Blog Post Author

Lessons Learned from Starting a 3D Printing Business

We’ve made it to the final post in Darrel Barnette’s series about the 3D printing company he started, Digital to Definitive. In this final video, Darrel shares the biggest lessons he’s learned as a new small-business owner and as someone who’d never done it before.

Darrel had no previous experience starting, running, or even working for a business in the realm of what he built. His career had been big companies, government, and universities – very much a different environment from what he found himself in with Digital to Definitive.

The lessons he’s learned have been invaluable: educating your clients on 3D printing is necessary for better project outcomes, 3D printing can be a finicky technology and isn’t always perfect, and most importantly, relationship-building — before you embark on starting your own business — is crucial.

The whole process has been a journey and learning experience, Darrel says. But for him, the long hours and late nights are worth it.

Have you thought about building your own 3D printing business from the ground up? Let Darrel give you a taste of what it’s been like and see if it might be for you.

Morgan Hamel

Blog Post Author

Gigabot Mods & the Open-Source Movement

If you’ve been following along with the Digital to Definitive Story thus far, you may have noted to yourself that Darrel Barnette’s Gigabot looks a little different than the rest. You’re not imagining it – he has modified the heck out of his bot.

And that’s what we like to see! From the start, we’ve been committed to keeping our products open-source, our parts transparent, and our designs un-patented. Our goal is to encourage Gigabot owners to customize their bots to their needs, and from this, our engineers get to learn what’s important to our community and add priorities to our R&D pipeline. We have users who have added webcams, remote printing capabilities, full enclosures… And then there’s Darrel.

He was an early Kickstarter backer – an engineer with a natural affinity for tinkering and experimenting – and those skills were put to work with his first-gen Gigabot.

We’ll let Darrel take you through the modifications he’s made to his bot and why he did them.

Morgan Hamel

Blog Post Author

This 3D Printing Story Will Blow You Away

We find ourselves now at the third and final leg of the stool making up Darrel Barnette’s business: contract 3D printing for other people/businesses (non-governmental contracts).

He describes it as being rewarding work, because it’s where he gets to give back to others in the form of his 3D printing skills that he’s spent the last several years honing.

Darrel’s first contract printing job as Digital to Definitive was for a group of engineering students at the University of Central Florida who had found themselves in a pickle. They needed a physical prototype of their [spoiler alert] vertical axis wind turbine (the clickbait title should make sense now), hadn’t had luck finding anyone with a 3D printer large enough to take on the job, and had exhausted their own attempts to build a working model.

Darrel came to the rescue, printing the three blades of their turbine all at the same time, standing them up on his Gigabot’s bed to print in one piece.

We don’t want to spoil too many surprises for you, but the project was a success. Check out the video to hear Darrel’s take on this win-win situation.

Morgan Hamel

Blog Post Author

3D Printed Patents

Darrel Barnette’s main focus for where he wants to take his company, Digital to Definitive, is towards the realm of producing the products he’s been mentally developing and cataloging over the last several decades.

Among the products he’s used his Gigabot to design: bracketing for a hydraulic two-wheel drive motorcycle, an adapter for hunters to mount devices to a firearm, and a horseshoe-shaped part that helped make his skeet thrower a lot easier to set up.

He also has noticed that beginning to physically prototype a rough idea he’s had in his mind can often allow him to hone in on what exactly makes his product unique and therefore patent-worthy.

And while Darrel has noted before that contract 3D printing work currently takes up about 75% of his time, the ultimate goal is to move the business more towards working on his own products.

As he puts it, his vision is that he “can just open up the door to my shop and there’s my whole factory.”

Morgan Hamel

Blog Post Author

3D Printing for the Government

Darrel Barnette understands that it may seem strange that the US government is paying other people to do their 3D printing.

But what they understand, he says, is that even an entity as large as them is not exempt from the 3D printing learning curve. “It takes a lot more than just having a 3D printer to produce a 3D printed part,” he explains. “The government realizes that, and they don’t have the time to stop what they’re already doing to learn something new.”

It’s in their best interest at the moment to dedicate their time and human resources to other projects and instead pay outside entities to do their 3D printing work for them. And this is where businesses like Darrel’s come in.

Digital to Definitive’s 3-pronged business model relies heavily on this 3D printing government contract work at the moment – about 75% of Darrel’s time is consumed by it, since he worked so hard with a Bid Protest Attorney in order to win the contract. In the future, he’d like to flip this ratio so that most of his time is spent working on his own projects, but he understands that he needs to, as he puts it, “walk before he runs.” It’s this work that will ultimately allow him to make the transition to focusing most of his time on his own 3D printed products.

Come get a glimpse into the first pillar of the business Darrel has built from the ground up: 3D printing for the government.

Morgan Hamel

Blog Post Author

Digital to Definitive: The Genesis

This is the first video in a series about Digital to Definitive, a company started by Texas-based Gigabot owner Darrel Barnette.

Darrel Barnette was one of the first Kickstarter backers of the original Gigabot four years ago – his bot’s serial number is GB2-028.

He got his Gigabot with no prior 3D printing experience – he had a background in aerospace engineering and a desire to use to use the blossoming technology to create product ideas he had been holding onto in his head.

It took him assembling his bot and starting to use it before he thought of the idea to make a business out of it. Two forces combined to plant the idea in his head.

One, his job at the time had him traveling a lot, which he wasn’t a fan of; and two, he began to see the power of the technology for himself. “Having the 3D printer and the capability of being able to make my own parts for the first time…was just enticing to me,” he explains.

Darrel began to realize that a business opportunity lay in the new Kickstarter product he had gotten for himself.

Entrepreneurs, inventors, tinkerers, dreamers – take note. Darrel’s got a story you’re going to want to hear.

Morgan Hamel

Blog Post Author

Investment Casting with 3D Printing

The following post was written by Todd Ronan. Todd joined the re:3D sales team after hearing a Co-Founder panel discussion on 3D printing & recyclable material at IEEE. From Michigan, parts Northwest, and now Austin (Portland’s si(hip)ster city) he is a Futurist, passionate about evolving technology, dreamer, and enthusiast of fine meade.

The thousand year old lost wax casting process has been revolutionized by the Human-Scale 3D printing of Gigabot

Several re:3D customers have augmented their foundries with Gigabot 3D printers because of the time savings, cost savings, and ability to convert more jobs into happy customers.

In traditional investment casting, a wax model is dipped into a ceramic slurry which is then allowed to dry. The resulting hard ceramic shell is then heated to melt the wax away, leaving a perfect model negative where the wax used to be.

Modern foundries however, have been making the move to 3D printing as a means of creating models for casting. With the ability to use  PLA prints in place of the wax models of old, 3D printing provides a cost efficient alternative method for producing investment casting patterns.

In layman’s terms: hot melted plastic can be printed in any shape, in any size, and allows for a cost efficient alternative to the traditional technique of lost wax casting.

In the past, 3D printers lacked the size to perform life-sized pieces and large format 3D printers, starting at $100K have been cost prohibitive. Enter re:3D’s Gigabot at 1/10th the price. A 3D printer with an 8 cubic foot build space for super-sized 3D printed parts.

Anyone lucky enough to find themselves outside of Austin in Bastrop will notice the beautiful, large bronze pieces of art around the city. These are courtesy of a high-point on the Austin Cultural Map tour, Clint Howard’s Deep In The Heart Art Foundry. Jamie and Clint Howard purchased the foundry in 1999, and have become the premier statuary design and manufacturing business in the state of Texas.

With demand for large pieces the foundry added a Gigabot FDM printer to their arsenal a couple of years ago. Instead of the long curing process associated with wax models, their Gigabot can make any design using standard CAD program, and print HUGE in PLA. It just so happens that PLA burns out just as clean as wax! The cost savings was almost immediate – cutting months and thousand of dollars off traditional casting allowing for increased bandwidth for contract pieces, and substantial revenue increase. With increased demand for printing, Deep in the Heart ordered a second Gigabot printer to keep up with the demand.

Another re:3D satisfied customer: family owned and operated Firebird 3D, located in Troutdale Oregon, recently participated in the Columbia River Highway centennial celebration.  Parts on this Model A (shown below) were Gigabot printed and cast along with this Rip Caswell piece, Devoted Passion, a re-telling of the exploration and creation of this amazingly scenic Pacific Northwest highway.

At Firebird they still use their traditional processes of wax casting but can use wax filament or PLA to print larger bronze pieces. It burns out, leaving a small amount of ash in the shell mold, which can be removed with washing. 3D printed PLA plastic burns out cleanly and is a more durable and more easily handled than a wax part. Chad Caswell (shown below) checks the layer height of their next print. They are, literally and figuratively burning through filament with a cost savings up to 70% by reducing labor!

We just got word Deep in the Heart purchased a 3rd Gigabot to help with workflow and high demand, and now has three 8 cubic foot 3d printers printing (money) while their workers sleep.

re:3D urges: Try a FREE print on us. Find out if Lost Wax (minus WAX + PLA) works for you! Please contact info@re3D.org for additional info on Gigabot 3D printers and lost wax castings!

Mike Strong

Blog Post Author

Making Electric Motorcycle Battery Packs with Farasis Energy

“I got into 3D printing while I was in college doing my electrical engineering degree. One of the things that really got me interested in it was being able to make a box for the electronics projects that wasn’t made out of cardboard and duct tape, which is kind of a trademark of most EE students.”

This is Chase Nachtmann, a Systems Engineer at Farasis Energy.

“That kind of sparked my interest in working with 3D printers, because it’s a way of designing things…and having them come out exactly the way that you want.”

Nachtmann ended up managing the high-end industrial 3D printer at his university, and has now put this knowledge to use post-graduation.

Farasis, based out of the San Francisco Bay Area, makes lithium ion batteries for electric vehicles. They use Gigabot to print parts for a variety of applications throughout their battery pack development process.

Part of that process involves bolting their pack onto a shake table for testing, which puts it through the ringer by vibrating at a punishing 90 G’s sinusoidal in each direction. This particular piece of equipment is pricey to rent time on.

“It’s very expensive, and it costs a lot per hour,” Nachtmann explains. Jackson Edwards, an Applications Engineer at Farasis, jumps in – “Four hundred and fifty dollars.”

Nachtmann continues, “ When you’re doing a custom-shaped box, at least one hour is just spent bolting it onto the table in a secure fashion.”

This is where their Gigabot comes in.

“By printing it, we have a custom box that has the mounting holes already integrated into it – we’re saving a lot of money that way – and we’ve found that printing it was definitely strong enough after we filled the inside with an epoxy body compound,” Nachtmann says. “It saved a significant amount compared to having it machined out of aluminum.”

This machining process was their only option prior to getting a 3D printer. Edwards recounts the process of shopping around for the most affordable option. “We were quoted between two and five thousand dollars for the piece of aluminum, and it also had a 2 week lead time,” he recalls. “Having the ability to make these fixtures in-house is a huge help.”

Contrast this with what it costs them to make the 3D printed version, an extremely dense, 100% infill piece, and it’s a no-brainer. The printed piece uses about five pounds of filament, bringing their cost of printing a custom box to just under $100. On top of that, there’s no lead time: it’s something they can do in-house as needed.

The Product in Action

One of Farasis’s battery packs’ big applications right now is electric motorcycles.

“We just recently completed a build for Brammo’s Isle of Man motorcycle,” says Edwards. “The bikes performed flawlessly and everything went great.”

Another notable name on their customer list is Zero, known for their high-performance electric motorcycles.

“They are right in the middle of their build year right now, making 17 bikes a day,” Edwards explains. “Going to a production-level status with them is pretty fun.”

Zero’s bikes use somewhere between 56 and 140 of Farasis’s battery cells, and the Farasis team has also made some 3D printed test fixtures and parts for their validation builds.

As a true sign of someone in love with their work, Jackson proceeds to wheel out a Zero bike of his own from the back of the office.

“I commute from the Santa Cruz area,” he explains. “I used to commute from Aptos, which was 67 miles one-way…but now I’m a little closer and it’s only a 50 mile trip.”

He explains that the bike has a range that would allow it to do the entire round-trip on one charge, but as he puts it, “it’s nice to have a little bit of headroom.” He opts to plug in at the office while he works.

I get my motorcycle-fantasy fix vicariously, so I leave with the question: how fast does this thing go?

“The fastest I’ve had this one is 105,” Jackson reveals. “It’s a heck of a lot of fun.”

Morgan Hamel

Blog Post Author