February Puzzler Solution Revealed!

Below is the solution to the Monthly Puzzler Chief Hacker presented in our February Newsletter. Want to play? You can sign up to receive our monthly publication by submitting your email address in the sign up at the bottom of re:3D.org. Proposed answers are presented on our forum at: https://re3d.zendesk.com/hc/en-us/community/posts/205859796-February-Puzzler

THE SOLUTION

Here are the two reasons you will see a visible mark between processes.

Answer #1. If the SECOND process settings (upper part of the print) has “First layer height” that does not match the layer height for the FIRST process there will be an odd layer thickness visible on your print. Make sure the first layer height and first layer speed for the SECOND process are set to 100%

Answer #2. When setting the “Stop Printing at Height” make sure the dimension is an even multiple of your layer height. Don’t forget to account for any changes in layer height if you enter a value other than 100% for the FIRST process “First Layer Height”!

Since Darrel had one of the two correct answers we will be sending you half a spool of filament 🙂  Just kidding Darrel! Thanks for playing and keep an eye out for next month’s puzzler.

Happy Printing!

Matthew Fiedler

Blog Post Author

@chief_hacker

Filament Testing – 3D Fuel Advanced PLA

Below are our notes that respect our new open source filament testing. ASTM test samples are being created and in the upcoming months you can anticipate a summary on our website that reflects our adventures in 3D printing material science. 

Material Tested: 3D FUEL/APLA

Manufacturer: 3D Fuel

Filament Diameter: – 2.85mm

Color Tested: Bright green

Date Tested: 2/29/2016

IMG_2143

OBSERVATIONS

Ease of use:  Extremely printable with excellent adhesion.

Appearance:  The green filament was vibrant with a smooth texture. Prints yielded a slightly “shiny” surface.

Size consistency:  Average, within .1mm within roll.

Color consistency: Great, consistent throughout roll.

IMG_2140

SETTINGS

Print temperature: 210 C (nozzle) / 55C (bed)

Printer Used: Gigabot

Speed: 45 mm/s

Layer Height: 0.3mm

Infill: 30%

Type(s) of print surface used: PRINTnZ

List of test files printed: re:3D’s test files 1, 2, and 3 (logo, vase, airplane gear piece)

 You can watch a video  summarizing our testing:

FINDINGS

Odor: None

Bed adhesion (1: terrible – 5: fabulous!)

  • 5 (only the settings listed above were tested, but the manufacturer’s recommendations seemed to be accurate)

Stringing (1: lots -5: none!)

  • 5 – None!

Shrinkage (1:lots-5: none!)

  • 5-None!

Interlayer adhesion (1:terrible-5:fabulous!)

  • 5- Perfect!
IMG_2154

NOTES:

  • The promise of a more heat resistant PLA is super enticing to the 3D printing community.
    • After testing, the landing gear was exposed to high temperature heat via a hair dryer and showed little warping.
      • Further controlled testing would need to be implemented to investigate this claim, but it does initially appear to be stronger and more heat resistant than traditional PLA.
  • NOTE: this filament was tested 4 months after receipt, however, for many users a 4 month shelf life is necessary.
    • Testing fresh filament is expected to yield similar or even better results.
  • Filament size consistency was about on par with most filament.
  • No delamination or curling was observed.
  • All testing was conducted at the midpoint of the temperature and speed range that the manufacture provided. It’s likely that the outcome would have been even better had the ranges had been explored in more detail.
  • The unboxing experience was well done and the recommendation sheet was highly professional.
  • We appreciated the Made in America reference, and date stamp of quality control on the box & insert.
  • Manufacturer recommended settings were easily referenced on the enclosed documentation.

RECCOMENDATIONS:

  • This filament is extremely impressive and more than exceeded it’s claims.
  • Upon review, we would highly recommend that this filament be submitted to ASTM testing by evaluating coupons at multiple temperature and infill settings.

Want to chat? Join our forum where we have initiated a thread about our experience!

https://re3d.zendesk.com/hc/en-us/community/posts/205198503-TESTING3D-FUEL-APLA

~Happy Printing!

Samantha snabes

Blog Post Author

Filament Testing: Printing with Algae!

Below are our notes that respect our new open source filament testing. ASTM test samples are being created and in the upcoming months you can anticipate a summary on our website that reflects our adventures in 3D printing material science. 

Material Tested: 3D Fuel/Algae-Fuel

Manufacturer: Algix3D

Diameter : – 2.86mm

Color Tested: Slightly green/brownish

Date Tested: 2/28/2016

IMG_2133

OBSERVATIONS

Ease of use: A little tricky due to the brittle nature of the filament, however, once you get started you are good to go!

Appearance: Aesthetic, reflects sustainability, “rough texture”, definitely not smooth!

Size consistency:  Average, within .1mm within roll.

Color consistency: Great, consistent throughout roll.

IMG_2134

SETTINGS

Print temperature: 175 C (nozzle) /55C (bed)

Printer Used: Gigabot

Speed: 30mm/s

Layer Height: 0.3mm

Infill: 35%

Odor: Earthy, smells like algae

Type(s) of print surface used: Print n Z

List of test files printed: re:3D’s test files 1, 2, and 3 (logo, vase, airplane gear piece)

 You can watch a video  summarizing our testing:

FINDINGS

Bed adhesion (1:terrible-5:fabulous!)

  • 4 (could have been optimized by adjusting cooling/ temperature)

Stringing (1: lots -5: none!)

  • 4 (could have been optimized by adjusting speed/ temperature)
    • Only noticed slight stringing in vase

Shrinkage (1:lots-5: none!)

  • 5-None!

interlayer adhesion (1:terrible-5:fabulous!)

  • 5- Perfect!
IMG_2155

NOTES:

  • A renewable filament that reduces the environmental footprint of production is highly appealing to the 3D printing community.
  • The biggest limitation is the brittle nature of the filament, making initial setup a little tricky. NOTE: this filament was tested 4 months after receipt, however, for many users a 4 month shelf life is ideal.
  • Filament size consistency was about on par with most filament.
  • Little delamination and no curling was observed.
  • All testing was conducted at the lowest temperature and speed range that the manufacture provided. It’s likely that the outcome would have been even better had the mid to high range temperature ranges had been explored.
  • The unboxing experience was well done and the recommendation sheet was professional.
  • We appreciated the made in America reference, and date stamp of quality control on the box and insert.
  • Manufacturer recommended settings were easily referenced on the enclosed insert

RECCOMENDATIONS:

Not all users may appreciate the aroma, however if you are looking for a more sustainable 3D printing alternative and doesn’t require a smooth surface, this materials may be for you!

Want to chat? Join our forum where we have initiated a thread about our experience!

https://re3d.zendesk.com/hc/en-us/community/posts/206091996-TESTING-3D-FUEL-ALGAE-FUEL

~Happy Printing!

Samantha snabes

Blog Post Author

re:3D & SXSW 2016!

It’s almost here!  That time of year where Austin embraces global creatives during the two week whirlwind we call SXSW.  We love being so close to the action and can’t wait to see you out and about. If you’re in the area, please stop by any of the events below to say hi!

SXSW Create

  • Dates/times: March 11-13th, 11am-6pm
  • Location: Palmer Events Center
  • Cost: Free!!
  • Website: SX Create, They also have a  SX Create Facebook event as a handy way to share the event.
  • Description: Exciting hands-on pavilion as well as a number of wonderful STEM sessions. Gigabot Generation 3.0 and OpenGb will be printing live for onlookers while the re:3D team gives high-fives.
  •  

News & Schmooze: A SXSW Media Mixer for Startups and Investors

  • Dates/times: March 11, 5:30pm
  • Location: Capital Factory
  • Description: We’re bringing Gigabot to print live at this invite only event hosted by our friends at Own Local! The re:3D gang will be out in full force while Jeric presents our mission and product!

Capital Factory - “Austin Goes Global” Pitch

  • Dates/times: March 11, 3-5pm
  • Location: The Hilton Startup Village
  • Website: http://schedule.sxsw.com/2016/events/event_PP58415
  • Description: Capital Factory will spotlight several startup and early stage companies already having big impact across borders, and several more on the threshold pondering what to do next…where to go…how to do it?  In this conversation Katy will share re:3D’s reach.

IEEE Tech for Humanity Official SXSW Party 2016 

  • Dates/times: March 13th, 8-10 pm
  • Location- The Driskill
  • Website: http://www.cvent.com/events/ieee-tech-for-humanity-official-sxsw-party-2016/event-summary-fcfd9489c2a54a739252ae5356e427ce.aspx
  • Description-Party like an engineer with IEEE and world-renowned technologists & body computing brainiacs! Join us at The Driskill with Gigabot and the re:3D team to let loose with a few drinks at the open bar and enjoy great music!

SXSW Hardware House - Hardware on Kickstarter

  • Dates/times: March 14, 9:30-10:30am
  • Location: Courtyard Marriot
  • Website: http://schedule.sxsw.com/2016/events/event_PP58037
  • Description: The exhilaration of the pitch isn’t just for Venture Capitalists anymore! Consumers, geeks and fans are tuning in each week for shows like Shark Tank (and others). How do inventors take a great idea to the airwaves and stay on task to become a great company? What are the pros and cons? Why are so many people watching and how do you capitalize on it? In this session Katy will explore how hardware innovation and entrepreneurship is being showcased and celebrated on prime time and how to make the most of it if you decide to go on the air.

Hubs/RE:3D / Draught House Pub 3D Printing Meetup

  • Dates/Times: March 14th 12-2pm
  • Location: The Draught House Pub
  • Description: Come meet Hubs, re:3D communities and other 3D printing enthusiasts in a laid back environment on March 14th! This is a great opportunity to share your love of 3D Printing and see 3D Printers live. Feel free to bring your best prints and ideas!
  • Want more? After March 14th Gigabot and the team are super flexible if you’d like to request their presence:)
  • Email: info@re3d.org

Samantha snabes

Blog Post Author

January Puzzler Solution re: Waavy Prints

Below is the solution to the Monthly Puzzler Chief Hacker presented in our January Newsletter. Unfortunately we didn’t have a winner, but look forward to receiving the entries in this month’s featured problem.  Want to play? You can sign up to receive our monthly publication by submitting your email address in the sign up at the bottom of re:3D.org.

If you remember last month’s puzzler, I was asking why the top solid layer was making waves and not laying down flat. If we zoom in on the picture you may notice the last layer of infill is oriented parallel to the solid top layer. Some “roads” or “tracks” of the solid top layer have nothing underneath to bond to and lifted up as it cooled and contracted thus forming the waves.

To avoid this you will need to verify the last layer of infill is printed orthogonal to the solid top layer. In Simplify3D use the toolpath verification and visualization to ensure the correct orientation of the infill. If required, you can change the infill orientation on the “Infill” tab in Simplify3D.

Happy Printing!

Matthew Fiedler

Blog Post Author

Materials Testing: PLA++, PLA, & n-vent

With some new filament in the office, I took the opportunity on a recent visit to Houston to do some materials testing, also known as breaking things, which happens to be my specialty.

My main goal was to test out a new filament called PLA++ by Breathe-3DP and compare it to the regular PLA we use. As they describe it, the second “+” is for functionality – where normal PLA snaps, their PLA++ stays strong. I wanted to see that for myself.

To spice things up a bit, I threw some n-vent into the mix, which ended up adding a nice third dimension to the spectrum of strength we saw.

I printed out a handful of the ASTM Tensile Test Specimen, dubbed the “dogbone” in the office, and got to breaking things. The PLA++ was first on the chopping block.

You can see in the video that I’m able to get the dogbone flexed into a nice St. Louis Gateway Arch shape – it had a good amount of give to it. I could feel the material bend under my fingers; in the video you see the edges in the center start to turn a slight white color as the print flexes. Only once I move my thumbs to the outside of each end and force the two together does the center finally give.

Even once it does finally break, only the top of the print has actually split – the bottom is still attached. It takes me ripping the two apart to separate the two halves. You can see in the video how much the print has curved due to my bending it, and it retains that bend even after it is broken.

The flexible nature of the PLA++ becomes more apparent when compared to the standard PLA test. PLA, our choice filament around the office, is known for its ease of printing, but also its brittleness.

I’m able to flex the PLA dogbone a fair amount – further than I expected, but not as far as the PLA++ – but its reaction to this flexion is explosive and violent. You can see pieces rocket off once the print reaches its breaking point, loud enough to make one of our engineers in the room jump and whip around to see what new trouble I was getting myself into.

Last up was the wild card, Taulman’s n-vent. What seemed promising to me was its ease of printing yet also its toughness and resistance to high temperatures.

The n-vent wouldn’t quit. I bent it one way, then the other way, then back the first way, flexing it beyond where the PLA++ made it. When it finally gives up the fight, it’s a slow, unceremonious break. With the outer edge finally split, I’m able to flex the two ends until they touch, and even then the dogbone wouldn’t break in two.

You may notice a hand model swap at different points throughout the video – our lead engineer jumped in for a piece of the action – and the n-vent put up just as much of a fight for him. He bent the two halves back and forth several times before forcefully ripping them apart.

In the close-ups at the end of the video you can see the stringy infill of the n-vent print, the internal structure which kept the two ends hanging onto each other so well. In contrast, the standard black PLA shows a clean break – unsurprisingly – after the gunshot-like force by which it broke. The PLA++ shows an edge somewhere between the two – not stringy like the n-vent, but with a rougher edge than the standard PLA, due to the slower, bendy break it experienced.

In the end, the n-vent won out in overall toughness, with the PLA++ a close runner-up; though the PLA++ has a leg up in the “ease of printing” category. The standard PLA continues to be a favorite around the office and strong recommendation from our engineers to our users due to the fact that it prints so well and easily. For design and prototyping it does the trick – it’s only once you venture into working prototypes that require some strength or temperature resistance that you may run into issues with it.

In conclusion, each filament has different strengths that lend it well to different applications – it’s all about choosing the right one for your particular project.

Morgan Hamel

Blog Post Author

2016: Stories Made in America

Over the past 3 years our company and community have seen a ton of changes. Through a shared vision to make industrial 3D printing more accessible, our team rallied from multiple locations across the US, scaled our idea in Chile, and later established headquarters in Texas. Since launching in Santiago, we’ve opened two offices in Houston & Austin, which is complemented by a remote sales presence in San Francisco.  Although our team is centralizing operations in the USA, re:3D remains thankful to our Chilean roots and the $40K in funding that gave us the opportunity to make an idea a reality.

We also recognize that through our 2 crowdfunding campaigns that Gigabot’s reach has expanded to new frontiers around the world.  We will always attribute our 2013 Kickstarter success to the thoughtful insight, organization, and advertising enabled through the Start-Up Chile program. However, since leaving Santiago after 7 months, customers and suppliers throughout both North America & South America have emerged in Texas and beyond.

IMG_0818
Visiting Mkerstudio MX / Impresión 3D Gigabot & team in Mexico City

With this in mind, we’ve invested considerable effort into analyzing how our community and resources have evolved over three years. For example, you can view a breakdown of where our customers are located in the map on our website. In our examination of where re:3D has impact, we’ve discovered that over 80% of the materials we source for Gigabot, 100% of our labor, and 78% of Gigabots in the field are in North or South America.

In 2014 & 2015 we also sent out surveys to our community, interviewed over 50 customers in person and attended events throughout the US that allowed us to engage with up to 500,000 people to hear your thoughts on human-scale 3D printing. Undeniably the biggest request of all of our road-trips was that we share stories of our personal adventures printing huge and those of the 300+ Gigabots worldwide. We’ve also had a strong demand for a more robust forum, which Mike is hoping to launch next month- more to come!

As we’re still proudly bootstrapping, it struck us that we have an enormous opportunity to immediately leverage the dense community around us to photograph, video, and document the customers we encounter. We’ve devised a list of questions to capture information we’re told you want to hear:

  • Longest print
  • Biggest print
  • Application/ reason for printing huge
  • Materials tested
  • Favorite print
  • Challenges, feedback and requests
  • Cost and Time Savings
  • Your Gigabot Workspace
  • Your workflow

We hope this is only the beginning of building stronger relationships with all of our customers personally. We aspire to eventually meet all our customers, and are focusing first on sharing the stories of those closest to our operations first. We’re hoping to socially engineer affordable ways to ultimately canvas the globe, but for the short term we’d like to intentionally focus locally.

route66

With this in mind, we’re pleased to announce our Made in America campaign. Each week, beginning next week, you can anticipate a blog, video and photographs that share the experiences of pioneers like you, who #dreambigprinthuge as we hit the road to engage with our American clientele.

To ensure we are fulfilling your requests for more curated content, we’d love your input. What questions would you like us to ask customers? Who would you like us to visit? Are there any National Parks we should check out enroute? We welcome your suggestions at marketing@re3d.org as we embark on an adventure to explore what’s being #madeinamerica on Gigabot.

Happy Printing!
~Samantha & Katy

re: 3D Printing Furniture

My first attempt at 3d printing furniture went pretty well. The stool I designed  and later printed on the Gigabot ended up on-stage with Samantha Snabes, Co-Founder of re:3D, presenting to 5,000+ attendees at Web Summit in Ireland. Somehow along the way, Prime Minister Enda Kenny struck a pose with it. What an honor!

re:3D won 2nd place out of the Beta Pitch group and the 3D printed stool made it into several of the pictures that ensued; very exciting to watch the twitter streams.

For my next project, the goal was to create a piece that combined 3d printing with existing materials. I had been saving a slab of walnut purchased from eBay and thought, why not turn it into a bench? It was a pleasant challenge designing the base to follow the feel and flow of the live-edge slab. I wanted technology and nature to seemingly merge. It’s a beautiful slab and I needed to do it justice! There’s a great book out there about how loads are distributed in nature which helped to inspire the bench; it’s called “Design in Nature: Learning from Trees” by Claus Mattheck.

benchinprocess

The piece required a two-part print due to the large size so it was split it at an inconspicuous angle down the middle. The base was designed with pocket-screw holes and once lined up, was secured to the live-edge slab with pocket-screws. While the print itself was structurally sound, I coated the entire bench in clear epoxy just for some added strength. The gloss finish on the base was sanded back down to satin using 200 grit sandpaper. The indicators on the bench represented spots that I had missed with epoxy; they pointed out where I had to touch up on a second coat.

I was very pleased with the result and honored to have been included in Big Medium’s Austin East alongside many other great artworks.  Even Google’s self driving car stopped by to see what’s up. I think they look good together.

Mike’s 3D printed bench is featured at the Big Medium East Austin Studio Tour (self-driving car for scale:)

Having access to a Gigabot has opened up so many more doors due to it’s scale and precision. Can’t wait to start my next project which I will be sure to post about in the next couple of months.

Happy Printing!

Mike Battaglia

Blog Post Author

re: thinking Buoyancy – Hanging 10 on a 4pc PLA Surfboard

The Big Idea

Like most start-ups intent on exploring the intersection of tech and sheer awesomeness, the vision to 3D print a surfboard was cast over beer, at a co-working space (Capital Factory), subsequent to a lack of sleep. Disregard the fact the nobody physically present at our Q2 re:treat had actually surfed, we were still proudly penny-pinching, and had few Gigabots available for extended personal print marathons. Instead, Marketing Co-Leads Katy and I corroborated with our Gigabot Ambassadors Rebecca, Morgan and Todd to develop a list of “use cases” to demonstrate functional 3D printing to be executed by a cadre of summer interns. Buoyancy made the shortlist, and a surfboard was an obvious case study.

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Q2 re:treat with @Marvin_3D

Our leadership team cultivated job descriptions, which Katy hosted under a tab she designed at re3d.org/careers. The response to our unpaid internship postings were higher than anticipated, and ultimately we selected Akshay as our 2015 Design Intern focused on 3D Printing a surfboard. Despite still being in High School, his confidence, professionalism and experience modeling through his high school FIRST Robotics team convinced me he was up for the challenge. He also had a glowing recommendation from his coach Norman.

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Brainstorming over Amy's Ice Cream w/Matthew, Annabelle & Akshay

The Design

Within just a couple weeks of on-boarding and conducting research on surfboard 3D printing, Akshay presented his concept. He had identified others who had been successful including a Father & Son, as well as professional 3D printed surfboard companies. Those that have gone before had done an amazing job curating surfboard designs that truly exhibit the benefits of 3D printing, whether it be enabling custom designs or geometries not easily produced in traditional manufacturing. However, due to the small volume of many affordable printers, we noticed multiple parts were required to later be stitched together like a jigsaw puzzle or they depended on expensive SLS printers to produce a monocoque body.

Endless Sinter SLS Surfboards
jigsurf
ABS Jigsaw Surfboard

Knowing that we had the benefit of leveraging one of the largest affordable industrial printers at our disposal, we set out with Akshay to investigate if we could make a FFF (Fused Filament Fabrication) design in the fewest pieces possible. We also wanted to challenge notions of material strength. Akshay’ s research unveiled that our desktop 3D printing peers used ABS, a plastic despised by many for its stinky smell during printing, but stronger than it’s as readily accessible counterpart PLA. Being bootstrapped, we work from a small office, so we decided to use PLA to print our board to see if the sweet smelling, accessible filament could support the weight of a human in the ocean repeatedly, thus challenging the assumptions of PLA’s limited value in functional, life-sized 3D prints. You see, we didn’t choose PLA because we thought it SHOULD be the material of choice, rather we wondered if it  COULD be used in a functional application.

And if it worked (even limitedly), we wondered…..what other applications would you and other members of the open-source community cultivate that could expand on our buoyancy experiment?

IMG_0994
Akshay dialed into Katy's Design Tag

To develop the initial concept, Akshay paired up with our Summer Stand-up Paddleboard Design Intern Evan, who was also exploring the possibility of supporting a load on water.  During Katy’s Thursday Design meetings they evaluated each other’s models in Solidworks, discussed stress points, and analyzed the best way to join components. They also ran a series of experiments to deduce not only if PLA floated, but also if it could be water tight. While they initially pursued similar concepts involving a series of rods conjoining dense pieces, they later opted for separate methods. The stand-up paddleboard included a series of hollow segments, filled with Great Stuff, bound with Gorilla Glue, and fiber wrapped.  The surfboard, Akshay decided, would be four, 6% honeycomb-filled segments held together by a series of 50% infill 3D printed bricks. Like Evan, his instrument of choice for sealant included copious amounts of Gorilla Glue.

This was our first foray into a “formalized” summer intern program and the weeks flew by. We learned a ton about setting deadlines, procurement delays, accounting for R&D or marketing inventory in our budgeting & bookkeeping, and how to better mitigate bottlenecks in Gigabot availability for multiple, multi-day crazy prints.

As June turned to July, the scaled-models and sketches transformed to full-scale experiments. Katy’s design meetings became increasingly important as the group collected feedback from the team and data from real-world tests which influenced model adjustments.

Fin Design

Throughout the summer, the surfboard fin underwent as significant an evolution as our scaling team using input from experts, the open source community, and our own failures. Askhay’s first design included two tabs to be glued into the frame, which floated and appeared to have the infill & form required to be successful based on our initial tests. However, after delving into the minutia of surfboard design, Akshay discovered that most fins are supported via a T-slot in the surfboard body. For this reason, he later designed a fin to be inserted into a groove. Unfortunately, we later learned we needed screws holes on either side to mount into the T- nuts. Mike responded to the challenge and mocked the final design, which included the re:3D logo as well as fixtures for the screws to mount into Akshay’s conceived T-nut slot. Mike also suggested that the fin be printed in black to complement Akshay’s silver board.

Final Construction

By the time the 1.5 long week print was ready for the final piece, July had morphed into August and Akshay had to return to high school.  A couple of weeks into September we attempted to resume the project and he modeled the 4th piece using feedback I relayed remotely. Despite my best efforts, the measurements provided were a little off and the 4th piece wouldn’t align. Both Jeric and Mike supported a redesign and during a long weekend, Mike ultimately generated the final component to Akshay’s vision as well as some much needed “deckholes” our research revealed was required for a surfboard leash, which we purchased from SUP ATX as we figured the extra length on stand-up paddleboard leashes offered might be needed later. With the body complete, we encountered a new set of challenges. During a commute between our Houston and Austin offices, our almost finished 3d printed surfboard took a tumble on our high-strength 3D printed bicycle designed by Patrick, leaving a rather impressive hole. Determined to make it work, I filled the  crevice with silicon prior to using Bondo to level the uneven Gorilla Glue texture.

Jeric did a stellar job capturing a time-lapse of the final piece!

The Test

While touring an untested BETA experiment 7000 miles might sound crazy, for our team it made perfect sense. We had won 2nd place at Websummit last year for pitching our vision to 3D print from trash and 1st at their US event, Collision which granted us free passes for our team to return to Ireland. It therefore seemed natural to transport a untested ambitious print across the sea in front of thousands of media & startups in the name of challenging assumptions around 3D printing.  Upon reflection on the flight to Ireland, it became evident that our success to date and win at Collision, was truly a testament to community support. For this reason, we decided it would be an honor to recruit as many stickers as possible from Web Summit attendees willing to affix their brand to our untested experiment. We humbly collected 150+ logos, including StickerMule, a popular vendor.

Shaun the Sheep

If you followed us or Web Summit/Surf Summit on social media in the past month, you might be a little confused by the multiple references to sheep, Shaun, Gigabot, Irish shepherdesses, and surfing sheep.

The idea to 3D Print Shaun the Sheep was conceived by a female Sheppard & blanket maker named Suzanna of Zwartbles Ireland. Suzanna maintains an active community via social media (@ZwartblesIE) and during our flight over suggested #Gigabot could #3dprint a #sheep in #ireland. The initial Tweet inspired a lively conversation and I found myself Googling open-source sheep stls while flying past Iceland. When Katy & I landed, Matthew suggested this Wooly Sheep by pmoews  to test out on Gigabot, which had been created using a 123D Catch, now ReCap Pro, scan of a garden ornament. Three days of continuous sheep printing and ewe puns soon began. Katy christened the first small-scale sheep as Dolly before making a larger 14 hour sheep. The downside of running large prints is that Gigabot has to work throughout the night. The 3rd shift security team had the pleasure of watching our biggest sheep complete and informed us one morning that they had named him Shaun. It wasn’t until later the next day that we learned Shaun referred to a popular show titled Shaun the Sheep. Shaun quickly garnered a small fan club, and we decided to take him to Sligo, Ireland for Surf Summit as the prize for the 1st surfer to successfully catch a wave on the surfboard.

Surf Summit: The Moment of Truth

As soon as Web Summit concluded, we crated Gigabot for the return to Texas, them scrambled to pack our bags, the surfboard, and sheep for the bus ride to Sligo, the host of Surf Summit. Surf Summit is an incredible post-summit event to cultivate friendships while experiencing the Irish countryside. As the video reveals, it was a breathtaking experience- our only regret being Matthew couldn’t attend in leu of a customer he committed to visiting in the UK. As complete surf novices, Surf Summit provided the perfect proving group for the surfboard test as several surf pros were in attendance to share their experience & wet suits!

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Shaun, Katy, the surfboard & I board the bus

Prior to surfing, we attended the kickoff festivities and allowed Shaun to circulate with the attendees before (he hoped) he would be gifted to a deserving surfer.

Session 1

The next morning we loaded the board, attached the fin, crossed our fingers for good luck and took off to Streedagh Beach. Upon arrival, we were greeted by a team of instructors from Surf World Bundoran, who helped us wax the board and taught birthday girl Katy & I to surf for our first time. The experience was unforgettable.

As our lesson concluded, SurfWorld Instructor Tony volunteered to take our stickered print out on the water. We grabbed our cameras and huddled with our new start-up friends from The Outdoor Journal to capture a mini photo shoot before take-off. The tension was palpable and we all lingered a moment discussing the project, for fear that the board was soon break or worse, sink, taking with it the evidence of so many peers who had supported the endeavor.

Tony proceeded with caution, first testing the buoyancy in shallow waters near the beach, then gradually paddling out further. After a few minutes, he headed out to see if he could catch a break. It wasn’t long before a series of rolling waves emerged and, as luck would have it, he was able to ride one in!

After Tony broke the seal, two other brave instructors also offered to take the surfboard out, despite loosing a fin!

Session 2

Wanting to optimize our wave catching, we headed back to the hotel, then caught a cab to Strandhill beach to join another surf instruction course after lunch. There we met the crew at iSurfIreland who agreed to try her out and broke personal records in distance traveled (which complicated picture taking)! Four surfers tested the board, and gave us valuable improvement ideas.

Feedback

In total 7 instructors braved the board. The advice we received was pretty consistent:

  • The current board is too thick
    • In the future it should be thinner and consideration should be given to reducing weight
  • The curve is not ideal
    • The board should bow more at the top
  • We could have better leveraged the benefit of 3D printing
    • The current design mirrors current manufacturing aesthetics and could have been sexier
    • Surfers appreciate custom features (holds for cameras, grips, personalized lettering)
  • The absence of a durable fin made it hard to maneuver
    • I should have printed the fin flat so it couldn’t delaminate, and/or used honeycomb for more density
  • A three or multiple fin design would be ideal
    • Ours had only a single fin
  • Stickers made the board more slick, albeit cool!
  • Everyone seems optimistic that 3D printed has great potential in watersports, especially wakeboards and body boards
IMG_0592
Photo by Katy Jeremko

One Month Later

Currently the surfboard resides in our Austin office. What began as an idea, transformed into a internship, that took us 7000mi and introduced us to new friends around the world. As we reflect on the people we met through Akshay, sheep printing, sticker collecting, and trial by water we are struck by the creativity & vision that the community shared. We hope this is the first of many use cases that will expand our perspective on what is possible through affordable, life – size 3D printing. We welcome your ideas on where we go from here!

Happy Printing,

Samantha snabes

Blog Post Author

~Special Thanks to: our Intern Akshay, Coach Norman, Mike Battaglia, Jeric Bautista, the makers of Gorilla Glue, SUP ATX, WakeBoard Graphics Austin, Sail & Ski Austin, to the ENTIRE Web Summit/ Surf Summit Staff, all the StartUps that shared their stickers, The Outdoor Journal, The city of Sligo, IDA Ireland for the rad T shirts, isurfIreland, Surf World, and our staff who all had a hand in this crazy adventure!

~~We're still catching up on post-summit sleep. It's possible I missed a credit or left a typo. Feel free to submit additional pictures, corrections, comments, or questions to @samanthasnabes

Improving print quality by reducing triangle count

This is a tutorial on how to reduce the amount of triangles in a file for print quality using Autodesk Meshmixer.

While test-printing a large design at a much scaled-down size, I noticed an issue with print quality and wanted to share my experience remedying it, for those of you who have seen something similar happen in a print.
Below is a picture of the first print of this scaled-down object.  You can see tiny globs of filament dotting the surface of the print.  What is causing this?

First it helps to know what is behind an STL file.  An STL file breaks the surface of 3D object into many little triangles to form the surface geometry — this is done automatically when you convert a CAD file into an STL file.  Here’s what that looks like.

pic 3

The more triangles in a part, the smoother the curves of the surface will be, but also the larger the file size, the longer the slicing time, and the longer the build time.  Conversely, fewer triangles in a part means it will slice and print faster, but the curves will look more faceted.

Here’s what happened in this particular instance.  We took a very large file — 443.13mm x 503.32mm x 434.38mm — and scaled it down to 25% of the original.  The original large file had 103,970 triangles, and all these triangles remained even as the size scaled down.  This meant that we now had the same amount of triangles for a part one quarter the size.  The little globs of filament you see on the surface of the print were the result of the printer processing all of these triangles, pausing just long enough at certain vertices to allow a little extra filament to ooze out and form a small blob.

So I tried a test.

Using Autodesk Meshmixer (it’s free), I reduced the amount of triangles in the print to see if that would fix the blobbing problem.  You can read a tutorial by Hubs about reducing triangle count in prints; here’s the basic process:

Import your file into Meshmixer, click Select, and double-click your object to select it.

pic 4

Click the drop-down menu next to Percentage and select Triangle Budget.  You can now either slide the Tri Count slider up and down, or double-click the number and input a specific number.

pic 2.5

Cut the amount of triangles by more than half, down to 50,000, and you can hardly see a degradation of surface smoothness.  You could do this and improve the blobbiness without sacrificing the smooth curves of the object.

pic 6

To show the extreme end of the spectrum, look what happens when we drop the triangle budget down to 500.  You can still make out the basic shape of the object, but its smooth curves have been lost underneath a sharply-faceted surface.  This is because there are less triangles, so we now see the polygons rather than the smooth mesh they normally form.

pic 8

I wanted to show something more on the extreme end of the spectrum, so I set the triangle budget to 2,000 and exported the STL file.

pic 9

Here’s how the final print turned out — no more filament blobs.  You can see the faceted surface, almost as though it’s a chiseled sculpture before being sanded.  We kind of like the geometric look!  But remember, we did this to demonstrate the two extremes: if your goal was to maintain the smooth curves of the original design, you could have reduced the amount of triangles significantly without swinging this far to the other end of the spectrum.  

If you ever see filament blobs like this, try out the above steps to reduce the number of triangles in your print to improve the quality.  Or, play around in Meshmixer just for the fun of it — maybe you like this geometric style as much as we do.

Happy printing!

Morgan Hamel

Blog Post Author