The Fastest Way to Create Tangible Color Models from CAD Data Introducing Z Corporation High Definition, Low-Cost 3D Printers
The Fastest Way to Create Tangible Color Models from CAD Data
Introducing Z Corporation High Definition, Low-Cost 3D Printers
Introducing Z Corporation
Introducing Z Corporation
• Z Corporation is the Growth and Innovation Leader in 3D Printing
• 2,500 customers worldwide
• Located in Burlington, MA USA (Boston Area)
• 125 distribution partners worldwide
• Quick facts from 2005
– Z Corporation’s 3D Printer shipments grew 60%, with revenue growth over 50%
– Z Corporation launched new products across the line-up in 2005, with more than 70% of revenue coming from new products by year end
– Z Corporation launched the award-winning Z510 Spectrum Full Color, High Definition 3D printer
• Z Corporation has created the category of high speed, low cost, full color 3D printing
Markets We Address
• We expect to be the 3D printer of choice for all forms of 3D Data
Product Design
Education
Architecture/
Engineering/
Construction
Medical
Entertainment
What is 3D Printing?
3D CAD File
A 3D Printer is an Output Device for 3D CAD Data
3D Printer 3D Model
How it Works
Spread Layer of Powder Print Cross-Section
1 2Spread Layer of Powder
3
• Software "slices" CAD file into thousands of thin layers
• Physical model is built one layer at a time
• Ink-jet print heads deposit binder into powder to create layers
Mainstream 3D Printing vs. Narrow-use Rapid Prototyping & Mfg.
“Rapid” Manufacturing
• Uses: short-run, end-use parts• Need: material strength, tooling-level
accuracy• Tradeoffs; very high cost, slow,
monochrome, difficult-to-use
Old “Rapid” Prototyping
• Uses: functional testing, late form & fit• Need material strength, tooling-level
accuracy• Tradeoffs; very high cost, slow,
monochrome, difficult-to-useMainstream 3D Printing
• Uses: – Design concept visualization– Early form & fit testing– Wide-ranging engineering,
sales, & marketing applications
• Needs– Very low cost for everyday use– Very fast print speed– High-definition resolution– Full-color, graphics, annotation– Easy to use
Mainstream 3D Printing vs. Narrow-use Rapid Prototyping & Mfg.
“Rapid” Manufacturing
• 3D Systems• Objet
Old “Rapid” Prototyping
• Stratasys• 3D Systems• Objet• Table-top CNCMainstream 3D Printing
Z Corporation
Proven Technology
Why Use 3D Printing?
Streamline the Design Process
• Create more prototypes, sooner
• Make ideas easier to visualize
• Make decisions faster by reviewing tangible options
• Identify form, fit, function errors early
• Improve clarity of communication with suppliers, vendors, prospective customers
• Output a single data file on printers in multiple locations. Instantly collaborate on design revisions
Physical Models Enable You to Communicate More Clearly
Jumpstart Sales & Marketing
• Create physical representations of concepts to win business even before the design process begins
• Create realistic prototypes for focus groups
• Affordably produce a variety of options, styles, fashions
• Develop and evaluate packaging options
• Begin selling before manufacturing delivers product
Explore Design Concepts
Evaluate Style, Fashion, Packaging, Feel, Size
Evaluate Form, Fit, Ergonomics, Assemblies
Improve Production Planning
Color-code assemblies, tooling components, or machining surfaces
to clearly communicate process steps
Display Engineering Analysis
Apply Cosmetic Finishes
Applications in Architecture
Applications in Architecture
Applications in GIS
Applications in Medical Modeling
Z Corporation Advantages
How to Evaluate 3D Printers
• How quickly do you need your parts?
– In the next hour?
– This afternoon?
– Tomorrow?
– Next week?
• How quickly does the person after you need their part?
• What can you afford to pay for each model?
– $10?
– $100?
– $1,000?
• Are your designs simple or complex?
All Prices in US $
Breakthrough Advantages of Z Corporation Technology
• High-definition resolution
• Only color printers available
• 5-10x faster than other technologies
• Lowest cost per-system and per-part
• Large enough for substantial models, or to print multiple models at once
High-definition for Exceptionally Realistic Parts
NY Museum of Modern ArtCelebrating 20 Years of Pixar
High Definition Parts are Museum Quality
Poor Definition of Other Technologies
Z Corp. High Definition
Others
Exclusive 24-bit Color
Why Color?
- More lifelike prototypes
- Shape and size are only two aspects of the design. Color is the third.
“ Color had a much bigger impact on our design process than we ever imagined. We knew it would save time and enhance communication, but it’s really been a giant leap forward for us. It won’t make monochrome prototyping obsolete, but it has dramatically accelerated our progress from simple sketches to success on the market”
Paul Bates – Reebok International
Real Product
Z Corp Part
Multi-Color Parts Without Paint
Labeling and Annotation
Breakthrough Speed
• Print a typical handheld part in < 2 hours
– 1-2 vertical inches (25-50 mm) per hour
• 5-10x faster than all other technologies
• Print multiple prototypes at one time
• Ability to service the queue
– When will the Nth engineer get his part?
Print Multiples in the Same Time Period
Z Corporation
Competition
The Value of Speed to a Team
Lowest Cost System-wide
• Lowest system purchase price in its class
• Lowest operating cost; $1.50 - $2.00/cubic inch ($0.10/cm3)
• Lowest cost/model (a typical handheld part costs $10)
• Lowest maintenance costs
– Features modular components for fast & inexpensive servicing
• Freely print parts on a low operating budget
All Prices in US $
Lowest Cost of Materials
Source: T. A. Grimm & Associates, May, 2005
Rapid Prototyping & Manufacturing Conference All Prices in US $
The Value of Combining Low Cost with High Speed
9,240$29,500120Others
1,080$7,200120Z Corp.
770$2,46010Others
90$60010Z Corp.
77$2461Others
9$601Z Corp.
HoursCost# PartsCost & time
to print this
32.5 in3 part
All Prices in US $
Why Stripped-down, Old RP Technologies Do Not Work in 3D Printing Applications
Dimension
• Models with MSRP
– BST 768: $18,900
– BST 1200: $21,900
– SST 768: $24,900
– SST 1200: $29,900
Stratasys Dimension –Low-end Rapid Prototyping
• 5-year-old technology at the end of its life cycle
• Painfully slow (the larger the part, the slower the build)
• Average-to-poor surface finish
• Lack of fine feature detail
Dimension; Dual-tip Extrusion (Hot Glue Gun)
• Like an old pen plotter
• Dual-tip design causes interference & distortion to adjacent vertical geometry
Breakthrough Speed
Time needed to print
this 32.5 in3 part
Z Corp.
9 HoursOthers
77 Hours
Dimension; Slow Print Speed
To complete this part would require 18 hours
Part after 2 hours using
Dimension
Identical part after 2 hours
using ZPrinter
Dimension; Slow Print Speed
This part requires 35
hours to print
Dimension; Poor Resolution
Dimension Specs: .012” tip x .010” layers
Spectrum Z510 Specs: 600 dpi x .003” layers (45x better resolution)
Dimension; Coarse Surface Finish
Dimension; High Cost to Own & Use
Dimension
ZPrinter 310
Cost of Printing Two 48-in3 models per week
All Prices in US $
Dimension Materials – 1000 in3
• $250/reel
• 58 in3 per reel
• You need support, so figure at least 30%
• 1300/58 = 22 reels
• 22 x $250 = $5,500
•$5,500
All Prices in US $
Materials Comparison – 1000 in3
•Z Corp: $1,650
•Dimension: $5,500
All Prices in US $
We are the Lowest Cost Solution
• Dimension BST
– $18,900
• Materials
– $5,500
• Training
– $1,000
• 90 Day Warranty
• $25,400 Package Price
• ZPrinter 310 Plus
– $19,900
– ZD5: $1,900
• Materials
– $1,650
• Training
– $1,000
• 90 Day Warranty
• $24,450 Package Price
All Prices in US $
We are the Lowest Cost Solution
• Dimension SST
– $24,900
– Tank: $3500
• Materials
– $5,500
• Training
– $1,000
• 90 Day Warranty
• $34,900 Package Price
• ZPrinter 310 Plus
– $19,900
– ZD5: $1,900
• Materials
– $1,650
• Training
– $1,000
• 90 Day Warranty
• $24,450 Package Price
All Prices in US $
ZPrinter® 310 ― Lower Cost of ownership than Dimension
$24,450 $25,400
Cost of Equipment + “first” 1,000 in3 (16,400 cm3) of material
All Prices in US $
Dimension SST Option
• $6K price-adder for SST 768 material print head
• $8K price-adder for SST 1200 material print head
• $3,500 additional for removal tank
– Not office compatible – requiring gloves & facilities to drain tank periodically
• Soluble supports
– Still requires some manual removal
– Phosphate bath must be replaced for every 30 cubic inches of material dissolved
– Supports dissolve in 3 hours, longer for larger parts
All Prices in US $
Dimension SST Option
• $6K/$8K addition for SST material head
• $3,500 additional for removal tank
– Not office compatible – requiring gloves & facilities to drain tank periodically
• Soluble supports
– Still requires some manual removal
– Phosphate bath must be replaced for every 30 cubic inches of material dissolved
– PS400 media (Water works liquid) has a PH rating falling between Ammonia and Lye. Heavy dilution and/ or chemical services needed for disposal
– Supports dissolve in 3 hours, longer for larger parts
– Occasional leakage of solvent into hollow part geometry
• (Keep parts on sponges, rags, and cloth for hours or days)
Dimension Support Structures
The Dimension process involves physical support
structures that must be painstakingly removed with tools
Dimension Tools for Removing Support Structures
• Exacto knife
– To cut away supports & base
• Sharp metal spatula
– To cut between the part & support structure
Dimension Part Processing
Step 1
Remove part with base and support structure from
Dimension printer
Support Structure = Waste
Base = Waste
Dimension Part Processing
Step 2
Attempt to tear part from support
structure. Support structure
cracks
Step 3
Cut support structure from the
rest of the base
Dimension Part Processing
Step 4
Begin removing support structure
Dimension Part Processing
Step 5
Continue to cut away support structure. Difficult because tools do
not reach all surfaces
Dimension Part Processing
Step 6
Remove base & discover more material to be removed
Dimension Part Processing
Step 7
Locate & unpack the correct size and number of picks, files,
tweezers, and other accessories included in Dimension Starter Kit
Dimension Part Processing
Step 8
Process continues …
Step 9
And continues …
Dimension Part Processing
Step 10
Conclude by sanding finish with 220/320-grit wet/dry sandpaper
included in Dimension startup kit
Case Studies
Case Study: Continental Tire
• #1 maker in Germany, sold worldwide as Continental, General Tire, Uniroyal
• Need – Multiple tread samples for timely product development decisions
• Solution; ZPrinter 310
• Results
– Rapid prototypes 5x faster
– Reduced prototype costs 50%
– Flexibility to develop, discuss, debate and refine tread designs
• “We’re making more money by making prototypes for our sales force, giving them something concrete and convincing to show major auto companies.” Matt Lamb, Tire Designer
Case Study: Black & Decker
• Global manufacturer of DEWALT®, Porter-Cable®, and Delta® tools
• Need – Fast, cost-effective early concept models
• Solution; ZPrinter 310
• Results
– Compressed design cycles
– Enhanced product aesthetics, ergonomics
– Improved resource utilization
• “We have been able to reduce model production time by as much as 75 percent. John Reed, Master Prototype Specialist
Case Study: Timberland
• Global leader in premium-quality footwear, apparel and accessories
• Need; More shoe prototypes, sooner, to evaluate comfort, performance, marketability
• Solution - Spectrum Z™510
• Results– Reduced prototype cost 80-fold
– Reduced prototype production time from one week to 90 minutes
– Reduce design time 33 percent
– Increased sales using 3D prototypes instead of 2D sketches
• “We can now quickly do innumerable iterations and variations, and the designers and marketing managers can really be sure the product is what [people on the street] are demanding.”
Toby Ringdahl, CAD Manager
Trinity Products
• $10 million manufacturer of remote-controlled cars
• Need – rapid prototypes for form, fit, function testing
• Solution; ZPrinter 310 for high-resolution parts (even 1/18 scale)
• Results– Prototypes now strong enough for
functional testing
– 80% time savings printing parts
– Cut design cycle 50%
– Eliminated earlier $800/part cost
• “ … the the single biggest step we’ve taken to improve the way we refine concepts, develop products, communicate with suppliers, and market products.”
Mike Wood, Chief Engineer
Case Study: Caterpillar Inc.
• World’s leading manufacturer of construction and mining equip.
• Need: Faster way to produce prototype castings to accelerate design changes.
• Solution: Z810 & ZCast process
• Results
– Reduced casting development time 70%
– Accelerated design changes
– Increased prototyping capacity 60%
– Reduced cost/prototype 50%
• “We can generally produce castings in a third of the time it used to take (5 days vs. 3 weeks), and at less cost.”
Joe Taylor, RP Team Leader
“ Architects just can’t collaborate around a napkin or computer file the same way they can around a physical model. Architects need to literally walk around a design, get their hands on it and maybe mark it up with a pen. This process is as vital as presenting to the client and just as rigorous?”
Al Vass – Associate VP
Case Study – Jerde Partnership
Case Study: Motorola V70
Motorola V70 Concept Testing
Motorola V70 Engineering
Motorola V70 Value
• No 3D data is released to create solid visual models without first making a model
• Mistakes caught before data released for tooling
• Designers work closer with engineers and human-factors teams when developing products
• Changes & revisions happen faster
Case Study: University of Michigan
• Broad curriculum support
• Study of EM wave propagation
• Plasma cutting template
• Study of ultrasound flow phantoms
• Architecture program
• Investment casting study
Case Study – Oliver Wolcott Technical School
• Machine Drafting students measure a real part & create that part in 3D CAD
– Part is made on 3D printer
– Students compare actual part with the Z Corp. part
• After completion of this project, students create their own 3D CAD design & “Zprint”
• All students trained on the Z Corp. printer & actively use it
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