D3D June17 PDF

Inventor 2018 P45 Siemens NX 7.
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TECHNOLOGY FOR THE PRODUCT LIFECYCLE JUNE 2017 | 6 | 7 | $10 | DEVELOP3D.COM
PEDAL
POWER
Whippet Bicycle offers a
new take on folding
PRODUCTS FOR THE POOCH FARMING MACHINERY CIRCULAR ECONOMY

p01_D3D_JUNE17_cover.indd 1 30/05/2017 21:55
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WELCOME
EDITORIAL
Editor-in-Chief
Al Dean
al@x3dmedia.com
+44 (0)7525 701 541
Managing Editor
Greg Corke
greg@x3dmedia.com
+44 (0)20 3355 7312
Digital Media Editor

Stephen Holmes
stephen@x3dmedia.com
+44 (0)20 3384 5297
Special Projects Editor

Tanya Weaver
tanya@x3dmedia.com
+44 (0)20 3384 5296
Consulting Editor
Martyn Day
martyn@x3dmedia.com
+44 (0)7525 701 542
W
DESIGN/PRODUCTION
Design/Production
Greg Corke hen we started DEVELOP3D back in 2008 we didnt
greg@x3dmedia.com really have a huge masterplan. No world map
+44 (0)20 3355 7312 on the wall, no blueprints for an underground
lair or RFQs out for a mono-rail and henchmen
ADVERTISING uniforms. We knew we wanted to create a
Group Media Director magazine that not only talked about design and
Tony Baksh engineering technology but importantly put the
tony@x3dmedia.com work of designers and engineers at the front and
+44 (0)20 3355 7313 centre. In the intervening years, weve met a
Deputy Advertising Manager small nations worth of folks that are imagining, designing, building, testing and
Steve King shipping products. Sometimes in the millions of units for the masses, other times
steve@x3dmedia.com painstakingly hand-built for the discerning customer.
+44 (0)20 3355 7314 Then a few years ago we decided to put on an event. Something small, something
intimate that could bring our community together. DEVELOP3D LIVE has grown
US Sales Director
Denise Greaves ever since and this year we had record numbers. Were also about to put on our
denise@x3dmedia.com second US event in Boston during October (d3dliveUSA.com).
+1 857 400 7713 In the course of all this, its become clear that folks get as much out of it as we
do. In fact, this month Tanya and I visited Graham Powell, former post graduate
SUBSCRIPTIONS programme director of Product Design at the Birmingham Institute of Art &
Design, who told us that during our second D3D LIVE, he was inspired to pursue an
Circulation Manager idea that had been kicking around in his imagination for a while. So he quit his job,
Alan Cleveland
snagged some funding and developed his folding bicycle idea.
alan@x3dmedia.com
+44 (0)20 3355 7311
Fast forward four years, Grahams hand built Whippet Bicycle officially launched
in April. You can marvel at the product (and it is, truly, a thing of beauty) on page
22 and read the story of its development, which we discovered when visiting his
ACCOUNTS
Warwickshire workshop for a cup of tea and a chinwag.
Accounts Manager What I love about Grahams story and the end result is that it demonstrates that
Charlotte Taibi folks get into design and engineering because of a passion, rather than a pure
charlotte@x3dmedia.com means to making ends meet. Theres a strange combination of passion, energy,
Financial Controller creativity and curiosity that makes those involved in developing products unique.
Samantha Todescato-Rutland And when that heady mix is combined with a little spark of inspiration, good
sam@chalfen.com things always happen.
I wont stretch that thought into a full combustion engine analogy. Instead, Ill
ABOUT leave you to enjoy this issue. Catch you on the other side of summer!
DEVELOP3D is published by
465C Hornsey Road, 1st floor, Unit 2,

London, N19 4DR, UK
T. +44 (0)20 3355 7310
F. +44 (0)20 3355 7319
2017 X3DMedia Ltd Al Dean
All rights reserved. Reproduction in
whole or part without prior permission
Editor-in-Chief, DEVELOP3D Magazine, @alistardean
from the publisher is prohibited. All
trademarks acknowledged
Opinions expressed in articles are those
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X3DMedia cannot accept responsibility Join our online community
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DEVELOP3D.COM JUNE 2017 3
p03_D3D_JUN17_Editor.indd 3 30/05/2017 21:55

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Visualize. Simulate. Immerse.
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2017 NVIDIA Corporation. All rights reserved. NVIDIA, the NVIDIA logo, and Quadro are trademarks and/or registered tradearks of NVIDIA Corporation. All company and product names are trademarks or registered trademarks of the respective owners with which they are associated.
PNY Ad.indd 1 09/03/2017 13:55

CONTENTS
JUNE 2017 ISSUE NO. 89
6 NEWS
Alibre 3D CAD system could make a return,
Formlabs improves post processing of 3D prints,
Onshapes online crash course and D3D LIVE videos
COMMENT
13 Tanya Weaver calls on designers and innovators to find
solutions for all the plastic waste in our oceans
FEATURES
15 This months role model is Jenni Sidey
16 Visual Design Guide: Jewellery holder
18 Product Design Gallery: Prosthetic arms
22 COVER STORY The Whippet folding bicycle
28 Beco provides pet products with eco credentials
32 Uncovering the most aerodynamic cycling positions
34 McLaren Honda F1 and Stratasys form new partnership
36 Q&A with Pierre Maheut of Substance Designer
38 Taking your 3D CAD data into AR with Creo 4.0
40 Lightweighting agricultural machinery with Altair
65 Where I Work: Kevin Jenkins, Plymouth College of Art
REVIEWS
45 Autodesk Inventor 2018
50 Granta Design CES Selector 2017
53 Rize Inc. Rize One
57 Xometry.com
62 HP Z2 Mini workstation
64 DEVELOP3D SERVICES
66 THE LAST WORD

With all our visualisation tech Al Dean wonders whether
there is a new era coming that includes sound and touch
The wood used to produce this magazine

comes from Forest Stewardship Council
certified well-managed forests, controlled
sources and/or recycled material
p05_D3D_JUNE17_Contents.indd 5 30/05/2017 21:56

NEWS
NEWS PRODUCT DEVELOPMENT NEWS
ALIBRE 3D CAD SYSTEM TO MAKE A RETURN

FOLLOWING DIVESTITURE FROM 3D SYSTEMS
It looks like the low-cost parametric modelling system Alibre is to make a return to
the market and active development after its "wilderness years" at 3D Systems
A
libre caused a bit of a stir in The post, from former VP of marketing at (Above) Geomagic
the mechanical CAD market in Alibre Max Freeman, informed users that Design will be
the 90s and early millennium "Myself and several ex-Alibre employees WHAT WE THINK rebranded perhaps
seeing a return to the
with a lower cost alternative have created a new company called
Under 3D Systems' control, Alibre Alibre name
to the likes of SolidWorks Alibre, LLC, and we have entered into a
could have been interesting but, at
and Inventor. While it never achieved definitive agreement with 3D Systems to the time of acquisition, the company
huge success, the system gained a loyal transfer Geomagic Design to our company was riding a wave of hype, had
following, particularly in the hobbyist for sales, support, development, etc." made some questionable decisions
and "I need a CAD seat at home" market. Freeman stated that more news would be under then-CEO, Avi's control. The
During the height of the 3D printing forthcoming in early June. There are also timing was ripe for a low-cost 3D
bubble five years ago, 3D Systems went plans afoot to, presumably, incentivise CAD system to address the growing
on an acquisition rampage, picking customers who have let maintenance slip "maker" community.
up (along with the likes of Geomagic, and that the Geomagic Design branding Alibre, before 3D Systems, was a
RapidForm and Cimatron), Alibre is going to be dropped (to return to the capable system and offered a truly
following a pretty successful partnership Alibre name). lower-cost alternative to the likes
between the two companies to sell And for those users that have been of SolidWorks, Inventor, etc. It also
3D printers alongside its seats of 3D using the system in the meantime, the experimented with subscription
design software. After a few months, the good news is that development should only business models, cloud-based
software was rebranded as Geomagic begin in the next few months. delivery before anyone else.
Design and pretty much disappeared When asked for a comment, a 3D So we're curious to learn how
without a trace, leaving those customers Systems spokesperson stated that "The the company will fair on its own
on maintenance wondering if they would Geomagic Design product is a strong in a very different market in 2017.
ever see another release. offering with a committed customer Subscription is the current trend,
Fast forward six years, the bubble has base that 3D Systems wants to enable cloud delivery is growing and there
most definitely popped around the 3D and support, but it is not a strategic are more lower-cost alternatives
from the likes of Fusion 360 and
printing market and it also looks like product for 3D Systems going forward.
Onshape.
3D Systems is going through a period of As a result, 3D Systems feels selling the
Even Onshape went after the
rationalisation not only in terms of its product to the newly formed Alibre, LLC is
'maker' community with its free plan
printer portfolio but also the software in everyones best interest."
and essentially blew them all off with
solutions it sells and maintains. That's about all we know, but should changes made to its initial offering
A low-key post on the Geomagic Design/ learn more in the coming weeks. in the middle of 2016.
Alibre forums earlier this month showed alibre.com Al Dean
that there was some news on the horizon. 3dsystems.com
6 JUNE 2017 DEVELOP3D.COM
p06_D3D_June17-NEWS.indd 6 30/05/2017 22:08

SOLIDWORKS-Promotion-Develop3D-Cadtek.pdf 1 18/05/2017 17:27:00
NEWS
FORMLABS LOOK TO ADDRESS NXTBLD a

DIFFICULTIES OF SLA PROCESS new AR / VR
conference
N
extBuild conference
(NXTBLD) will take place
on 28 June at the British
Museum and will examine
new digital tools and
processes for the built environment.
The show is run by DEVELOP3D and AEC
Magazine publishers, X3Dmedia, in
conjunction with Lenovo Workstations,
Intel and Nvidia.
This first annual event will explore
emerging design technology for the
built environment, beyond BIM, through
technologies such as VR / AR, artificial
intelligence, generative design, reality
modelling and digital fabrication. There
will be industry speakers and technologists
examining different aspects and uses of
these technologies.
General admission will be just 25. If you
would like to attend visit:
nxtbld.com
F
ormlabs has launched two Alcohol) solution to remove any residual The Formlabs Wash
and Cura, next to
devices which look to improve
the post processing of 3D
resin after the parts have built. There's
a small impeller at the base of the unit
the Form 2
Get thinking
prints from its desktop SLA
machines. The Formlabs Wash
which will keep the solution moving around
your geometry, so it should clean up for the Climate
and Cure are intended to assist with the
clean up of SLA resin from parts post
quicker than simple soaking. There's also
a hydrometer built into the unit to monitor Change Challenge
T
build and to assist with the essential the fluid and to notify the user when it's
curing of those parts. time to change. he 'What Design Can Do
Anyone whos used a 3D printer knows Priced at 699, the Formlabs Cure is a UV Climate Action Challenge' is
the dirty secret of the process: a lot oven intended for providing that additional a global designcompetition
happens in between hitting print and curing that most SLA prints will require that is calling on the creative
holding a final product. particularly if you're looking to achieve community to come upwith
"We know our users time is better spent the optimal characteristics of the resin. It fresh and innovative solutions to help
designing and creating, so we developed features a turntable, again, reducing the mankind adapt to climate change.
Form Wash and Form Cure to bridge that time to achieve that cured state. What Design Can Do (WDCD), the IKEA
missing gap; making it easier than ever Interestingly, both machines will have Foundation and Autodeskinvite applicants
to go from finished print to ready-to-use presets for each of Formlabs' different from all countries and disciplines, to take
part, said Dvid Lakatos, chief product resins, to assist with the process and are part.Both existing and completely new
officer at Formlabs. ideal for the build size of the Form 2 ideas and solutions may be entered.
Priced at 499, the Formlabs Wash is a although they're both suitable for other The call for participation opened
top loading, automated machine that will desktop SLA machines too. on23May and will close on 21 August 2017.
wash off your prints in an IPA (Isoproypyl formlabs.com whatdesigncando.com
EOS unveils EOSPrint 2.0 software for industrial 3D printing
S
elective sintering expert productivity and part quality. should make the initial steps of the
EOS has unveiled its latest EOSPrint 2.0 is now available for the actual 3D printing build process easier,
software for the 3D printing company's metal 3D printing systems while the additive manufacturing CAM
process, as it looks towards EOS M 290 and EOS M 400, while future environment should enable engineers to
pushing the technology to iterations will include support for all reach higher quality and lower costs.
industrial process levels. current EOS metal systems and future The latest release introduces a
Together with data preparation polymer systems. workflow-based approach for the
software like Siemens NX or Materialise We advanced EOSPrint in accordance graphical user interface reflecting the
Magics, the new EOS software provides with market needs, particularly in the AM CAM process, effectively meaning
an enhanced user interface with greater fields of ease of use, higher part quality that the software architecture is
freedom for application-specific parameter and increased productivity said Gerd built around the workflow of data
optimisation and easier part optimisation, Denninger, software product manager preparation for industrial 3D printing.
which should allow for increased at EOS, adding that the latest updates eos.info
p08_09_10_D3D_JUNE17-NEWS.indd 8 30/05/2017 21:57

ROUND
Onshape offers users an online crash course UP
A
self-guided online learning PTC has announced that
program for experienced 3D Systems has selected
engineers and designers has and plans to embed its
been launched by Onshape ThingWorx Internet of
to speed up their transition Things (IoT) platform into
from traditional desktop-installed CAD its 3D printers. This will
to the brands full-cloud CAD. enable customers to create
Access to the Onshape Learning Centre real time dashboards to
is free for all its annual Professional Plan monitor their printers as
subscribers, with the curriculum breaking well as allowing 3D Systems
down into short introductory courses with to remotely diagnose them
practice exercises that CAD professionals thingworx.com
can complete at their own pace and also
revisit later.
The Learning Centre was created as an LimitState has launched the
alternative onboarding option to Onshapes new version of its design
interactive Overview Training, which is themselves, said Onshape customer The Learning optimisation software,
comprised of four daily two-hour online success director David Katzman. Centre offers users LimitState:FORM 3.0, which
a new means of
sessions with an expert instructor. He added that the online courses will it claims is a breakthrough
learning about
Even though Onshape has a very quick appeal to those who want more structured working with full- in optimisation technology
learning curve for anyone with a 3D time to practice and who require more cloud CAD as it uses layout and
parametric CAD background, were finding flexibility with their schedules. The live geometry optimisation
that giving customers a crash course in training will still be available for those who technology, rather than
how full-cloud CAD differs from installed prefer to interact with Onshape instructors, the widely used topology
file-based CAD gets them up and running he concluded. optimisation technology
faster versus them trying to learn it by onshape.com limitstate3d.com
Autodesk and TraceParts
Materialise adds HP Jet Fusion 3D 4200 have announced that

the Fusion 360 format
M
is now available from
aterialise has commenced Processor for the HP Jet Fusion 3D Printing TraceParts standard and
production with the HP Solution, a tailored software solution that manufacturer specific
Jet Fusion 3D 4200 at simplifies the 3D printing process. The parts library. Users no
its European production Materialise Build Processor is currently in longer need a plug-in
facility. The technology beta testing ahead of final release. and can now choose from
is currently available for orders for With its partner program, Materialise TraceParts 100 million or
Materialise selected partners, and will aims to help identify the most suitable so parts
soon be made publicly available for applications for the HP Jet Fusion 3D 4200 traceparts.com
online quotations and orders. printer. Success in 3D printing hinges
The HP Jet Fusion 3D 4200 printing around selecting the right technology
solution was installed in November 2016. for a given application. The versatility of Built for the recent grand
An initial benchmarking period followed the material, PA 12, combined with the opening of the 36,000
in which R&D and engineering teams have exceptional isotropy and low porosity of square foot Axalta
been testing the Materialise Software and parts produced with HP Multi Jet Fusion Customer Experience
Materialise Manufacturing on the machine. leads us to hope for a good diversity of Centre, Axalta Coating
It worked closely with HP throughout potential industrial applications, stated Systems has announced
this testing period to share findings and Bart Van der Schueren, Materialise CTO. its new Color [sic]
ascertain areas for future development. www8.hp.com Configurator for its paint
Among these is the Materialise Build materialise.com and finishes, which runs in
realtime using KeyShot 3D
rendering technology
axaltacs.com
CGTech launches VERICUT Force in the UK
C
MSC Software, now part of
GTech, the developer of analysing tool geometry and parameters, Hexagons Manufacturing
VERICUT CNC simulation, material properties of the stock and cutting Intelligence division,
verification and optimisation tool, detailed cutting edge geometry, and is to acquire Vires
software, will officially launch VERICUT cut-by-cut contact conditions. Simulationstechnologie
VERICUT Force in the UK with a The Force Roadshow will kick off at GmbH, a software provider
series of half day nationwide seminars. the Advanced Forming Research Centre, for the development,
The Force module is a physics-based Scotland, on 14th June 2017. A further three testing and validation of
optimisation method that determines the seminars will take place at KYOCERA SGS automated driving, driver
maximum reliable feed rate for a given Precision Tools, Wokingham (28th June), assistance, and active
cutting condition based on four factors: Nikken, Rotherham (4th July) and the safety systems
force on the cutter, spindle power, maximum Manufacturing Technology Centre, Coventry mscsoftware.com
chip thickness, and maximum allowable (6th July).
feed rate. It calculates ideal feed rates by cgtech.com/foreceroadshow

NEWS
AMD TARGETS PRO VIZ Get a kick from

USERS WITH NEW GPU Kickstarter
C
rowdfunding site Kickstarter
is teaming up with hardware
manufacturing experts,
Dragon Innovation, and Avnet,
a global technology distributor
that helps customers design and make
their ideas and bring them to market.
Together Kickstarter is looking to take
ideas at the prototyping stage through to
production, and possibly reduce some of
the failed projects that have cast a negative
light over the idea of crowdfunding.
"Figuring out how to engineer a product
for large-scale manufacturing can be
daunting. Some creators have a great idea
and a working prototype, but could use help
taking the next steps, said Kickstarter.
Two parts of this effort will launch in
September: the Hardware Studio Toolkit,
a collection of tools and tutorials; and the
Hardware Studio Connection, which will
offer advice, feedback and services from
Avnet and Dragon Innovation.
A
kickstarter.com
MD has announced what For single precision compute operations The blue Radeon
it claims to be the most (including GPU rendering) the Vega Vega Frontier
Edition is air
powerful graphics card in Frontier is rated at 12.5 TFLOPs, which is
cooled
the world. The Radeon Vega
Frontier Edition is the first
only a touch more than the 11.45 TFLOPs on
offer in AMDs recently launched Radeon Bre Pettis buys
GPU born from its much-anticipated
Vega architecture.
Pro Duo.
The Vega Frontier includes several Other Machine
F
The Vega Frontier is a dual height board architectural advantages including faster
with 16GB HBM2 memory that is focused HBM2 memory and a faster geometry ormer Makerbot head honcho
on professional users, rather than gamers. engine, which AMD says delivers much Bre Pettis has re-entered the
But it doesnt belong to the same Radeon better real time performance when desktop fabrication market
Pro WX family (previously FirePro) that working with large 3D models. as the new owner of the Other
is designed and certified for 3D CAD and However, unlike the Radeon Pro Duo, Machine Company.
other professional 3D applications. which is designed, optimised and certified California-based Other Machine is the
Instead the Vega Frontier is a new for 3D CAD, the Radeon Vega Frontier maker of rapid prototyping tools for
GPU brand that is focused on three Edition will not have a professional electrical and mechanical design engineers.
main workloads: 1) Artificial Intelligence certified driver. However, AMD have Its latest OtherMill deskstop CNC machine
(machine learning), 2) Professional confirmed that new certified Radeon Pro the Othermill Pro has a spindle speed
visualisation and photorealistic rendering cards will be launching in the summer. of around 26,000rpm, quiet enough to use
and 3) next generation games and creative The Radeon Vega Frontier Edition is due in an office or classroom, and priced at
development. to ship in late June. It will be available in around $3,100. It can mill circuit boards,
For readers of DEVELOP3D, all eyes will two versions: air cooled (blue) and liquid carve complex 3D shapes in metal, wood and
be on professional visualisation, which cooled (gold). AMD has not disclosed other materials, make moulds and engrave a
should mean three things real time pricing as yet. variety of materials.
visualisation, GPU rendering and VR. amd.com othermachine.co
Missed DEVELOP3D LIVE 2017? Watch the videos online now
I
f you couldnt make it to with all the connections made face-to-face
DEVELOP3D LIVE this March or at the show as well as generating over 20
there were simply too many hours of video presentation covering a wide
amazing talks to see them all, range of topics, which we upload for all to
the good news is that many of the see and use as reference. We now have well
videos are now available online for your over 100 videos online.
viewing pleasure. Plus we have the best One of the recent videos we've uploaded
of the rest from 2012 to 2016. from this year's event is Andy Rahden,
As D3D LIVE's event director Martyn Day VP of Pluralsights creative, design, and
puts it, D3D LIVE is like a big firework, it engineering business (right), who shares
spends months in development and then it the importance of learning to progress
explodes and sparkles for eight hours. But technology in an ever-changing world.
unlike a firework, the event always lives on, develop3dlive.com/videos/

CADCAM
lets make
nt it happen
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NT Cadcam Ad.indd 1 30/05/2017 13:56

Advertorial
Autodesk University 21 & 22 June at

Tobacco Dock, London
A
utodesk University (AU) is the conference On-site manufacturing, on-demand
for those who design, create, and make the
world around us and for the first time ever
its coming to the UK.
AU London 2017 is your chance to connect
with the best in the business, share technical
knowledge, solve unique business challenges, and
gain a deeper understanding of cross-industry
opportunities. Plus, you can learn best practices,
Image courtesy of RAMLAB

stay on top of the latest trends, and experience
advanced technology firsthand. Join your global
community of professional designers and engineers
as we explore the future of making things.
Todays dominant technology trends are driving
businesses and consumers alike to explore new
ways to design, make, and use things. Attend the Future of Making Things Workshop The Rotterdam Propeller demonstrates the potential
Here are a few of the highlights you can expect to with Autodesk Fellow Tom Wujec. This workshop for on-demand Hybrid Manufacturing and producing
see at AU London: dives deeply into emerging technologies that are large-scale metal parts in just a matter of days,
transforming the AEC, Manufacturing, and M&E instead of weeks or months.
INSPIRING KEYNOTE PRESENTATIONS industries. It will help you chart the specific digital
Amar Hanspal, co-CEO tools to introduce capture, compute, and create Bridge to the future
and Chief Product Officer, workflows. Youll have a chance to explore where to
Autodesk will discuss the instrument your products or processes, when you
Image courtesy of Joris Laarman Lab
trends that will help create might add machine learning to your workflow, and
your future of making how you might add new fabrication techniques. The
things. This keynote workshop will also help to identify the places your
will feature stories from organisation can create new business value, from
companies around the incremental workflow improvements to disruptive
world who are embracing business model transformations.
new methods and
technologies to catapult how they innovate. Foster TAKE AUTODESK CERTIFICATION EXAMS
+ Partners Martha Tsigkari and Miles Walker will FOR FREE AT AU The MX3D Bridge combines digital design
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on the design and delivery of projects such as Attaining Autodesk Certified Professional status production to 3D print a metal bridge in mid-air over a
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including machine learning, AR/VR and robotics. AU London, we are offering free Autodesk certification Designs next great leap
Youll leave inspired to embrace this future in your exams on the latest versions of several Autodesk
own work. products. Spaces are limited, so register to avoid
Chris Bradshaw, SVP disappointment.
Media & Entertainment,
Education Experiences, AUTODESK GALLERY
and Impact at Autodesk will We are bringing our infamous Gallery to AU London
talk about whats driving allowing you to experience how designers and
Autodesks product and engineers from around the globe are using new
platform innovation, and technology to design and create a better world. Some
how were moving our of the exhibits include:
technology to be ever more
cloud-centric. Chris will be Bespoke Supercar
joined by Autodesk manufacturing product expert,
Stephen Hooper. This is your chance to get a firsthand
look at whats new in Fusion 360 and Forge.
The Elbo Chair illustrates how Generative Design
OVER 90+CLASSES AND SESSIONS will soon replace traditional design approaches by
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experts from across design and manufacturing. to meet set constraints.
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p12_D3D_JUNE17_Autodesk AU advertoriall.indd 1 30/05/2017 22:03

COMMENT
There could be more plastic than fish

in the ocean by 2050 if we dont do
anything about plastic waste.
Tanya Weaver finds this shocking and
discovers the solution lies in shifting
towards a circular economy
I

f I told you to imagine a small
uninhabited South Pacific
the notion of a circular economy and that,
just as she had limited supplies that she
In a circular economy we redesign
island, thousands of miles could take with her, the earth has a finite the way products are made to
away from civilisation, what supply of resources.
would you see? Id see white Following her retirement in 2010 she keep them and the materials they
sandy beaches, palm trees announced the launch of the Ellen MacArthur are made from circulating and
bending over clear blue Foundation, a charity to help businesses
water and maybe the odd move towards a circular economy. Our contributing to the economy
seabird bobbing in the waves and a crab
scuttling along the sand. The reality is
current economic model is largely based on
the linear take, make, dispose in which we
horrific plastic waste strewn along the are using finite materials to create single message, After 40 years of effort, globally
shore, waves bobbing with debris and use products that end up in landfill (or found only 14% of plastic packaging is collected for
crabs making their homes in bottle caps floating on the sea). Whereas in a circular recycling, one third escaping collection and
and cosmetic bottles. economy we redesign the way products are ending up in the environment. If we want to
This is Henderson Island, which made made to keep them and the materials they change this, we must fundamentally rethink
headline news in mid-May when Jennifer are made from circulating and contributing the way we make and use plastics. We need
Lavers and her research team at the to the economy. Effectively, designing better materials, clever product designs
University of Tasmanias institute for marine products that maximise recycling and re-use. and circular business models. Thats why
and antarctic studies in Australia revealed Knowing the crucial role that design and we are launching the New Plastics Economy
the nearly 38 million pieces of plastic waste in turn designers have to play in this shift Innovation Prize, calling for innovators,
theyd found on the islands beaches and the from the linear to the circular, product design designers, scientists and entrepreneurs to
13,000 new items washing up daily. consultancy IDEO joined the Ellen MacArthur help create a plastic systems that works.
How can this remote island show up our Foundation as a knowledge partner. The two The prize is actually two parallel challenges
throwaway culture in this way? But a quick have collaborated in the creation of the New (newplasticseconomy.org). The first is the
google into the murky waters of plastic Circular Design Guide, which was launched Circular Design Challenge, which invites
marine pollution revealed even more horrific earlier this year. This practical guide is aimed applicants to rethink how we get products
statistics. For instance, a study in Science at helping designers and businesses get to people without generating plastic waste.
Magazine in 2015 estimated that around started in applying circular principles and This challenge focusses on small-format
eight million tonnes of plastic waste ends up also supports complex challenges such as re- packaging (the scrooge of the sea those
in the ocean every year. thinking global plastic flows (read more here: single use disposable items including take-
And its not just whats floating on the circulardesignguide.com). away coffee cup lids, drinks bottle caps,
surface (disposable plastic being the biggest Another organisation extolling the sauce and shampoo sachets, wrappers etc.)
culprit bottle caps, straws, polythene benefits of the circular economy is the that are the hardest to recycle.
bags etc.), its those tiny plastic particles International Sustainability Unit (ISU), which The second is the Circular Materials
or microplastics swirling around below it was established by HRH The Prince of Wales Challenge, which seeks ways to make all
that fish and shellfish ingest. Scientists at in 2010. One of the many challenges it is plastic packaging recyclable, and is inviting
Belgiums Ghent University revealed in a addressing is plastic waste in the marine applicants to find alternative materials that
study earlier this year that shellfish lovers environment and how a transition to a would be recycled or composted.
are eating up to 11,000 plastic fragments more circular economy in the plastics value Im no environmental crusader, but I do
each year whilst Plymouth University chain can be achieved through cross sector feel quite passionately that we need to take
similarly reported that plastic has been collaboration. With this in mind, in February responsibility for how we treat our planet
found in a third of UK-caught fish. A side of 2017 it held a workshop with business and do something to halt the damage we are
plastic with your moules-frites anyone? leaders, designers and material experts on doing. So next time you throw that piece of
One person who has spent a fair share of the role that design and innovation can play plastic wrapper or packaging in the bin, think
time on our oceans (71 days, 14 hours, 18 in stemming the flow of plastics into the about how you could design it differently.
minutes 33 seconds to be precise when she ocean. I for one would like to keep plastic off our
broke the world record for the fastest solo Then, putting their two heads together (the beaches and out of my bouillabaisse.
circumnavigation of the globe) is the now ISU and the Ellen MacArthur Foundation that
retired English sailor Dame Ellen MacArthur. is), on 18 May 2017 they jointly launched the
During this feat with nothing for company New Plastics Economy Innovation Prize a GET IN TOUCH: Email me on tanya@x3dmedia.com or say hi on
but the sea, her boat, the odd bit of wildlife $2 million prize to find solutions that keep twitter @tanya_weaver. For those wondering about the bees, its
and no doubt the occasional piece of plastic plastics in the economy. At the launch Dame been an action packed Spring with expanding colonies, swarming,
waste floating by, it got her thinking about Ellen MacArthur had this rather poignant queen squashing and the relocation of a feisty colony. All good fun!
p13_D3D_JUNE17_tanya.indd 13 31/05/2017 08:59

DriveWorks Ad.indd 1 30/05/2017 13:57
PROFILE
ROLE MODEL
NAME JENNI SIDEY
JOB ROLE UNIVERSITY LECTURER
Whether youre still in education or a few rungs up the career
ladder, we could all do with inspiration to show us what is achievable
and to gain an insight into what others are doing in the field of design
and engineering. This month our role model is Jenni Sidey who despite
being young has already achieved a great deal, including being
applauded as an advocate for women in engineering
H
aving studied Mechanical Im sure one of the biggest challenges Ive for everyone in our society. As an added
Engineering at McGill faced has been my own self-doubt. Its benefit, diverse teams have been shown to be
University in Montreal, difficult to always trust yourself and your more creative, productive, and even profitable
Canada, Jenni Sidey moved ability in a competitive and demanding in recent studies. We cant afford to ignore
to the UK in 2011 to take workplace.Ive learned that its important the need for diversity in engineering.
up a Ph.D. at the University to push to succeed even when you doubt
of Cambridge studying combustion as yourself. Eventually, evidence of your success What technology or design tools do you use
part of the Rolls-Royce University Gas will improve confidence and silence self- day-to-day in your job?
Turbine Partnership. She was appointed doubt. My job can vary so much day-to-day, so we
as a university lecturer in the Department use a range of technology and design tools.
of Engineering in 2016 and is now a What has been a career high or most When working on experimental projects, we
fellow of St. Catharines College. Her memorable work moment? use a range of CAD software to develop our
research interests include alternative fuel This year has been an amazing one for me. tools and rigs. We collect experimental data
development and pollutant reduction for Nearly one year ago exactly, I started in my with imaging software and LabView, while
energy and transport combustion devices. current role at the University of Cambridge. we post process with a range of software,
In December 2016, she won the Institution This was a huge success very early on in my including Matlab. A large portion of our
of Engineering and Technologys (IET) career.A few months later, the recognition work also involves computational modelling,
Young Woman Engineer of the Year Award for my efforts encouraging women in for which we use ANSYS Fluent and
for her professional success and work as an engineering by the IET was a very important OpenFOAM. Our work is varied, so our tools
advocate for women in engineering. She is moment. Recently, Ive had the unique are too!
also one of the final 17 candidates for the experience to participate as one of 17 finalists
ongoing 2016/17 Canadian Space Agencys in the 2016/17 Canadian Space Agency With the advantage of hindsight, what
Astronaut Recruitment Campaign. Astronaut Recruitment Campaign. These career advice would you give to your
three career successes are memorable and younger self?
What do you most enjoy about your job? incredibly special to me. I would tell my younger self not to sweat the
I love teaching, so interacting with students small stuff. Always look at the big picture as
and passing on knowledge is a highlight of In terms of your career, who has been your it will help you overcome minor setbacks and
my current role. role model? challenges along the way.
From a very young age, I looked up to
What inspired you to become an engineer? Canadas first female astronaut, Roberta If you were hosting a dinner party who
I was inspired to become an engineer once I Bondar. She was an inspiring scientist and would you invite and why?
learned what the profession really was from a groundbreaking role model for me. Since Id invite Ada Lovelace and Charles Babbage,
my uncle, a civil engineer. He recognised then, Ive always found trailblazing women the duo credited with the development
early on that I could solve problems in unique in science and engineering to be particularly of the first mechanical computer and the
and creative ways, plus I was interested in inspiring. first computer program. They made an
science.He made an effort to involve me in outstanding team with their creativity and
projects he thought Id find interesting. Once What is your view on diversity in the vision. I think theyd love to hear what
I learned from him that engineering was a engineering and design workforce? weve done with the computer since their
profession which applied science to solve Diversity in the engineering workforce remarkable first steps.
problems creatively, I was hooked. is essential. We need to recruit as many
engineers as possible to address the This years Institution of Engineering and Technology
What has been one of the biggest challenges we are facing today. If the Young Woman Engineer of the Year Awards are open
challenges youve faced in getting to where workforce we recruit is diverse, we can for entry until 7 July 2017. For more information visit
you are? address these challenges in ways which work conferences.theiet.org/ywe/
p15_D3D_JUNE17_role model.indd 15 30/05/2017 21:58

VISUAL DESIGN GUIDE
JEWELLERY HOLDER
As a graduate of the Birmingham School of Jewellery, Katy
Tromans created an Alice in Wonderland-inspired jewellery
holder, which was the winner of the Primassure Award for CAD
Design at the Goldsmiths Craft & Design Council Awards 2017
DESIGN FROM
CHILDHOOD
The process began with Tromans choosing
a story from her childhood, before making
sketches and photography of relevant details
and textures - the focus being on form, shape
and the tiniest details. In her own words,
Theres no better feeling than polishing
my pieces and the texture twinkling back at
me when Im done, I do love the tiniest of
minuscule details.
CLASSIC THEMES
This solid silver pocket watch-style case with
an enamelled lid is based on the literary classic
by Lewis Carroll, and was designed so it had
a purpose when the jewellery inside was not
being worn
DIGITAL TOOLS
FOR ORGANIC
SHAPES
The design uses three main software tools:
Rhino 5.0, Matrix 8.0 and Artcam R2. Rhino
for building the main shapes and structure,
while Artcam adds textures and organic shapes
to the surfaces. Matrix is mainly used for
rendering purposes so she can get a feel for
how the piece is going to look in metal
JEWELLERY BOX
It houses a silver playing card soldiers ring,
an Alice pendant and a Mad Hatters tea table
pendant. A turning base plate lets you hide
and reveal the ring and it also reveals a laser
engraved poem as you turn it
p16_17_D3D_JUNE17_VDG KT.indd 16 30/05/2017 21:58

WAX WORK
The design is enhanced for 3D printing,
working out the best way to print it in a
castable wax, taking into account metal
weight, sprue points for the casting process
and using a variety of 3D printers to ensure
the best finish for the job
CASTING
The wax model is sent to be cast in precious
metal in Birminghams prestigious Jewellery
Quarter; using Weston Beamor for the smaller
castings, and Wardles who specialise in large
scale castings, with both companies combined
offering over a century of expertise
BUFF AND POLISH

The most difficult elements to achieve are
the textures and tiny details ensuring they
come out in the 3D print and cast can be very
tricky and, being very delicate, being careful
not to polish them away when post processing
OPTIONS, PRICE & AVAILABILITY

Full Alice In Wonderland set costs 2,500 from
katytromans.weebly.com
p16_17_D3D_JUNE17_VDG KT.indd 17 30/05/2017 21:58

PRODUCT
DESIGN
SHOWCASE
PROSTHETIC
ARMS
Tanya Weaver looks at three very different
prosthetic arm projects from an inventor, a
team of academics and a design student
HELPING
HAND
B
en Ryan is the inventor of Ambionics a In December he reached out to Autodesk
fully-functioning 3D printed hydraulic and was put in touch with Paul Sohi, a
prosthetic which he specifically created product designer at Autodesk in London.
for his two-year-old son, Sol. However, a year Paul showed me a really neat workflow for
ago he would not have referred to himself as modelling sockets from a scan of the arm a
an inventor let alone a designer or engineer mere hour of his time led to a step change
or even someone familiar with the product in what I was able to do life changing
development process. However, circumstances really. I modified Pauls workflow and was
necessitated that he did and he embarked on a subsequently able to 3D print hydraulic
huge learning curve. actuators on a Stratasys Connex 3D printer
When Sol was born in March 2015, that were perfectly modelled to the contours
complications resulted in the amputation of of Sols arm.
his lower left arm. As a psychology teacher Ambionics embarked on its first
at the time, Ryan carried out research and crowdfunding campaign earlier this year,
discovered that children not fitted with a the funding of which has enabled it to start
functional hand until after theyre two years a beta trial in which 20 passive arms were
old tend to reject prosthetics. This was an given away to babies and infants.
issue as Sol would have to wait for three years In the meantime, Ryan is back in the
for a myoelectric prosthetic from the NHS. So prototyping hot seat. My brother and I are
Ryan decided to act. prototyping the manual and power assisted
This time last year I had never used hydraulic arms ahead of the patent deadline.
CAD and knew nothing of manufacturing We had a major breakthrough recently.
techniques.Like everyone else I had heard Thanks to the new polymer from Stratasys
about 3D scanning and 3D printing but that Agilus30 we now have the first working
was about it. It was early July 2016 when I first double acting hydraulic bellow for bench
downloaded Autodesk Fusion 360 and began testing with a 5psi micro pump and sensors.
to play around with the workflows. This will be for when Sol is a little older.Im
My approach at that time was to use an hoping it will lead to a greater readiness for
Xbox 360 Kinect scanner to create STL files of Sol to use something like the Luke Hand
Sols NHS socket.I was chopping these up in [lukehand.org], which is undoubtedly the
Fusion, adding hydraulics and moving parts coolest project around.
but I couldnt get it to work. ambionics.co.uk
p18_19_20_JUNE17_PDG PROSETHICS.indd 18 30/05/2017 21:59

PROFILE
Ben Ryan and his son

Sol, who is wearing the
customised 3D printed
hydraulic prosthetic
which Ryan developed
specifically for him
DEVELOP3D MONTH 200X 19

HAND THAT SEES
P
rosthetic limbs which will allow
the wearer to reach for objects
automatically are currently in
development and soon to be trialled.
Led by biomedical engineers at
Newcastle University and funded by
the Engineering and Physical Sciences
Research Council, the bionic hand is fitted
with a camera which instantaneously
takes a picture of the object in front of it,
assesses its shape and size and triggers a
series of movements in the hand.
Dr Kianoush Nazarpour, a senior
lecturer in Biomedical Engineering at
Newcastle University, explains: Prosthetic
limbs have changed very little in the past
100 years the design is much better
and the materials are lighter weight and
more durable but they still work in the
same way. Using computer vision, we
have developed a bionic hand which can
respond automatically.
Responsiveness has been one of the
main barriers to artificial limbs. For many
amputees the reference point is their
healthy arm or leg so prosthetics seem
slow and cumbersome in comparison.
A number of amputees have already
trialled this hands with eyes and now the
Newcastle University team are working
with Newcastle upon Tyne Hospitals NHS
Foundation Trust to offer it to patients at A team at Newcastle
University have developed
Newcastles Freeman Hospital. an intuitive hand that
ncl.ac.uk | epsrc.ac.uk can react without thinking
PERSONAL TOUCH
W
hen an amputee is fixed with
a myoelectric prosthetic they
control this artificial limb
with the electrical signals generated
naturally by their own muscles. However,
extortionate costs mean these prosthetics MYO is a university degree
cannot be supplied through the NHS. project that features
Isobel Billau, a product design customisable covers to
enable users to express
engineering student at Brunel University their individuality
London, decided to tackle this issue in
her final year project. Using minimal
components would not only ease assembly
and cut weight but would also reduce cost.
Fortuitously, a former graduate Ben
Armstrong had already been addressing
this in his MYO project and Billau decided
to further his work.
Ben left the project in quite a theoretical
stage he had the mechanism of the
elbow moving but never received the
components and had it tested. I have
changed some of the components to
reduce the prosthetic by about 50 per
cent, she explains.
Billau designed her components in
SolidWorks and then 3D printed them
on the universitys in-house Stratasys
Dimension Elite printer using ABS.
She then used laser cutting for the
customisable covers.
Billau and her fellow design engineering
students will be showcasing their final
year projects at Made in Brunel from 15
18 June in London.
20 MONTH 200X DEVELOP3D
madeinbrunel.com

SLM_Ad.indd 1 30/05/2017 13:58
Whippet Bicycle
utilises twin oval
tube arrangements to
deliver a comfortable
ride as well as a clever
new folding solution
p22_23_24_25_26_D3D_JUNE17_cover story Whippet Bicycle.indd 22 30/05/2017 21:59

PROFILE
FOR Stylish and simple, Whippet is a new take on the folding bicycle
THE that puts equal emphasis on the ride and its slimline storage.
LOVE
Tanya Weaver visits Graham Powell in his Warwickshire workshop
OF where he has spent the past four years hand building his design
CYCLING DEVELOP3D.COM JUNE 2017 23

PROFILE
I
1
nventions of the first bicycle emerged in the for the past four years hes put a lot of work into designing,
1 Graham Powell
in his Warwickshire
mid 1800s and despite being surpassed by developing, building, refining and test riding his own
workshop where
faster and less labour intensive means of bicycle. Called Whippet Bicycle its a folding design that he spent many
transportation, the bicycle is arguably more doesnt actually fold, it retracts. hours hand building
popular than ever. Most of us had one from A classic diamond frame with a difference, Whippet components for the
various Whippet
a very early age and probably still have one, utilises twin oval tube arrangements that offer controlled Bicycle prototypes
or a few, now. Why do we covet them so? As a ex to absorb road shock. This allows for a comfortable
means of getting around, yes, but as objects ride despite its 20-inch wheels. And, when youre done
whats the fascination? riding and once its been retracted, Whippet can be easily
For designer and engineer Graham Powell its that they rolled along on its rear wheel.
offer a perfect mix of form and function. Part of it is just It does ride really well and for me that was as important
the joy of engineering because you can see immediately as folding, admits Powell. You can, and I have, ridden it
what it does, he says. But you also form an emotional for 40-50 miles and its pretty comfortable and that is due to
connection far beyond merely being a purely functional the twin tubes that you can just about ex with your hands.
item they almost become part of the family and often This of course means that you dont need a suspension
cyclists will have more than one, but couldnt part with an system, which small wheelers tend to have to make them
old one. That emotional attachment not many machines more acceptable in offering a less bumpy ride.
have that. This is, of course, the Whippet Bicycle now after its
Powell admits to being a life long cycle enthusiast and four year journey, a journey that began in March 2013 at

DEVELOP3D LIVE. Powell, who at the time was working as
the Post Graduate programme director of Product Design
National Cycle Archive at Warwick University. He provided
Powell with the patent abridgements from the 1860s to
Looking
at the Birmingham Institute of Art & Design, was attending the 1900s and then Powell went to the university to look
our annual event at Warwick Arts Centre on a work trip through the rest up to the 1920s. back,
research day. He is a true historian of vintage cycles and told me that playing
The next day feeling inspired by both the talks he attended 25 per cent of patents in the late 1800s were bicycle or in 2D on
as well as a meet-up at the event with Mark Sanders (the tricycle related because that was the innovation at the time.
inventor of the Strida folding bicycle), he was day dreaming The patents were amazing to look through and it makes
the table
about bicycle design during a coffee break. He started you think that people are claiming something is new now heavily
playing around with some items on his desk namely CDs but here it is in 1882, just not in carbon fibre, says Powell. inuenced
and wooden coffee stirrers. By his own admission, Powell Full of theory, research and practical ideas, in Summer the
likes to challenge the rules and was thinking does a folding 2013 Powell successfully applied for a grant from Innovate
bike actually need to fold or is there perhaps another way? UK, resigned from his teaching job and set up a workshop retractive
Looking back, playing in 2D on the table heavily in rural Warwickshire close to Leamington Spa. solution
inuenced the retractive solution I came up with for the With 18 months of funding secured, he bought a small I came up
bicycle. Its quite obvious when you think about it, it is very lathe and milling machine to set up what he refers to as
2D, says Powell. a lean workshop with an old school approach in that it
with for
He then got out his sketchbooks (and purchased a few involved technical drawings and hands on making. the bicycle.
more) to sketch out his ideas. Of course, he was indulging Its quite
his own love of bicycles and attempting to discover whether FACING UP TO CHALLENGES obvious
he could indeed design a viable alternative to the traditional A folding, or retracting bicycle in this case, is a complex
folding bicycle, but even at this early stage he did have a product that poses many technical challenges and the first
when you
style of bicycle in mind and a user it might appeal to. The crisis occurred a year down the line from his original idea. think about
style clean, minimal and modern was also inuenced by The angled top bar on his first prototype, which hed built it, it is very
designhunter.co.uk, a luxury lifestyle website that Powells from wood, plastic and aluminium, had always proven 2D
wife Helen, an interiors writer and stylist, founded in troublesome and the solution he arrived at was to simply
2009. At the forefront of my mind and his, as I was going
alongside him on this journey, was who is this bicycle for? It
remove it and lift up what were the middle twin tubes.
The sloping third top bar was a nightmare, just too many

wasnt like lets design a bike and then see who might want joints and pivots that would require complex engineering
one, she recalls. like hydraulics to make it work, and that wouldnt suit the
As Powell explains, the target audience could potentially bicycle, admits Powell.
be anyone who loves cycling and appreciates good design, The answer was obvious of course once I saw it it was
whether young or old, male or female. Offering a slim to just get rid of it. Ironically this is what I originally did
storage solution means that it may also appeal more to the with the coffee sticks but I went straight to idea number two
urban dweller where space and security is a priority. thinking that was the solution.
He reworked this from what he calls Metal Bike One,
BICYCLE RESEARCH which was a fully working prototype that he machined from
Before getting any further into the design process Powell 6061 aluminium. It weighed a tonne, he laughs,but I
decided to carry out research and immerse himself in all still managed to take it out for test rides.
things bicycles from reading the relatively modern history For his next prototype he used custom rolled T45 steel
of folding bicycles particularly Pederson, Moulton, tube for the frame from ProFormance Metals in Daventry.
Brompton and Strida to checking through thousands of It was at this stage that he then enlisted the help of a sub
patent abridgements, some that go as far back as 150 years. contractor to model the bicycle up in CAD to create a full
Whilst working on Obsessionistas, a website about set of files with accurate dimensions, geometry and details
collecting hed set up a few years previous, hed met an for machining and manufacture, including laser cutting
engineer and historian Andrew Millward, who has over and 3D printing. As the design was taking shape in
360 Edwardian bicycles and was involved in setting up the SolidWorks, I have to confess to having been a bit of a back

2 The bicycle was
only modelled in
SolidWorks halfway
through the project

3 Where the
inspiration began
during a coffee
break playing around
with CDs and coffee
stirrers

4 Graham Powell
then filled many
3 4 sketchbooks with his
folding bicycle idea

PROFILE

It didnt
seat driver, smiles Powell.
At this stage, Powell also had a few small concept
risks and failures whilst also adopting the designer-makers
mantra, which he describes as, make it, make mistakes,
parts 3D printed by AME Group for testing including make it work, make it again, make it good, make it again,
look great curved washers and tube end caps, which were proving make it even better.
but it was challenging to machine himself. With prototype four the design was definitely taking
solid and it He commuted around 1,000 miles on this prototype, but shape and after the careful machining and hand filing
did it in stealth mode as it had to be fitted with a special full (which Powell says he dedicated many an hour to), these
reassured fabric IP jacket to keep prying eyes from spotting its secret parts together with new lighter weight oval 25CrMo4 frame
me that design before the patent was filed. tubes, commissioned from Columbus Tubing, were joined
the whole It didnt look great but it was solid and it reassured me together by local master brazer Lee Cooper.
twisty, that the whole twisty, lateral stiffness thing was totally Following extensive test rides and folding, Powell
resolvable although it was slightly over engineered. further refined the design into bicycle number five with
lateral new details, materials, aesthetics and, what he refers
stiffness KEEPING THE FAITH to as, engineering jewelry (in other words, those
thing was It was whilst working on the third prototype that the second shiny aluminium components and widgets that bicycle
major crisis struck. This time it was the front locks and enthusiasts love).
totally after reviewing his early sketchbook ideas, he redesigned It was in the gearing up for launch that Powells wife
resolvable them again, but not without a lot of hard work. Helen became very much involved in the project, lending
although it This was probably the hardest part of the project. With her skills in styling, photography and branding as they
was slightly the retraction design the locks are key, and with the front worked together on digital marketing and website design.
wheel tucking up through the middle they have to tighten
over up fully, be fail-safe and accommodate longer term wear FIRST PUBLIC OUTING
engineered and potential abuse, explains Powell. In April 2017 it was time for the big reveal and the location
Challenges like this can really test your resolve especially

when working long hours on your own in the dead of winter
they chose in which to do this was Bespoked 2017, the UK
hand built bicycle show, located in Brunels Old Station and
in a cold workshop. As Powell admits, often the hardest part Engine Shed in Bristol.
of this project was keeping the faith. You have to embrace We always wanted to launch Whippet Bicycle at Bespoked
where fellow cycle enthusiasts of all persuasions would be
able to give us valuable and honest feedback about our new
5 6 design. We were expecting a lot of criticism but received
largely positive comments, and many from Brompton and
Moulton owners, which was a real surprise.
As an added pat on the back for all the hard work, Whippet
was awarded a Technical Excellence Award from the event
organisers.
Although buoyed by this reception, and rightly so,
Powell realises that its still early days and the next phase is
working on an appropriate route into production and also
to get an additional pair of engineering hands onboard. I
see myself more as a designer rather than an engineer and
the bike needs to be drawn up in CAD again and fully FEA
analysed. I have all the standards and have intentionally
over engineered it so it could be lightened and refined as we
learn more.
Whippet Bicycle has certainly been on one hell of a ride so
far and its not over yet
whippetbicycle.com

5 Slim and retractive, Whippet Bicycle
is just 190mm wide in its folded mode

6 Metal Bike One was the first fully
working prototype, which Powell
machined from 6061 aluminium
7 The hope is that Whippet Bicycle
will appeal to anyone who loves cycling
and appreciates good design, whether
young or old, male or female

SOLIDWORKS-Promotion-Develop3D-SolidSolutions.pdf 1 18/05/2017 17:33:17
PROFILE
The pet products industry is booming, but in the unregulated

world of manufacture, British brand Beco is applying design
thinking and eco responsibility to create fantastic fun for Fido.
Y
Stephen Holmes goes to see a man about a dog toy
oure creating a product for a standards the product had to meet.
user whose mission, from when Theres none of that in the pet industry at all! exclaims
it wakes up in the morning, is Massey, readily pointing out that the pet industry is also
to destroy your product, offers a shocking four times the size of the equivalent baby
Toby Massey, co-founder of Beco products business.
Pets. Thats what most of my It does help differentiate us. Were able to speak with a lot
customers do. more confidence about what materials are in our products
Its not a mission statement most we have a lot more due diligence on what the materials
designers have to adhere to, yet supply chain is like.
in the world of dog toys its the challenge that faces a pet The entire process is overseen from Becos headquarters
products company. in South London, where the majority of its design team
Becos designs walk a fine line between fulfilling the dogs work in an office perched above its distribution warehouse.
needs and attracting the attention of an owner that first has A full operation is also maintained in China, where the
to buy the product, all the while holding up some serious production and distribution arm of Beco is taken care of. As
eco credentials. Massey explains, the business plan is straightforward: Use
That came first. Our Beco bowls were our first products the waste materials at source, produce [products] and ship
with the idea of using offcuts of bamboo and rice husks, them to all our customers around the world.
says Massey. Left-overs from chopstick factories and leftover rice husks
Having left university, Massey challenged himself with from food production centres locally in Asia are recycled
finding a commercially viable market into which to launch and mixed with natural rubber, before being used to
a product that could be made from materials recycled from produce the product out there, before being shipped to the
mass manufacturings waste. rest of the world where dogs can play with them, with the
Dog bowls: youre not producing them like toothbrushes, additional eco benefits of a reasonably low carbon footprint.
where theyre turned out in the millions and millions. You
can produce 500, or a thousand dog bowls, and make a DESIGN FOR DOGS
profit, he explains of his brainwave. The design of the products is a fine balance, given that the
When youre starting up a company its quite a challenge main consumer the dog gets the fun, while the owner is
to find that niche, and just because its eco-friendly doesnt more typically focussed on the way its styled.
mean its 25 for a dog bowl its a fiver and everyone can With this in mind, the design process typically begins
afford a fiver for a nice dog bowl. with the search for a market sector that has potential.
Sometimes I have a good idea moment when Im out
SET TAILS WAGGING with my dog, and that starts off a chain, says Massey, But
Over its nine year history, of which a stint was also spent generally its looking for needs thats the commercial
designing baby toys, the range of Beco products has side of what were trying to do: were looking for something
expanded to include chew toys, throwing ropes, soft that we think will be commercially viable right from the
play animals, and even poo-bags. Everything it produces beginning.
demonstrates an eye for detail and a deeply ingrained This method gives the team a set of guidelines to work
concern for the wellbeing of pet, owner and environment. within. Sketches are shared with dog owners and retail Providing a dog with
A lot of this arises from the experience of dealing with outlets to work up solid concepts, which progress swiftly to endless hours of fun,
the Beco Ball on Rope
the requirements for launching a toy or product for a child 3D modelling and producing prototypes rubber toys from is made from natural
mountains of testing certifications, legislation and other moulds or stitched fabric. rubber and cotton
p28_29_30_D3D_JUNE17_Beco Pet.indd 28 30/05/2017 22:00

Youre creating a product for a user whose
mission, from when it wakes up in the
morning, is to destroy your product
Toby Massey


PROFILE
The development from this point is solely about testing

with animals, how theyll react, play and set out to break
them.
When youve got a very expensive rapid prototype that
youre going to give to a dog and watch them destroy thats
a bit depressing, but at the same time you have to do it to
see how a dog can interact with the toy and get the pleasure
out of it.
While exing a signature green Beco Bone, Massey
explains the challenge for chew toys is to make them as
pleasurable as possible, from a material that is inherently
uninteresting to the dog: a block of rubber.
Here is where the crossover with baby products returns
bright colours, interesting shapes, and how the toys bounce
and roll and move are all important. Additionally, for dogs
its all about textures felt with their mouths.
Testing with animals is completely different to testing
with humans, laughs Massey.
You can give it to any number of dogs, and then give it to
another dog and youre left thinking how the hell has that
dog managed to do that to it?!.
Physical testing can also solve many problems that initially
had not been thought of.
The shore hardness determined by the mix of recycled
rice husks and rubber is an important factor.
Softer materials are weaker in a standard strength test,
but prove longer lasting in the real world due to how the dog 1
gets enjoyment. When the dog bites it, the ex of the rubber
is what it enjoys. Bones that are really solid and rigid are grow, distributing Beco products to 40 countries worldwide. 1 DEVELOP3Ds
resident hound
broken far too quickly for that reason. The reason why were quite successful, I think, is I still
Mycroft Holmes
So instead of ripping it to shreds, the right amount of ex believe that people like the idea anywhere in the world with his toy bone,
helps keep the pooch interested for longer. of buying products that have had some consideration and which is tough, extra
thought put into how its been designed and produced. bouncy and made
from natural rubber
NEW TRICKS Next is Becos entry into the pet food market, and and rice husk
The precision engineering needed in making a dog bone tackling the non-recyclable metallised plastic bags that 2 The Beco bowls
is not at the same level needed to make a 200mph wheel most come in, as well as the huge carbon footprints many were the companys
holding a car to the road, smiles Massey, yet, he explains, ingredients bring. rst products born
from the idea of using
at the same time it needs to be designed in a way thats Beco has spent a lot of time and cost working with a offcuts of bamboo
engineered precisely enough to produce thousands of packaging company on a fully compostable design glue, and rice husks
pieces as quickly as possible; doesnt break the tools, and seal, inner, even a stay-fresh zipper to house its own,
can be produced for the right price. produced local-to-market, food.
In my mind its all about real world design, what The dedication to being eco-friendly is fortified
were trying to do is use our design understanding and throughout the company, even down to warehouse staff,
knowledge and make things as efficient, as cost effective who collect used cardboard from neighbouring companies
and as great for a business as we can, while having as little then shred it to form the packing for its order boxes.
impact on the environment as we possibly can. Yet, for all its work highlighting what can be done with
Unlike most mass-produced pet toys, Becos have a full the by-products of mass manufacturing, the success of the
lifecycle plan from recycled beginnings, the toys are products is down to those with four paws.
biodegradable once in landfill, and much safer than many Having returned from our visit with some Beco goodies
mass-produced plastics should the dog manage to consume for Mycroft, DEVELOP3Ds [sometimes] faithful office
any of it by accident. hound, its fair to say he has done nothing since but work

give
You can
it to
As Massey asserts, this attention to design as part of its passionately at destroying them in the best possible way. any number
wider business planning is what has seen the company becopet.com of dogs,
and then
give it to
another
and
2 youre left
thinking
how the
hell has it
managed to
do that to

it?!

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PUT

Chris Froomes position was more
aerodynamic than that of the chasers, but
TO
not aerodynamically superior all-round
Bert Blocken

THE
TEST
A research project conducted
collaboratively by a number of
universities set out to explore
the aerodynamic performance
of different hill descent positions
in cycling using both wind tunnel
testing and simulation. Tanya
1
T
Weaver reports
hose who watched last years Tour de that adopted by other professional cyclists in several races.
1 In order to test
the various descent
France may have noticed the curious There would be four in the study namely: Position Froome;
positions in the wind
position that UK cyclist Chris Froome Position Pantani (from the late Marco Pantani); Position tunnel 1:4 scale
adopted when he descended the Back Down (from Vincenzo Nibali); and Position Back models were made
Peyresourde during stage eight of the Horizontal (also from Vincenzo Nibali, and one that is
2 Comparison of six
competition. He broke away from his adopted by many cyclists whilst descending). positions in terms of
speed, either without
competitors just before reaching the pedalling or when all
1,569m summit and then descended LET THE INVESTIGATION BEGIN cyclists are pedalling
the 15.5km towards the finish line to win that stage by 13 Two different methods wind tunnel testing and CFD with the same power
provision
seconds. Whilst doing this he was effectively sitting on the would be used to carry out the investigation, both based on
the assumption that none of the cyclists would be pedalling.
3 Three members
crossbar with his chest on the handlebar, placing the bulk of the project team
of his weight on the front wheel. For the wind tunnel testing, a cyclist was scanned in these with the scale models
Surely, this was a dangerous descent position but was it four positions and the data was then used to create 1:4 scale in the wind tunnel
at Liege University,
worth it to make him more aerodynamic? When questioned models that were cut using CNC technology. The tests Belgium. From left:
by the press afterwards and asked whether he or Team Sky were performed at 216 km/h for Reynolds similarity with Thierry Marchal, Bert
had practiced it beforehand, Froome answered, It was the physical reality at full scale and 54 km/h (= 15 m/s). Blocken and Thomas
Andrianne
really just a spur of the moment thing. I felt like a kid again, 216 km/h is a hurricane of category four, so the models
just trying to ride my bike as fast as I could. needed to be reinforced with vertical bars in the wheels.
Bert Blocken, professor of aerodynamics at both Corrections were made to remove their contribution to the
Eindhoven University of Technology (TU Eindhoven), aerodynamic resistance, describes Blocken.
The Netherlands, and Leuven University, Belgium, was It was calculated that Position Pantani was 2
watching this stage of the race and within ten minutes aerodynamically
hed received two emails from colleagues and one from superior being 4.8%
Thierry Marchal, Ansys global industry director for faster than Position
sports, medicine and construction, all suggesting that Froome. Then it was
they investigate this particular descent position to uncover Position Back Down,
whether it really is aerodynamically superior. which is 2.4% faster,
So an independent and unfunded collaborative research Position Froome, and
project was put together with Blocken as project leader, lastly, Position Back
Thijs van Druenen and Yasin Toparlar, both PhD students Horizontal, which is
at TU Eindhoven, Thomas Andrianne, lecturer in 0.5% slower.
aerodynamics and director of the wind tunnel laboratory at In the second
the University Liege, Belgium, and Marchal of Ansys. method, these four
The project team would compare Froomes position to positions were analysed
p32_33_D3D_JUNE17_Ansys cycling.indd 32 30/05/2017 22:00

PROFILE
with Ansys Fluent CFD software pressure distribution in all positions tested is very complex
using extremely high-resolution and very different and this difference causes the varying
models of 36 million calculation drag forces, he explains.
cells with a near-wall cell size Although the researchers cannot recreate the exact
of less than 20 micrometers (= Peyresourde descent with all the time differences between
0.020 mm) close to the body of each competitor, based on Froomes average speed during
the cyclist. this descent (62.5 km/h), they have estimated how much
time can be gained in each position purely from an
ADDING TO THE STUDY aerodynamic point of view:
As the two methods produced Position Back Upwards:+1 min 17 secs
very similar results, the Position Back Horizontal:+ 8 secs
researchers decided to add a Position Froome
further two positions to the study: Position Back Down: 23 secs
Position Back Upwards (from Position Pantani: 46 secs
Fabian Cancellara) and Position Position Top Tube Safe:1 min 7 secs
Top Tube Safe (from Peter
Sagan and so called because, as FINAL CONCLUSIONS
opposed to Position Froome, the The ultimate conclusion from all this hard work (and it was
body weight is distributed more hard work as it took the team 10 months to get reliable and
equally over both wheels). highly accurate results, both within the wind tunnel and
2 3 In the final results, most of the CFD) is that Position Froome is not faster, not safer and
percentages are larger than the not more powerful compared to other positions. And the
deviations between the wind tunnel and CFD results (see reason why he won stage eight is because he accelerated
graph opposite). Why is this? Well, according to Blocken, before the summit and already had a substantial lead when
the aerodynamic resistance or drag force is determined by he started descending and so increased his lead until his
an equation in which four factors are discerned: the cycling competitors started descending. Additionally, the chasers
speed, the frontal area of the cyclist, the drag coefficient of had adopted non-aerodynamic positions (mainly Position
the cyclist and the air density. Back Horizontal) once they started descending.
Assuming the same cycling speed and air density, the So, yes, Froomes position was more aerodynamic than
frontal area A and drag coefficient Cd remain. The higher that of the chasers, but not aerodynamically superior all-
the values of A and Cd, the larger the drag force. The main round. Descending Back down or Top tube safe would
reason for the difference in results in this study is the have allowed the chasers maybe to catch up with Froome
different drag coefficients. The drag coefficient is the result and prevent him from winning, concludes Blocken.
of the pressure distribution on the body of the cyclist. The ansys.com
p32_33_D3D_JUNE17_Ansys cycling.indd 33 30/05/2017 22:00

PROFILE
SPEED
CYCLE
McLaren Honda F1 and Stratasys have launched
a new partnership to utilise 3D printing for the
racetrack. Stephen Holmes paid a visit to Race HQ
to see how this is enhancing not just the cars, but
the abilities of additive manufacturing

If we can bring new
developments to the car one
race earlier going from new
idea to new part in only a few
days this will be a key factor
in making the McLaren MCL32
more competitive

1 The McLaren
Honda MCL32 Neil Oatley
is currently

L
competing in the
2017 Formula One
egendary F1 team McLaren as part of its trackside equipment, to races new part in only a few days this will be a key
Honda recently opened around the world, enabling the team to factor in making the McLaren MCL32 more
its doors to DEVELOP3D produce parts and tooling on demand from competitive.
to showcase the first the pit lane. Not to waste an opportunity, the feedback
developments of its four- Although, on the face of it, this desktop from such a high-level client is directly
year partnership with 3D machine working away behind the likes influencing Stratasys own engineers and
printing expert Stratasys, of Fernando Alonso in the garage looks scientists.
and it hasnt wasted like a marketing gimmick, the engineers When asked, Stratasys EMEA president
anytime. at McLaren were happy to show us parts Andy Middleton said that the relationship
A full plethora of Stratasys machines has theyd worked on specifically as trackside will see Stratasys looking to work to solve its
been installed onsite since the partnership performance enhancements. engineering challenges in the workshop, in
announcement back in January, leading Small aero fins and wing tips printed in the wind-tunnel, and on the track.
to new digital manufacturing workflows the pit garage can be attached to the cars We believe that this, in turn, will enable
for a company that produces over 6,000 to potentially give it an edge in changing us to develop new materials and applications
components a week. conditions. that bring new efficiencies and capabilities
The team estimates that the design of the We are consistently modifying and to McLaren Racing and other automotive
current F1 car evolves every 14 minutes improving our Formula 1 car designs, so the designers and manufacturers, he says.
throughout the entire season. With time ability to test new designs quickly is critical to With preparation for the next race
the crucial factor, new methods of tooling making the car lighter and more importantly season already underway, the speed of
for composites, as well as jigs, fixtures and increasing the number of tangible iterations implementation and the evolution of
end-use parts that go straight into the cars are in improved car performance, says Neil Stratasys technology onsite could mean
being produced at its Woking HQ. Oatley, design and development director, everything for a team looking to reach the
To further accelerate design and McLaren Racing. next golden age of its long championship
manufacturing cycles, McLaren Honda will If we can bring new developments to the pedigree.
be transporting a Stratasys uPrint SE Plus, car one race earlier going from new idea to mclaren.com/formula1 | stratasys.com
p34_35_36_D3D_JUNE17_maclaren stratasys.indd 34 30/05/2017 22:01

1
3D The current MCL32 race car

has already been modified as
Three different designs were
iterated and 3D printed in one
at elevated temperatures.
The final result is a tubular
PRINTED a result of the partnership, day, and the final component structure with very smooth
RACE CAR and is running a selection
of parts directly benefitting
was 3D printed in just two
hours allowing the new, more
internal surface finishes to
ensure the required airflow
PARTS from both Stratasys FDM
and Polyjet technologies,
comfortable radio harness
assembly to be used in the first
to brakes, whilst maintaining
maximum aerodynamic and car 2
including: Grand Prix race of the 2017 performance.
season. The custom design also
Hydraulic Line Bracket incorporates a McLaren logo. Rear Wing Flap
A structural bracket to attach Flaps, fins and edges are a
the hydraulic line on the MCL32 Carbon Fibre Composite constantly evolving quirk of an
race car using a Fortus 450mc Brake Cooling Ducts F1 car, with each one changing
The hydraulic line
2
3D printer with Stratasys To efficiently control the brake to suit track and even weather
bracket was produced carbon-fibre reinforced nylon component temperatures, conditions as the teams look
using a Fortus 450mc material Nylon 12CF. McLaren Honda 3D printed to shave off hundredths of a
3
in Nylon 12CF The bracket is said to sacrificial tools to create hollow second from their lap times.

3 The radio harness have been produced in just composite brake cooling ducts. A large rear wing flap
location boot is a four hours, compared to an The wash-out cores, 3D extension designed to
flexible, rubber-like estimated two weeks to create printed using ST-130 soluble increase rear downforce was
part using traditional manufacturing material, are clearly one of manufactured in carbon fibre-
processes. the standout reasons why reinforced composites using a
4 A large rear wing
McLaren are beaming about 3D printed lay-up tool produced
flap extension was 4
Flexible Radio Harness the partnership, as it boosts its on the FDM-based Fortus
created with the help Location Boot composites production process 900mc 3D printer.
of a 3D printed mould Taking advantage of the massively without the need for The team 3D printed
in ULTEM 1010 Stratasys J750 3D printers time consuming tooling. the 900mm wide, high
5 A selection of 3D ability to print in flexible Developed specifically for the temperature (177C) mould in
printed parts that materials, McLaren designed application, and then wrapped ULTEM 1010 for the autoclave-
have been produced and 3D printed a rubber-like with carbon fibre-reinforced cured composite structure in
on McLarens onsite boot to join the harness wires composite material the parts just three days, saving time in a 5
Stratasys machines for the communication system. are then autoclave-cured critical limited testing period.
p34_35_36_D3D_JUNE17_maclaren stratasys.indd 35 30/05/2017 22:01

INTERVIEW
Q&APIERRE MAHEUT
WE TALK TO THE PRODUCT MANAGER FOR
ARCHITECTURE AND INDUSTRIAL DESIGN
AT ALLEGORITHMIC ABOUT ITS MATERIAL
AUTHORING TOOL SUBSTANCE DESIGNER
F
rance-based Allegorithmic is a software developer of 3D D3D: What applications does Substance Designer work
content creation tools. Starting out in 2003 with the aim alongside?
of reimagining the process of texture creation, today its
Substance suite of tools is used widely by 3D professionals PM: Since you can always export texture maps (in 1-8K),
in a range of industries for PBR (physically based Substance Designer works with all 3D software. Over the
rendering) material authoring. The software appealed years, weve also created deeper integrations with game
initially to users in the gaming industry but over the years engines like Unreal and Unity; 3D modelling tools like
it is increasingly being used by designers, engineers and 3ds Max, Maya, Cinema 4D and Modo; and CAD tools like
architects to fulfill their need for rapid, efficient texturing. Catia. When we talk about deeper integration, it means
that you can still tweak and modify the materials within
D3D: Lets start with the basics what do Allegorithmic the game engine or 3D software. For rendering, we easily
and its Substance Designer application do? connect with V-Ray, Iray, Corona, Arnold and many more.
PM:We make the Substance suite of tools, a collection D3D: When it comes to design and engineering,
of software applications and services that help designers workflow is fundamental as time pressures are ever
create and customise virtual materials. Substance present. What are the benefits of your approach?
Designer is made for designers that want to create their
own PBR materials. Those materials can be created PM: When designers use Photoshop to create textures it
procedurally through algorithms, from scans or even a can take them a long time, especially if they are replicated.
mix of the two. Where Substance materials really stand We recently had a user tell us that what used to take two
out compared to classic texture maps is how malleable days now takes an hour in Substance Designer. He can
they are. Everything can be adjusted by the user, enabling make custom materials in less time and at a higher quality
designers to experiment with ideas in a much more fluid level than in Photoshop. Companies have also been getting
and photorealistic way. in touch with us, especially material manufacturers, who
see the value in experimenting with high-quality virtual
D3D: Although more designers and engineers are taking materials before they go to production.
advantage of photorealistic visualisation techniques,
many rely on pre-baked materials and textures. So why D3D: Lets say Im experienced with moderately complex
invest in your tools? visualisation techniques, what do I need to consider
when looking at Substance Designer? Where should I
PM:Quality and flexibility. When you rely on an existing focus my first few hours of working with the tool?
texture map, you have to make tradeoffs. Colour, finish and
texture these elements are so ingrained in the product PM:If you are familiar with a node-based approach, as you
experience but are often skipped due to virtual limitations. would be if you are a Grasshopper user, then it should be
With Substance, designers dont have to make those a fast process since you already know that it is a non-linear
compromises. and non-destructive way to describe PBR materials. What I
Our tools allow users to do stunning renderings with would recommend is to focus first on each output channel:
a level of realism never before achieved in the material Base Colour, Normal, Roughness and Metallic. Learn the
world. Users can finally match their exact design intent. role of each and how they can be mixed together to achieve
For customers like Louis Vuitton and Dassault Aviation, different effects (our PBR Guide is very helpful for that
where quality is a part of the brand identity, this is a must. allegorithmic.com/pbr-guide).
Our users also have access to tweaks, scan processing and I would also recommend exploring our free video tutorial
Substance Source (our ever-growing library of high-fidelity, portal, Substance Academy tutorials.allegorithmic.com
ready-made materials), so most are finding that they are specifically the Getting Started with Substance Designer
spending less time with the materials and more time on the course.
creative process. Finally, just have fun. Select a material you want to
p36_37_D3D_JUNE17_Allegorithmic Q&A.indd 36 30/05/2017 22:01

T
Our tools
allow users to
R do stunning
renderings
with a level
of realism
never before 1
achieved in
the material
R world

reproduce, whether its plastic, metal or a textile, and try

to build it. You can also download a material on Substance
Share (our free community library) and study a graph made
by someone else. 2
D3D: Lets talk about measured materials. Youve
recently launched Substance Source whats the goal
behind that?
PM: We know that in industrial design its all about saving

time and efficiency, so we wanted to provide our users
with a pre-made library of PBR materials. We work with
industry experts to make sure we only upload the best
metals, fabrics, plastics, etc., so the process of finding that
ideal material is simple.
Its a great way to become a Substance user and benefit
from a tweakable, flexible material without a requirement
to master Substance Designer. Today we have 1,000 PBR 3
materials in Substance source. The idea behind it is to
have an ever-growing library with a very high level of
quality. We are producing those materials using our tool,
so it is also a great showcase of what can be achieved in
Substance Designer.
1 Hyundai and
Allegorithmic created
D3D: Does the future lie in measured materials or will a full set of materials
for the Hyundai
there always be a need for users to create their own Genesis 380 using
materials? Substance Designer
(Image courtesy of
Hyundai)
PM: Both, as they serve different purposes. 3D designers
and modellers want something that will work out of the 2 3 Substance
Source is a pre-made
box, while a colour and trim designer, for example, might library of PBR
want to explore and create new materials that dont exist yet. materials including
4
tweakable, flexible
Most designers are already creative, they just need creative materials such as
tools to express themselves. Like Tilt Brush is for 3D, we copper brushed and
want Substance to be that tool for material design. mahogany wood
Scanning is also especially exciting for us because it will 4 Substance
Designer 6, launched
allow our users to capture physical samples wherever they earlier this year,
are. We recently did two blog posts on that exact subject: features new scan
Photogrammetry using a smartphone and material tools (Image courtesy
of Texray)
scanning with a smartphone (allegorithmic.com/blog).
In this case, we developed a pipeline in Substance to 5 3D artist Peter
Kolus used Substance
streamline the process and make it accessible for non- Designer to create
experts via templates and filters. From the feedback we are this rendering of
receiving, this is something a whole lot of people have been the New Balance
Visaro trainer (Image
waiting for. courtesy of Peter 5
allegorithmic.com Kolus)
p36_37_D3D_JUNE17_Allegorithmic Q&A.indd 37 30/05/2017 22:01

TUTORIAL
3D CAD TO AR
Al Dean takes a look at how to take your 3D CAD data into Augmented Reality
with Creo 4.0 and then share that experience with clients or colleagues
A
augmented Reality (AR) is a hot topic PREPARE THE MODEL & THINGMARK
1 Create, scale and
in the general tech industry at the position your unique

The first step is to prepare your 3D model with the ThingMark directly in
moment. From the smartphone in materials in place and the product configured the way the Creo 4.0 interface
your pocket to Microsofts Hololens to in which you want to share it. Now you need to find the youll find the tools
SnapChats glasses and every point in Augmented Reality group in the Tools ribbon inside under Augmented
Reality group
between, AR is coming. And with the Creo. There are only four commands in the group and
acquisition of Vuforia and its work the first action is to place the ThingMark using add
with ThingWorx and the Internet of ThingMark.
Things (IoT), PTC has been investing heavily in the field. The ThingMark is fundamental to how all of PTCs AR
While the company has its full blown ThingWorx Studio applications work. Its a graphical device that allows you
for creating service instructions, interactive product models to not only connect the real world to a digital experience,
and maintenance applications, it has recently introduced but also control scale and position. Essentially, it solves a
tools, which are available to all customers, within its couple of problems.
flagship Creo product design system that allow everyone The first is that theres an encoded link to your AR
to create and experiment with AR, right from the 3D CAD experience within the inner border. So when you point
workstation. your ThingWorx View app at it (which you download onto
In basic terms, you go about creating an AR experience your smartphone or tablet see box opposite), itll know
by firstly using Creo to create a ThingMark (similar to a QR which web address to send it to. Alongside this pure URL
code) of your 3D model, that ThingMark is then scanned information, the ThingMark also acts as a 3D positional
by a smartphone or tablet via the ThingWorx View app. tracking target.
The digital 3D model can then be viewed in the AR world Theres some internal wizardry at play here but,
through the devices camera by pointing at the ThingMark. basically, the app on your smartphone looks at the
Heres how you do it. ThingMark and it can work out where it is in 3D space,
p38_39_D3D_JUNE17_ PTC THinkgmark.indd 38 30/05/2017 22:02

both in terms of position and scale. Not just as a static scan, it works ProductView), but with the acquisition of Vuforia, that knowledge
live, so as you move your phone in/out or around the ThingMark, has expanded into the AR realm.
the app tracks that location. When you create your AR experience, youre presented with
What this means when used with 3D model data is that when you three levels of resolution. High, medium and low which relate
place and position your ThingMark in the digital world (as shown to the fidelity and tessellation of the geometry. The greater the
in Figure 1), youre defining the relationship between that digital tessellation, the quicker itll load, but thats oset against a lower
ThingMark, the model and the real world printed ThingMark. The resolution model.
scale set in the digital model is reflected 1:1 in the real world.
If your ThingMark is printed at 115mm (like ours is) and LIMITATIONS OF FREE SERVICE
your ThingMark is set to 120mm in the digital model, Essentially, youre allowed five AR experiences per PTC
itll map across. Obviously, this means you can account log-in. Each of these will last for six months.
also play with scale. When you upload and share an AR
In Figure 1, weve set the scaling of the experience, youll be presented with a list
ThingMark in the digital world so of the four other experiences youve
that the bike model displays created. If you upload a sixth,
nicely on the page below. the oldest will be deleted and
Consider that for a these experiences will remain
moment. This isnt just live until the six months is up.
about wandering around a
digital 3D model with your NEXT STEPS
smartphone or tablet as a Clearly this is a free trial of
display device. By thinking PTCs larger set of AR tools
through the positional and and the goal is to get folks
scale capabilities of the hooked on creating these
ThingMark, its possible types of experiences. So what
to create digital assets that else can you do with the fuller
are not just overlaid over application set in ThingWorx
the real world but which Studio?
integrate with it. Position a The answer is pretty much:
ThingMark where you want whatever you want.
it in the digital model and In the first instance, the
itll pop into the AR world full product will give you
right there. way more control over how your
That might be a redesigned console models appear, let you add animations,
on a machine tool, a new wing mirror on a additional controls, shaders and more.
car or a whole new robot cell in-situ in a factory. Outside of pure CAD type functions, theres huge
Thats all possible with just this free tool within Creo, a potential for integrating this type of AR technology with
smartphone or tablet and a printer. data from IoT applications. PTC makes a big noise about the
potential for service and maintenance and rightly so. The latest
DATA COMPRESSION updates for ThingWorx Studio have also started to bring in more
The final step before you make your experience live is to compress realism in the 3D models (in terms of texture mapping) as well
the data. AR experiences thrive on lightweight data to keep as starting to add support for AR headsets such as the Microsoft
interactivity optimal. PTC already has huge experience in reducing HoloLens.
the complexity of heavy CAD datasets with its Creo View (formerly ptc.com
THINGWORX VIEW APP: VIEWING THE AR EXPERIENCE
N
ow that weve created the Thingmark, lets try it out on your
mobile device. With your own examples, youll need to send
the Thingmark to print (or you can scan it off your screen).
Heres what you do once you have:
1. Download the ThingWorx View app for your smartphone. Its freely
available for iOS, Microsoft and Android/Google devices. And get it
installed.
2. Once installed, re it up and youll be asked to allow the app to access
your camera. The app uses the built in camera to capture the Thingmarks.
3. Youll then be asked to scan the Thingmark. Point it at the image above
or the one you printed out.
4. This unique Thingmark will then load the dataset shown in the
tutorial. This is a 800Mb dataset reduced down to 20Mb to make it easily
transportable over the web.
5. Hey presto! Youll nd the model, sat on the page of the magazine. Youre
able to move around it (or rotate the page), zoom in and out by moving the
device closer or further away from it. Clever, eh?
p38_39_D3D_JUNE17_ PTC THinkgmark.indd 39 30/05/2017 22:02

FIELD
PROFILE
DAY In a new process that combines 3D printing and casting, an

agricultural machine part is made more durable and lightweight
F
ounded in 1883 in Germany and connections. With these inputs, the software calculated
still a family owned company, how much material was needed, at which position, to meet
Amazone manufactures a wide range requirements such as structural strength.
of agricultural machinery. It goes From the optimisation result, the engineers created
without saying that, as these products a detailed design that was then evaluated in an FE
are subjected to harsh and varying analysis with OptiStruct. When compared to the welded
conditions, they need to be robust, construction, the casted version featured lower weight and
durable and yet competitively priced. fewer stiffness variations.
Amazone recently conducted a project The overall loading in the casted material of the new
in which a formerly welded rocker arm, part of a soil tillage design was significantly lower compared to the loadings in
unit known as Catros-2TS, was subjected to optimisation to the weld seams of the original assembly. Due to the load-
evaluate the parts material usage and durability. specific structure of the casting part, subsequent physical
This rocker arm is a complex part weighing in at 245kg, tests showed increased durability by a factor of 2.5 while the
including a total of 16.5 m of weld seams needed to join the weight was reduced by 8 per cent.
single parts. This amount of welding made production very The new version of the rocker arm component is already
time and cost intensive. in operation and Amazone claims that it has reduced
Amazones engineers decided to take a closer look at its manufacturing costs by one third compared to the formerly
design and assess the potential for making the part lighter welded construction. Also, as the casting mould is reusable,
but also stiffer and more durable. tooling costs were quickly amortised.
In the first instance, Amazones engineers realised
that a move from welding to casting would offer several LEVERAGING 3D PRINTING
advantages. Since the component can be cast in one piece Impressed by the results achieved with this redesign,
and needs no welds, production would be much simpler Amazones engineers looked to make even further
and the process less error prone. improvements. Additive manufacturing or the combination
of additive manufacturing and casting could potentially
FROM WELDING TO CASTING provide even better results. So the project was been taken a 1 The Catros-2TS is a
compact disc harrow,
To get to a new design for the casted part, Amazone step further. which is pulled by a
conducted a topology optimisation. To optimise the Altair, 3D printer manufacturer voxeljet and material tractor and used for
intensive mixing and
structure, the engineers used solidThinking Inspire from supplier Procast Guss supported Amazone in this study
shallow cultivation
Altair, a global developer of simulation technology. and jointly created a technology demonstrator of the rocker
2 The challenge for
First, they defined the possible design space and the arm, using a new process Altair and voxeljet had created to the project was to
boundary conditions, such as loads, required stiffness, combine the advantages of 3D printing and casting. redesign an originally
and manufacturing restrictions. Non-design space areas Components produced with this process offer significant welded suspension
component as a part
were determined as well, where the structure must not performance improvements and the solid potential for cast with a 3D printed
be modified, for example at support points or cylinder serial manufacturing and mass production. Bringing sand form
p40_41_42_D3D_JUNE17_Altair farming.indd 40 30/05/2017 22:02

1
DEVELOP3D.COM JUNE 201741

PROFILE
manufacturability into account, the new part resulted in a

3 further weight saving of about 11 per cent, while keeping
durability and stiffness at the same level as with the casted
part.
To make sure that the new design could be cast, the
engineers also conducted a casting simulation with
solidThinkings Click2Cast (C2C) tool. C2C was used at two
points.
In the early phase, C2C allowed designers to test the
manufacturability of the component design and optimise it,
avoiding internal defects and analysing critical areas while
also reducing iterations between the design and production
departments. At the end of the design phase, C2C was
used again to simulate the full mould filling process and
thermal solidification, helping create the most efficient
manufacturing method and guaranteeing a controlled
filling process for increased quality and so minimising any
waste in energy, time and material.
4
REDUCE TURBULENCE
Turbulence is always a factor in the flow of molten metal as
it can trap gases in the casting material and cause defects.
It can be reduced by the design of a gating system that
promotes a more laminar flow of the liquid metal. With the
aid of simulation and 3D printing in combination, almost
any shape is possible and this reduces the risk of casting
defects. As a result, a controlled fill is ensured which
prevents oxidation of the alloy due to turbulence during the
filling process and improves casting quality further.
In the next step, voxeljet had to produce all the tooling
(cope, drag, and mould) for the casting process. Before
printing, a digital core and mould set was designed for the
optimised demonstrator. The final cast set consisted of only
four pieces.
All pieces were then 3D printed in silica sand, using a
VX4000 printer with a build envelope of 4.000 x 2.000 x
5 1.000 mm. Once all pieces were printed, they were now
ready for the casting process.
Within a few days, the mould set was printed, packed and
shipped to Procast Guss. With a production capacity of
40,000 tonnes of casted products Procast Guss produces
unit weights of 0,5 350 kg of machine moulded castings.
The range of cast iron materials offered by the company
varies from grey cast iron and spheroidal cast iron to SiMo
and ADI to highly alloyed austenitic or wear-resistant
materials.
The material used in this process was the EN GJS 500 -14
cast iron. Procast Guss applied a die coating to receive a
smoother surface before the actual casting process. It then
combined the four parts into one mould. After the part was
cast, final manual adjustments were made like separating
the non-essential parts, left over from the casting process,
from the final component. Finally the entire part was
design optimisation, fill and solidification analysis, casting, cleaned to receive an optimum result.
and 3D printing together addresses the challenges of The new rocker arm, printed and cast for the first time
lightweight design in a new way and enables the set up as a demonstrator in real size and ready to go has a weight
of an innovative design and manufacturing process that of only 200kg, which is another 11 per cent less than the
enhances performance and efficiency. traditionally casted part. At the same time, the new rocker
In this combined process additive manufacturing is arm is as stiff and durable as the traditional cast part.
used to print a casting mould, which offers a higher The project partners hope that this demonstrator, which
design freedom compared to traditional methods used in has already been showcased at the industrial technology

3 FE-simulation of
producing such moulds. the final part trade fair Hannover Messe in April, will show that 3D

4 3D printed sand printing in combination with both topology and casting
TOPOLOGY AND CASTING SIMULATION form for casting, simulation is an extremely powerful tool offering improved
The first step was a new topology optimisation. The made by voxeljet part quality as well as assuring an energy and material
design space was defined and loads were derived from 5 Final casted part
efficient production process.
ready to be shipped
a motion analysis with Inspire and then applied to the to Hannover Messe altair.com
model. After running the optimisation, which also took 2017 voxeljet.com

The latest Inventor update is
available now dont miss out
Autodesk Inventor 2018 is packed with amazing
new features and improvements that deliver better
productivity, faster performance, and expanded
interoperability. From favourites like AnyCAD to
powerful new additions like Model-Based Definition
(MBD), youll find the capabilities modern engineers
like you demand.
See how Autodesk Inventor 2018 delivers the

professional-grade tools modern engineers like
you demand.
autodesk.co.uk/campaigns/inventor
youll find the capabilities

modern engineers like you
demand.
Autodesk, the Autodesk and Inventor logo are registered trademarks or trademarks of Autodesk, Inc., and/or its
subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks
belong to their respective holders. Autodesk reserves the right to alter product offerings and specifications at any
time without notice, and is notresponsible for typographical or graphical errors that may appear in this document.
2017 Autodesk, Inc. All rights reserved.
AUT-MFG1213 Inventor Print Ad Artworked.indd 1 25/05/2017 11:04

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44.indd 1 30/05/2017 14:05

REVIEWS
Autodesk Inventor 2018

With Autodesk going all guns blazing in moving its customers to subscription, the
perception of value in that recurring fee is key. Al Dean takes a look at whats
new in Inventor 2018 and what users will get for their subs money
I
nventor has now been on the Product: removing material) as a distance from and larger datasets enabled by higher
market for a good 15 years. Having Inventor 2018 a face. This isnt the same as a face powered computing and demands of
been launched as a move away Supplier: Autodesk offset, rather it allows you to define a richer models. That said, it doesnt mean
Price: From 1,760
from Autodesks AutoCAD-based per year relationship between the geometry of that that vendors cant address performance
Mechanical Desktop, Inventor has gone autodesk.com feature and any other face in your model. improvements. For 2018, this focuses on
on to be the mainstay in the widespread Itll save you time as well as make providing easier access to Express mode
adoption of 3D modelling-based design feature histories more robust as the when opening larger assemblies (not
systems. system does the donkey work that available in Inventor LT).
Lets delve into the 2018 release by firstly previously would have required a couple There are some additional performance
looking at the part and assembly modelling of features to achieve the same end result. updates elsewhere in the system as well.
tools that we all use on a daily basis. As ever Another solid update is a small one made A good example is the delay introduced
with mature systems like Inventor, these to the hole command, which traditionally into drawing view generation. This lets you
are always going to be iteration rather than built features in the direction of the hole. dial in the scale for the view with the view
innovation but that doesnt mean there The new addition called extend start starting to generate, which means you can
arent some nuggets of goodness in there, allows you to build backwards from the nail it down then have the system perform
as there most certainly are. placement plane so geometry is cut away, the computation.
For me, one of the most interesting is this would have previously needed a
an update to feature limit options. While secondary sketch and cut. MEASUREMENT TOOL
every system has the usual array of The last one is the ability to add a Given that much of any design or
options for extruding distances, to faces partial chamfer to an edge. This allows engineering project centres around
and to offsets, its when you get into the you to define the distance along an edge measurements, its perhaps surprising
finer points of such features that things (or chain of edges) or the chamfer length that the measurement tools in most
really start to get intelligent and reduce specifically. Again, this reduces secondary 3D design systems are awful overly
those complex work-arounds. 1 Performance has features or work-arounds and for those complicated and, in many cases, split
A good example is the addition of been a focal point for designing fabricated (in particular, across multiple commands or weird
distance from face to the extrude this release, letting welded) assemblies this will be like manna workflows. Inventor was historically no
you work with large
operation. This not only allows you to from heaven. different.
assemblies more
project a 2D curve onto a face as the efficiently both Moving onto assembly modelling, the For the 2018 release, the measurement
starting point, but to set the limits for in design and when big focus for this release is performance. tools have been consolidated into a single
that extrude (whether youre adding or creating drawings As ever, users are building more complex dialog your geometry selection will drive
p45_46_47_48_D3D_JUNE17_Autodesk_Inventor_2018.indd 45 30/05/2017 22:03

SOFTWARE REVIEW
the measurements displayed, angles are tools are often marketed as removing assemblies. 2 &3 Inventor 2017
much easier to gather and youve got dual the pain of translation. The reality is For Inventor 2018, the AnyCAD tools saw greater support
for working with
units, which is useful for those that have that there is still translation occurring, build on the work from previous releases
mesh-based data
to mix and match. but the systems have become more adept (which now include the ability to not only formats, such as this
at hiding the process from the user and load native, proprietary files such as NX native data. In
DATA EXCHANGE AND SUPPORT maintaining the link to the originating file. Siemens NX, Catia V5, SolidWorks et al, 2018 this has been
Recent release cycles have seen Autodesk AnyCAD allows you to read in native but also STEP files) and the versions have extended to allow
introduce the concept of AnyCAD which data, but not convert it per se. Rather, been updated, most notably support for the use of such part
geometry in drawing
allows users to work more effectively with where that data is loaded its linked back Catia V5-6R2017. Its also worth noting the view creation
third party data. Its important that those to the original file. So if your Siemens moves that Autodesk has made to make
who havent experienced data exchange NX data changes, you immediately get Inventor backwards compatible. If youve
tools understand the fundamentals. These an update where that data lies in your got the Inventor 2017.4 release running

4
then this can also read data from 2018. it also allowed you to do more with that parts. This release doesnt add much to 4 Inventor is building
While this will be of benefit to those mix of data types. Meshes could be this set of functionality, but rather adds up a nice set of tools
for not only working
working in sub-contract situations, within actively used within assembly, assembled, the ability to use those mesh forms in
with large native
a supply chain or in regular receipt of interference checks run and much more. downstream documentation, namely in assemblies, but
customer or partner data, the key update This was also extended to allow the drawings. also working more
for 2018 is with mesh data, which builds creation of basic geometry types of mesh As shown in Figures 2 and 3, you can effectively with
on the capabilities introduced in the 2017 data and was particularly useful for read complex data contained in mesh files imported data (this is
release. Not only could you import mesh those with resultant data from laser scan (in this instance, from mesh geometry an example from Creo)
geometry and display it alongside more processes that needed to ensure good fit held in a Siemens NX assembly) and use
traditional solid and surface geometry, between scanned articles and their own that within drawings. While the drawing
INVENTOR TO REVIT: 3D DESIGN & ENGINEERING MEETS BIM
W
hile Inventors core user base is in used by thousands in the Architecture, Engineering With Autodesks leadership in the AEC market,
the world of heavier engineering and Construction (AEC) industry. This crossover both with AutoCAD and Revit, theres huge cross
and design, it also crosses occurs where organisations are developing pollination of use of these systems with Inventor
over into the world of its sister products that eventually nd their way into the built and the transfer of data between the two has been
application suite, Revit. environment whether thats HVAC components, a focal point in recent years.
For those that arent aware, Revit is Autodesks mobility solutions (elevators, escalators and the The Inventor 2018 release sees this work
Building Information Modelling (BIM) tool and is like) or down to architectural hardware or structural continue in a number of areas and the whole
steel work. makes for a quite slick workow. As youd imagine,
The Revit world is currently undergoing a huge most suppliers arent too keen (and theres no
expansion of standardisation, driven by national real need) to provide complete CAD assemblies of
and industry specied requirements for more components. As a result, the new workow allows
rich descriptions of construction projects using you to take advantage of Inventors shrink-wrap
increasingly intelligent tools than has traditionally tools to defeature a model and remove any
been the case. unwanted details or components combining
This 3D focussed working practice, referred to as them into single geometric lump if needs be.
Building Information Modelling (BIM) has meant You then use the BIM Content Environment to
that many working as suppliers or contractors to dene MEP (Mechanical, Electrical or Plumbing)
this industry need to provide richer descriptions connectors that allow your model to connect up to
of their products that can be readily inserted into the Revit model.
Revit models. The UCS tool is then used to control the
If models can be supplied, it not only saves time positioning of that product as well as other meta-
in the process, but can also mean that specied data required (referred to as Omniclass title and
products are installed more accurately, correctly number). Theres also the potential to make use
and the whole process works more eciently. And, of Inventors built-in automation and parametric
of course, with a richer 3D description of a building control tools (iLogic) combined with its Congure
or facilities, that same information can be reused 306 cloud-based conguration system here to add
downstream. Yes, the AEC industry has nally product families that are parametrically controlled.
realised that what the mechanical engineering The nal step is to use the Export Building
and design industry has been doing for 20 years Components tool to write out the data to either IFC
makes sense. models or RFA les native to Revit.

SOFTWARE REVIEW
views arent quite as you get from surface is pretty straightforward, assuming you make me either work more efficiently or
5 Autodesk worked
or solid geometry (theres some seriously know what youre doing. work in new and exciting ways? with Sigmetrix to add
impressive mathematics going on under Interestingly, the whole process builds On both of these, Inventor represents 3D annotation into
Inventor 2018
the hood to interpret mesh edges), theyre quite intelligent models, so any design some good value for money. The toolset
more than useful for representing this changes after the MBD elements have is rich and mature, but the development
type of geometry. been added will be reflected where is still finding areas that can be improved,
possible whether thats changes to hole workflows made less time consuming,
MODEL-BASED DESIGN (MBD) sizes, dimensions or datum changes. That more intelligent or robust and new
If theres a headline addition to the 2018 information can then be shared using the efficiencies gained.
release, then it has to be Model-based Inventor parts or extracted downstream Then there is the addition of new tools
Design (MBD). Although this term varies and placed into drawing views. that havent seen the light of day before.
across vendors and industries (Siemens, One thing worth noting is that at present, The new MBD tools are going to appeal to a
for example, refers to it as Product while Inventor supports exporting of this sub-set of Inventors user community, but
Manufacturing Information), the result is type of data to STEP AP 242, it doesnt for those that work in environments where
the same. support reading of MBD-enabled design MBD processes are becoming standard,
If youre unfamiliar with the term, it files from other vendors, whether thats this will be a huge benefit and allow them
is the act of using your 3D model as the natively or using standard formats such as to provide the information their customers
container for not only the geometry of STEP or JT. You can import the geometry, desire or mandate.
your part, but also the critical annotations, but the 3D annotations wont currently The same can be said of the Inventor
dimension and tolerances youd typically show up. to Revit or IFC workflow thats seen vast
place on a 2D drawing. improvement in this release. Again, this
While were all used to fully detailing 2D IN CONCLUSION reduces what might have previously been
drawing views to capture this information, Inventor is a functionally rich application a convoluted workflow and makes it easier
the process of adding it to 3D models is and has been for some time. Whether to generate the information that those in
more complex. After all, youre looking to youre interested in traditional, prismatic this environment are required to produce.
link not only 2D drawing view entities to modelling, looking to mix in a little It wont be for everyone, but for those that
dimensions, but in this brave new world, to surfacing or maybe even some sub- do require it, itll make life much easier
3D geometry too. As such, the tools used divisional modelling use, then all of the and more efficient, allowing them to get
to accomplish this are inherently more tools are there. on with developing those products rather
complex. More recent releases have seen this than trying to wrangle the data into the
Inventors new MBD tools, developed core set enhanced with some pretty correct format.
in partnership with Sigmetrix, are found nifty tools for topology optimisation and Ultimately, judgement of the value of
under the Annotate ribbon and give you other technologies. Essentially, if youre subscription depends on your point of
a good set of tools that allow you to set-up on subscription, youve already got a lot value, but if youve invested in Inventor
datums, then work through the process of bang for your buck but, at the same so far, youre unlikely to look elsewhere.
of selecting the geometry and adding the time, youre going to want to see new Although it might have lost a little of
appropriate GD&T information. capabilities added. Whether or not you the spotlight to the newer, shinier and
Theres a good amount of intelligence actually use those tools remains to be seen altogether different Fusion 360, it is still
built into these tools, right from the off. its just natural consumer behaviour. growing in capability thats not only time
The system finds common groups and But gauging the value of a subscription proven, but its robust tools suit a wide
allows you to preselect geometry (for and the benefit you get from it comes down spectrum of the engineering community.
example, a pattern of similar holes) and to two factors. Do I need my system kept
the construction of the various elements up to date and do I want new tools that can autodesk.com

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SOFTWARE REVIEW
Granta Design CES Selector 2017

Materials selection is often guided more by intuition and prior experience than by
formalised research. Al Dean takes a look at the commercial version of a venerable
tool, built by true pioneers in the field, that could offer something for the pros
C
hances are if you studied design Product: CES available (as CES Selector) for commercial and such, but you want to explore potential
or engineering in the last two Selector 2017 purposes at all. So lets remind ourselves materials within a more select grouping.
decades, you probably took a Supplier: of what it does, how it does it and whats Whichever approach, the first step is
Granta Design
module or two (minimum) in been added to the system in the time since typically to filter down the huge range of
Price: 1,500 per
materials selection. As part of those user (based on 5 user you probably used it last. materials to a shortlist. You have a full
modules, you more than likely had a licence) range of properties for materials to choose
copy of one of Mike Ashbys materials grantadesign.com MATERIALS SELECTION IN USE from in doing this strength, stiffness,
selection books. You might even have Use of CES Selector is probably best cost, recyclability. If your requirement
used CES EduPack a software system explained in the form of a workflow, is for parts that have high notched Izod
that allowed the user to combine following the various steps you might take values, you can add this in. If your material
extensive materials databases with to arrive at a materials shortlist. Even at needs to be acceptable in your key
functional or performance indices and this point, the application for this system markets, you can include this with the
filters to explore potential materials for is wide open. latest release, that also includes a lot of
a given application. One approach is with a clean sheet, no data regarding restricted substances.
While CES EduPack is widespread in prior history case, where you have a set Then you need to define the objectives
academia across the globe, the reality of parameters within which you know that you are trying to trade-off in making
is that this type of analytic approach to your chosen material has to work and you your selection. These may also be
materials exploration is rare in the field. start with the widest field of materials straightforward properties, like mass or
Materials selection is more often lead by available to choose from. CES Selector cost. But very often they are so-called
prior knowledge, of both the individual and has a set of built libraries that give you performance indices: combinations of
the enterprise. not only generic material classes across properties that capture an objective such
In the professional field, Granta Design the spectrum of material types, but also a as minimise weight per unit of stiffness
has been working with the likes of Siemens range of more narrowed databases. If you for a beam in bending. Dont panic! CES
PLM, PTC and Autodesk in recent years want to include everything so that you can Selector has a graphical user interface that
to integrate more materials information explore potential, you can. lets you choose your engineering problem
capabilities into our workhorse CAD 1 CES Selector will
The second, and probably more common and defines the performance index for you.
be familiar to many,
systems. Weve not yet seen its materials approach, is that you have a good set of Once you have your objectives in place,
but refamiliarising
selection knowledge and tools become yourself with the operating requirements for your material, youll see the Ashby chart pop up. Those
very widespread in industry. In fact, many system will show how be they material type (metal, polymer that know this will need no introduction,
might not even realise that this tool is far it has come etc.), manufacturing process requirements but for those that dont its a method of
p50_51_D3D_JUNE17_CES_Selector_2018.indd 50 30/05/2017 22:03

plotting materials space so that you can its core these will be useful for many,
see easily how materials perform against particularly those that are experimenting
the chosen objectives. In Figure 1, the or looking to use new materials of which
big bubbles represent different material they might not have a huge knowledge.
classes (polymers, metals, foams, etc.). One such tool is the Engineering Solver.
The small bubbles are individual materials This is a digital equivalent of rough hand
within each class. Greyed out materials are calcs. You tell it which the basic use case
those that the filtering criteria excluded. is (such as cantilevered beam, a panel
We can see how the remaining materials under load or a tie in torsion), give it rough
compare, in this case, for price and Youngs dimensions and shape information, and itll
modulus. give you back a rough set of characteristics
The reality is that, while the wider you need to search against.
searches are interesting, a more practical The second is Synthesizer. This
use of such a system is to ensure that enables you to run models that predict
youre using the optimum material for (synthesize) material records. Two types
your given use case and that means that of model are provided off the shelf:
youll be starting with a pretty good idea Hybrid Synthesizer to model composite
of what type of material you need, how itll materials, enabling comparison with
be processed (this might also be controlled more traditional materials, and Part Cost
by in-house production facilities) and the Estimator, for exploring the cost impact of
performance requirements. In the case different processing options. 2
of metals, it might be that youre looking The other area is in eco auditing. This is
to ensure youve got the correct or most a growing area of concern for many and
suitable alloy for your application. CES Selector gives you a set of tools to add composites in not only aerospace, but 2 The Engineering
CES Selector, in this instance, could pay data regarding your products, material across the board, or the shift from metals Solver is the digital
equivalent of the
huge dividends. Itll allow you to feed make up, manufacturing methods, use to plastics in the medical field, theres a
back of the fag packet
in your performance and processing case and transportation then feeds lot of knowledge to be caught up on and calculation or, for the
requirements and give you a list of alloys back with a comprehensive environmental potential materials to be explored against younger users, quick
that could be suitable some of which impact audit. your products requirements. Whether calcs and a google
might not be familiar to you. its a clean sheet, lets start from scratch search
The same is true for polymer based parts. IN CONCLUSION approach, or investigation into materials
Its often the case that we rely on prior CES Selector has been around for a within a given category, whether thats
knowledge and experience (our own or that good long while and the methods that polymers or metals, theres huge potential
of a supplier) to guide materials choices. it encapsulates have become industry here.
This allows you to broaden that search standard, but is the process used much We often talk about the benefits of digital
(using the built CAMPUS Plastics database) outside of academia? Probably not as simulation and experimentation in design
which will let you find the best polymer much as it should be. and engineering, but what if we extended
from a huge database of tens of thousands. Considering todays environment, where that back up the process to the first
many companies are looking to shift principles? Imagine the benefits that could
ADDITIONAL TOOLS materials for their products, it holds huge be derived from making smarter, more
It is worth noting some of the more recent potential. informed material decisions.
additions to the system which sit alongside Look at the shift from metals to grantadesign.com
WORKFLOW: FINDING A NEW MATERIAL WITH CES SELECTOR
1 Lets run a selection process on a lens for a device 2 The first step is to add in the known parameters for 3 Once your limitations and requirements are added
operating in the Antarctic. It has to be transparent, impact the part you'll add in "limits" which are filters for the (these can be done separately or grouped), you can then
resistant, injection mouldable and able to operate at ~80C. material's known requirements. start to sort options using charts with indices.
4 Your first chart will show your chosen selection of

5 Once you have a shortlist of materials, these can be
6 Once your selection is made, the system gives you tools
materials against your performance indices. These can be collected together and examined in more detail in a single to generate a report that details the steps you took to
filtered, cropped and labelled as needed. document. arrive at your decision.
p50_51_D3D_JUNE17_CES_Selector_2018.indd 51 30/05/2017 22:03

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3D Print B Ad.indd 1 30/05/2017 15:19

HARDWARE REVIEW
Rize Inc. Rize One

With a founding team that includes luminaries from the 3D printing industry,
Rize looks to remove the pain of post processing 3D prints and bring superior
strength where it counts. Al Dean takes a look at its first machine, Rize One
W
TECH-SPECS hen it comes to using 3D This results in weaknesses in the axis of the Not only the materials themselves, but your
printing to build plastic build the Z-axis. ability to recycle them.
Rize One prototype parts, while The material is fused together at a near
Proprietary there are a multitude of melting temperature, rather than being in ENTER THE RIZE ONE
thermoplastic
filament, release
benefits, there are also issues compared liquid form as per injection moulding. This Given these challenges, its interesting to
agent and marking to using injection moulding. means that theres an inherent weakness in see a 3D printer manufacturer come to
ink One of the first is the pain of removing the part along that direction. market looking to solve all of these issues
300 x 200 x 150mm the supports from parts when they come Add to these two factors the issue that in a single machine.
build volume out of the 3D printer. While there are a these parts and materials themselves, This has been Rizes driving guidance
543 x 915 x 644mm range of machines and methods that help in most instances, have a very short life since the company was founded in late
machine dimensions deal with this issue, when it comes to single span. With a prototype part you build it, 2016 by a team comprised of folks from 3D
61 kg weight build material machines, this is generally you check it against your requirements, printing heavyweights such as Objet,
0.25mm layers still time consuming. perhaps have a design review and then you Z Corporation and Stratasys.
Filament spools, ink Given that supports are commonly usually dispose of it. Its intent is to create a process and
cartridges, build plate built using the same material feed stock This, of course, creates a lot of waste. machine that not only improves the
USB key and as the part, removal at the connection Not only in the support structures (which mechanical strength of parts in the Z
ethernet connectivity point between the support and the parts are binned immediately), but also the parts direction, but one that also looks to address
3 month warranty form can be tricky and could even impact that arent required once the next revision post processing and end-of-life treatment
(extendable)
surface quality. comes along. As a result, almost everything of the parts that are built.
Price From $26,000
The second common issue is down to is eventually scrapped. So shall we take a look at what its first
rize3d.com the build method used in filament-based While its impossible to avoid building machine, the Rize One, is capable of and
machines. The process requires that parts prototype parts, the concern for many is how the parts produced stand up to the
are built up using a layer-based approach. the environmental impact of those parts. companys aims?
p53_54_55_D3D_June_Rize3D.indd 53 31/05/2017 09:06

HARDWARE REVIEW
THE MACHINE
Although billed as an office machine, the
Rize One is a beast thatll require its own
workbench and a fair bit of space.
Weighing in at over 60kg, this isnt a
desktop FDM and is more in line with
higher-end 3D printers, such as the likes of
Stratasys Fortus machines.
In terms of build process, it features a
heated chamber of 300 x 200 x 150mm,
is network connected and gives off zero
harmful emissions during build. That,
combined with the post processing, means
that its perfectly suited for a true office
environment.
Once you have it installed, its a case of
slotting in the materials (there are three)
and setting the build platform, before
loading up your first print.
Rizes set up software is pretty standard:
it only runs on Windows but can be 2
shared around the office for print queue
management and remote pre-processing.
Theres network connectivity but, as yet,
no wireless connectivity. You can, as youd
expect, also take your parts to the machine
and load them via a USB key.
THE BUILD PROCESS

On initial inspection, the Rize machines
build process is pretty standard for a
filament machine it builds up each parts
form using an extrusion head, layer by
layer, until complete but theres more to
it than that.
Most FDM machines slice each part into a
layer. That layer is made up of movement of
the extruder to create the outer boundary,
then filled in to a specified percentage
commonly referred to as the in-fill value.
The more of this internal structure there
is, the stronger the part, with the exception
of the Z-axis, where the bond between each 3
layer isnt as strong.
The Rize process, referred to as
Augmented Polymer Deposition, differs
from the standard FDM method through its The Rise One is priced at $26,000, which The layer thickness is fixed, so if youre (Previous page)
ability to add in a layer of ink (via a print includes a three month warranty but this OK with .025 mm layers and the inherent 1 The Rize One
head) between each layer put down by the can be extended to a year for an extra two surface finish, then youre golden. benchtop and
standard extruder mechanism. grand. The colour ink is an optional $3,000. Here, theres always going to be a perfectly suited for
use in an office due
This serves two functions at present. The Out of the box, the machine is supplied trade-off tough parts or finer details. to zero emissions
first is that it can add a layer of release with a spool of material, two build plates, The tough parts the machine produces and clean support
ink where needed, between the support and a cartridge of the part release ink. certainly stand up to Rizes claim of being structure
structure and the part. Theres also an ink waste cartridge and a more akin to injection moulded parts and
This makes the supports easier to remove set of support removal tools as well. you certainly get better strength in that all (This page)
and, while its not a release agent per In terms of consumables, materials is important Z-axis. However, if youre looking 2 Rizes set up
software showing our
se, the deposited substance changes the the biggest outlay, coming in at $119 for for a smoother surface finish, this isnt the
test part during pre-
properties of the thermoplastic. In this 840 grams. The release ink consumable highest quality youll find from filament- processing
instance, weakening the bond between the is $199, and the same for the colour ink. focussed machines. Think of it more as a
3 One of our test
part and the supports. Replacement build plates should last six combination of SLS-strength nylon with the parts with the support
In addition to this release ink, Rize is months and will cost $50 to replace. resolution of the lower-end of FDM. structure intent. The
also experimenting with other applications, Its this combination of toughness and majority of these snap
including the second function, coloured IN CONCLUSION a good quality part where the machine off with little effort.
The internal supports,
ink, which is also shipping with the release The Rize One builds tough parts really excels against the list of challenges that the
however, do require
machine. tough parts. The Rizium material is a Cyclo- company was founded to solve. a little more effort to
This ability is ideal for adding graphics to olefin Polymer (COP) and analogous to a Itll be ideal for those looking to remove
a part, including useful things such as part polycarbonate. prototype more functional parts and for
serial numbers and basic decals/logos. I do love the fact that the material and additively manufactured jigs, fixtures and
While only available in blue at present, process are much cleaner than most. If the likes. But if its presentation models
the intent is to expand it to support full youre looking for a true office-based youre after, there are better and cheaper
CMYK printing in the future, as well as an machine, then this is a good option. There options out there.
intriguing use of electro conductive inks for are no noxious chemicals or heavy post Theres also the ability to build (or
internal circuitry. processing its simply down to you, a set rather print in) ink into the system. This
These extra abilities come at a cost. of hand tools and a bit of time. will be useful for those looking for more

LARGE & BULKY PART
Test part: Rockerbox Cover
Challenge: This is a chunky part with complex

features that need to be replicated on all sides.
Internal features also test support removal. This
was even more key when evaluating Rizes process.
4 Material usage :
0.083 Kg Rizium One thermoplastic
Build time:
14 hours (@ 0.25mm layers)
Cost: $23.22
Results: All of the features replicated well

although the resolution of the machine meant
that some post finishing would be needed,
particularly on vertical side wall features. The
internal supports proved a challenge to remove,
but once you realise that the key is to break up
the supports to remove them, its pretty painless.
THIN WALLS & DETAILS
4 Our rocker box test traceability in their production processes. processing is a bit misleading.
part with supports Its not at the resolution (and currently, Our rocker box test part is evidence
intact. As you can
lacks full colour options) that youll be able of this and its the reason why we use it
see, external features
are supported well to add huge details into it, but itll be useful for such tests. Rizes machine built an
and those supports for some. excellent, strong part but there was still
removed quickly The other aspect to consider is the considerable effort required to remove the Test part: Oculus Internal Components from DK1

5 The internal material and build process itself. The all important internal supports. dataset
supports proved much material is a medical grade thermoplastic Yes, its quicker than many and theres
more of a challenge and the whole process is done in a no soaking in tubs to remove supports, but Challenge: This is a matching set of components
to remove, but the that have thin walls, more complex internal
clean environment. This, along with the there is still manual effort involved.
surface finish was structures and some tricky details.
excellent, particularly combination of watertight parts, means For its first release, Rize has moved closer
compared to other that these are ideal for use in certain to tackling the key issues that blight the
Material usage :
single build material situations in the medical field (as they can single material FDM process, with its quick 0.061 Kg + 0.098 Kg Rizium One thermoplastic
machines be sterilised). release supports on the whole being slick
With respect to the companys claims of and pretty easy (geometry dependent, Build time:
there being zero post processing (which has of course). With further materials and 9 hours 8 minutes + 11.5 hours (@ 0.25mm layers)
recently been adjusted to near zero), Im functions promised, it makes it a very
going to have to disagree. For test cases interesting machine. Cost: $8.74 + $14.00 = $22.74
and parts that dont have internal support Ultimately, the Rize One builds quickly,
Results: These are particularly complex
requirements, yes, support removal is very offers tough parts in a clean environment
components, both in terms of their geometry
quick indeed. Yet the reality is that there and, if those properties match your own
(thinner wall sections, internal geometries) and
are many instances where you need a part requirements, then its a solid machine. their function (in terms of snap fits and associated
that requires internal supports and these, Yet, for the size of build envelope features). The results came out well, but the
despite Rizes claims, still require effort offered, its a costly option particularly resolution of the Rize One meant that the smaller
and planning. The technology does a good in comparison with what else is available features didnt replicate well. That said, they
job of making them easier to remove, but at the bench-top or studio level, and its performed their function which wouldnt happen
theres still a fair bit of effort required. As currently limited set of material options. with many thermoplastic based build processes.
a result, even claiming near zero post rize3d.com

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56 Ads.indd 1 30/05/2017 14:08
SERVICE OVERVIEW
Xometry.com
Online provision of manufacturing services has grown massively in recent years.
Al Dean takes a look at Xometry, which has taken the US by storm, and finds a
service thats taking a very different approach to the whole industry
T
he last few years have seen but its primary focus is to build a network gives you access to quotes directly from the 1 Xometry, which
a multitude of online part of manufacturing partners to expand out SolidWorks UI. Whichever route you take, works in the browser
provision services come on its reach and capabilities as well as to the end result is the same. but also has a
plug-in available for
stream. These are typically increase its capacity. Once your part is uploaded to the quote, SolidWorks, will find
split into two camps. The first is the So shall we explore what the service offers youre then able to start to fine tune the any errors in your part
offering of in-house manufacturing and what we can learn from the experience? process and material you want to build. that are incompatible
capabilities using digital services to To do that, were going to start with the Xometry offers a best-guess based on the with your selected
provide communication and quotation quotation process. geometry of your part and as you start build process or
material
for potential customers. to filter down your material or process
Protolabs are probably the best known GETTING A QUOTE options, the price updates accordingly.
and perhaps have the widest spread of Xometry is, as you might expect, focussed Whether you lead with a material choice
capabilities on the market. Then you have on a web-based quotation service. Once or select a process will depend on your own
the hub model which uses a single resource youve registered for the service, you can preferences. As a best guess, most folks
to provide access to a range of service start to upload your geometry files and know what they want in the first place, so
providers but all run through a single start to build up quotes. selecting the process, then the material
interface. There are numerous of those out While for 3D printing, youre most makes sense but this is by no means
there, particularly in the 3D printing and likely to want to choose STL as a means a forced decision. In fact, its ideal for
additive manufacturing services space, look of communication, its worth noting that experimentation.
to 3D Hubs as an example. because Xometry offers much more, its Once the process and material are chosen,
Then you have an organisation like often the case that youll need a non- you can then start to define any post
Xometry. The company has hit the headlines tesselated file of your part handy as well. processing options. Again, these vary from
in recent months due to its huge investment Xometry supports a range of formats material/process and include all manner of
(up to $23 million at the latest count) from including several native file formats (such as standard finishing techniques from bead
a wide range of household names (General SolidWorks, Catia, Inventor) as well as the and sand blasting to anodising or powder
Electric being perhaps the best known). usual array of standard and neutral formats coating.
Xometry combine the two models into (such as STEP, IGES, Parasolid, ACIS etc.). At this point, youll also start to notice that
a single offering. It has some in-house If youre a SolidWorks user (running 2017 the quote is building up. Perhaps the final
manufacturing resources (currently onwards), then theres also a plug-in that selection is the number of parts you want.
covering CNC and additive manufacturing) sits inside your property manager and Whats interesting here, even before you get
p57_59_60_D3D_JUNE17_Xometry.indd 57 30/05/2017 22:17

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SERVICE OVERVIEW
to ordering the parts, is that Xometrys services shows the disparity Theres a range of feedback thats available at the quotation (This page)
of economies of scale between most additive processes and CNC stage. If the system finds any issues with the parts (according to 2 The Xometry add-
processes. the process youve selected), itll flag them up. If you need more in for SolidWorks gives
One of our test parts is a Ducati brake lever that we had additively complex features (particularly when dealing with CNC components) you live feedback for
production costs for
manufactured. While the one-off cost was around the $600 mark, such as threading etc. or there are more exacting requirements in the part on screen
adding multiples to this only saw the price drop by around 50%. terms of tolerances or surface finish, its also possible to upload
Conversely, another of our test parts (a smaller hex nut shaped technical drawings alongside your geometry files. (Page 60)
ring component with some tricky internal cavities) was CNC You pay for your parts and the next thing that happens (from 3 Two of our test
machined from aluminium. While the one-off cost was around the the customers perspective) is the parts arrive through your door parts from Xometry.
$120 mark, subsequent multiples saw that price drop dramatically. within the allotted delivery schedule. The rocker box cover
in SLS nylon and the
Why the difference? The reality is that once the hard bit (the
Ducati brake lever in
programming and machine set-up) is done, its pretty simple to A.I. & THE RFQ DMLS aluminium
repeat the process. Whats perhaps most intriguing about Xometrys offering is not
WORKFLOW: INSTANT PART QUOTES FROM INSIDE SOLIDWORKS
1 Open your part in SolidWorks and ensure you have the 2 The first step is to upload the part to Xometrys server,
3 Start to experiment with your selection of process and
Xometry add-in loaded and log-in to your account. and the analysis will begin to check for manufacturability. materials filters youll see the price update as you do.
4 The plug-in will flag up any potential issues according to

5 Next step is to define any finishing requirements (bead 6 Submit the order to Xometry itll handle production of

the process chosen allowing you to make edits and update. blasting, coatings, treatments etc.) and finalise the quote. the parts and ship them out to you.

SERVICE OVERVIEW
the breadth of services they offer (which are would imagine thats on its to-do-list. work. They do the programming work, machining
pretty rich and deep) but rather the part thats For those looking to procure parts, the end result or sintering (or whatever), finish the parts, package
hidden almost entirely from the customer. While is that you are immediately presented with a range them up and send them back to you. You get your
Xometry has capabilities in-house, its primary role of options than span a diverse range of capabilities parts, they get paid 15 days later.
is to work with a wide range of partners that have and processes. For the customer, that means a transparent and
spare capacity on their own machine tools and At present, Xometry offers a variety of additive efficient quoting and ordering process. No sending
capabilities. processes (including FDM, SLS, DMLS, SLA/PolyJet), out RFQs and waiting a week for a response. Submit
When you place your order, the algorithms look CNC machining, casting and sheet metal. The the order, pay for it, parts ship. Done.
at the part and works out a price for you based materials available vary depending on the process For the machine shop on the other end, they dont
on previous history. What then happens, in the you select, but again, cover the most common youd have to waste time filling out RFQs, quoting for jobs.
background, is that work is offered up to a suitable expect. They bid on the work, get the work, do the work,
partner within the network. The partners then Ultimately, your selection of whether to get paid. The business is nationwide so these
accept or reject it, if its the former, the work use Xometrys services depends on price smaller manufacturers are gaining work outside of
is done and sent to you (sometimes directly, and competitiveness as well as, I suspect, their own localised area and outside their particular
sometimes via Xometrys logistics hub). convenience. If the price is good, the process is specialisation. Of course, Xometry gets its cut of the
Heres where things get interesting. Xometrys simple, ready to go and fully traceable. It comes action, but thats how it makes its revenue.
platform is constantly learning about how to quote down to competitiveness of the price and the ease Theres also a lot of talk around at the moment
for work more accurately. It might adjust it upwards of the whole process. about how machine intelligence and automation
or downwards, with the goal being to offer the most But alongside the pure commercial, service is going to remove manufacturing jobs. Personally
competitive price for your job. provision aspects, Xometry also represents speaking, Im dubious.
What that means is fascinating. In the instance something else thats truly fascinating. Manufacturing isnt something that can be
that the algorithm gets it wrong and quotes too low Theres a lot of talk about machine learning in the replaced with robots quite as easily as the media
meaning none of the partners accept it, itll accept manufacturing space, but other than the odd bit of thinks. Itll always require human intervention.
the work, pay a premium to the partner (effectively topology optimisation and some talk about artificial But perhaps those doing the hard work of
making a loss) and you still get your parts. But intelligence driving 3D printing, theres very little manufacturing parts can take advantage of
next time around, the system has learned from its in terms of actual solid examples as yet. When you machine intelligence and learning, keep their
miscalculation and adjusts the quotation process distill what it is that Xometry does, it becomes machines humming, filling up spare capacity,
accordingly. fascinating from a technology point of view. Why? remove downtime and some of the drudgery of
Its using its own algorithms to quote for work, paper work.
IN CONCLUSION based on geometry and part requirements. Whats Xometrys success will ultimately rely on its
Xometry has come from nowhere in the last couple interesting is that this is being done with a serious ability to compete in an increasingly competitive
of years to doing some serious business in the amount of human effort on the back end of it. manufacturing landscape, but its pushing the
manufacturing sector. At present, it is focussed on Once you hit that order for a CNCed part, the job boundaries of what tech can do as well as keeping
the North American region and while the company is sent to a job shop that has spare capacity and manufacturers in business.
has no immediate plans to branch out further, I experience with that type of job based on previous xometry.com

REVERSE ENGINEERING MADE SIMPLE
IN YOUR OWN CAD ENVIRONMENT
SOLIDWORKS
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Technical-Sales-2015-Half-Page-Develop3D_v2.pdf 1 13/03/2015 15:34:31
61 Ads.indd 1 30/05/2017 14:09

HARDWARE REVIEW
HP Z2 Mini workstation
HPs impressive micro machine is great for bread and butter 3D CAD but, with rigid
specs, buyers need to be confident that workflows wont change, writes Greg Corke
S
Intel Xeon E3-1245 mall Form Factor (SFF) 802.11ac module you can connect to WiFi up to 32GB of DDR4 RAM across two
v5 (3.5GHz, 3.9GHz workstations like the HP wherever you go. SODIMMs, which should be plenty for most
Turbo ) (4 Cores) CPU
Z240 SFF are becoming much The third is, admittedly, subjective, CAD workflows.
16GB (2 x 8GB)
more prevalent in design and but we think it looks rather cool. HP has Despite the thermal challenges of
DDR4-2133 non-ECC
SDRAM memory engineering offices. What were once obviously paid a lot of attention to the producing such a small machine, the Z2
512GB HP Z Turbo considered entry-level workstations, styling of its mini workstation, but the Mini offers pretty much the same level of
Drive G2 (NVMe SSD) with compact chassis of around 100 x corner detail is actually derived from CPU performance as one can find in a SFF
Nvidia Quadro 350 x 400mm, are now powerful enough functional requirements. The custom workstation. Our test machines top-end
M620 GPU (2GB) to satisfy the requirements of most 2D cooling system, which features dedicated Intel Xeon E3-1245 v6 (3.7GHz up to 4.1GHz)
Microsoft Windows and 3D CAD users. fans for both GPU and CPU, draws in air is only a shade slower than the Intel Xeon
10 Pro 64-Bit HP has now gone one step further with an from the front two corners and out at the E3-1270 v6 (3.8GHz up to 4.2GHz), the
216mm (w) x 216mm even smaller workstation called the Z2 Mini. rear two corners. As the vents shouldnt fastest model available in the HP Z240 SFF.
(d) x 58 mm (h) Similar in stature to the Apple Mac Mini, become obstructed for obvious reasons, In use, such subtleties will likely go
3-year (3-3-3) HPs beautifully styled machine is small they are protected by the chamfered unnoticed. Indeed, in our multi-threaded
limited warranty
enough to be held in one hand. A mere 58 x edges of the main chassis. A lot of science KeyShot rendering benchmark, the HP Z2
and service offering
includes 3 years of 216 x 216mm in size, it can happily sit on a went into this. HPs workstation team told Mini was only 9% slower than the Armari
parts, labour and desk, but can also be mounted on the back DEVELOP3D that, in designing the HP Z2 Magnetar V25 we tested back in February
on-site repair of a display or under a desk. Mini, it did more simulation and analysis (tinyurl.com/armariV25), which had an
There are many advantages to this new cooling work than on any other product. overclocked 4.7GHz Intel Core i7 7700K CPU.
1,219 + VAT mini form factor. First, and most obvious, Computational Fluid Dynamics (CFD) While the CPU is on par with most CAD-
hp.com/go/z2mini is it takes up less desk space, which can be was even used to optimise the individual focused desktop machines, the same cant
CPU benchmarks
a big benefit in a world of rising property spacing of the cooling fins. be said of the GPU. The Quadro M620 is
(secs - smaller is better) prices. HP reckons there has been a 60% This attention to detail results in very much an entry-level 3D GPU. But
Rendering space reduction per person in the US a remarkably quiet design, which is this doesnt mean its not suitable for 3D
(KeyShot 6.1) - 733 secs over last 10 years. One could argue that impressive for a machine of this size. When CAD. Indeed, while our benchmark scores
Graphics benchmarks you simply get around this by putting idle, the workstation is virtually silent and show it to be significantly slower than the
(bigger is better) your workstation tower under your desk. noise levels are still perfectly acceptable fastest GPUs you can expect to find in a SFF
CAD (SolidWorks 2015 However, when kept down by your feet when the CPU is being pushed to its limits. workstation the Nvidia Quadro P1000 or
- SPECapc graphics they become serious dust magnets and One minor criticism would be that fan AMD Radeon Pro WX 4100, for example
composite FSAA) need to be cleaned regularly to keep fan speeds are not always consistent. When in practice we found it to be a very capable
FHD - 5.30 / 4K - 1.65
noise in check (clogged fans need to work rendering a scene in KeyShot, for example, 3D graphics card. However, it is important
CAD (Creo 3.0 - SPECapc
graphics composite) harder to achieve the same cooling). we found the fans cycled from low to high to acknowledge its limitations.
FHD - 4.78 / 4K - 2.87 Floor standing machines can also create every 30 seconds, or so. The noise would The bulk of our tests were done at FHD
a micro climate under your desk. This can actually be less noticeable if the fans (1,920 x 1,080) resolution. In shaded with
be great in winter to warm frosty toes, but remained on high for the duration of the edges mode in SolidWorks 2015 we had a
not so much in summer. Even when your render. Hopefully this might be remedied perfectly good experience with all our test
office is air conditioned, the environment in a later BIOS update. models, recording frame rates in excess
can become unbalanced. We have heard of 20 FPS. The Z2 Mini even kept pace
anecdotes of people wearing jumpers on THE POWER INSIDE when RealView was enabled on the PC
top and shorts down below. The Z2 Mini features a combination of computer model taken from the SPECapc
The second benefit is portability. The HP desktop and mobile technologies. It has for SolidWorks 2015 benchmark. However,
Z2 Mini is so small and light (it starts at a desktop CPU Intel Xeon E3-1200 v6 or the machine did become sluggish when we
2.04kg) that you can easily pop it in your Intel Core i3 / i5 / i7 but a custom entry- switched on Ambient Occlusion, something
bag to take home or to a meeting. And level mobile GPU, the Nvidia Quadro that wouldnt happen with a more powerful
with an optional built-in Intel 8265 WLAN M620 (2GB). The machine can support GPU like the Radeon Pro WX 4100.
1 HP Z2 Mini with
1 2 33 HP Z240 SFF for

comparison
2 The HP Z2 Mini can
be housed in a metal
sleeve and mounted
behind a display, on a
wall or under a desk
3 By rotating the
metal sleeve by 90
degrees, firms can
block off USB ports for
security
p62_63_D3D_JUNE17_HPZ2.indd 62 30/05/2017 22:05

We had a generally good experience
in Autodesk Revit, but this came as
no surprise as this BIM application
Workstations and plenty fast enough for
standard CAD workflows. Boot up time
was impressive a mere 17 seconds.

It delivers
encloses the HP Z2 Mini in a metal sleeve
that can be mounted behind a display, on
a wall or under a desk. The sleeve also
is very CPU limited, meaning that the The drive itself sits directly under the pretty doubles as a security device, featuring a
performance bottleneck usually comes GPU blower, directly on the motherboard. Kensington lock slot and pad lock loop, plus
from the CPU, rather than the GPU. Should it fail, youll need to remove the
much a means of restricting access to the USB
The HP Z2 Mini started to show its entire GPU fan assembly, which should everything ports. Simply rotate the security sleeve by
limitations in the game engine viz only be done by experienced users. one needs 90 degrees and all the ports get physically
application LumenRT, which places a big The only components that are easily blocked off.
emphasis on visual quality. Here, frame serviceable are the 2.5-inch drive, which for bread With the ease at which the Z2 Mini can be
rates dropped to as little as 5 FPS which sits on top of the GPU blower, and the and butter attached to a desktop display, one wonders
really impacted the experience. memory, which can be found under the what the future holds for HPs All-In-One
At 4K resolution, with four times as CPU fan that flips up on a hinge. Opening
3D CAD workstation, the HP Z1.
many pixels to render, the HP Z2 Mini up the machine is easy. Simply pull on the work and
started to slow down. While it kept pace in cover latch at the rear and the lid pops does so in a CONCLUSION
Revit and SolidWorks (shaded with edges off. The 200W power supply is external, Having spent several weeks testing
mode), in the game engines LumenRT borrowed from a HP ZBook mobile beautifully the HP Z2 Mini, we have to say we are
and Autodesk LIVE (based on Stingray) it workstation, we believe. styled very impressed. It delivers pretty much
became largely unusable as frame rates Despite its compact size, the Z2 Mini is everything one needs for bread and butter
dropped to as little as 2 FPS making it well equipped with ports. There are 2 USB
micro 3D CAD work and does so in a beautifully
almost impossible to move your model 3.0 and 2 USB 3.1 Gen 1 Type-C at the rear chassis styled micro chassis. With temperatures
into the right position. For such graphics-
intensive workflows you really need a
higher-end GPU like the Quadro P4000,
and 2 USB 3.0 (1 charging) on the side. The
always on port has the obvious benefit
of being able to charge phones and other
hitting 26 C in London over the past few
days, weve also noticed a big difference in
comfort when using the 200W Z2 Mini on
which is only available in a desktop tower devices when the machine is off, but also the desk and a 400W tower on the floor.
like the HP Z240 Tower. has an added benefit. Once enabled in Of course, there are tradeoffs in having
When designing a machine of this size, the BIOS, you can plug in a USB such a small machine, mostly centring on
the temptation would be to go all in 3D performance. While the Z2 Mini should
for Solid State Drives (SDDs). be able to handle most mainstream
However, HP has CAD workflows, it will struggle
allowed room for in more demanding 3D
both 2.5-inch HDD/ workflows, such as
SSD and an NVMe, game engine
M.2 form factor design viz,
SSD (HP Z Turbo particularly at
Drive G2). This is a 4K resolution.
nice design choice You can also
as it gives users forget about
access to up to 1.5 TB VR, which is
of total storage (when an important
configured with a 512GB consideration
HP Z Turbo Drive G2 and if you intend to
1TB HDD). It also helps keep this machine
bring down the price of for 3-4 years, as is
entry-level models, configured typical for most of our
only with a 2.5-inch drive, readers. With a standard
though we would never recommend tower you can always upgrade
buying a workstation without an SSD. the GPU, so if your workflows change then
Our test machine came with a single keyboard, then simply press any key to you can adapt. This is simply not possible
512GB HP Z Turbo Drive G2. This PCIe switch on the machine when it is powered with the Z2 Mini.
NVMe SSD is actually a Samsung down. This is particularly useful when the In summary, if you want a small, stylish
SM951, but HP also repackages SSDs machine is out of sight. Indeed, while the workstation with exceptional portability,
from other manufacturers that offer Z2 Mini will look great on any desk, HP has then the Z2 Mini ticks all the boxes. Its
similar performance and durability gone to great lengths to help it be hidden perfect for entry-level to mainstream
characteristics. The HP Z Turbo Drive G2 is away. To this end, HP has developed an 3D CAD work now, but it could leave you
exactly the same SSD you get in most HP Z ingenious VESA Mount solution, which short in the future.
4 GPU heatsink
11 (underneath)

5 2.5-inch drive

6 HP Z Turbo Drive G2
4 10 (underneath)
5

7 GPU blower

8 CPU blower
8 9

9 Memory modules
6 (underneath)
7
10 CPU heatsink

11 HP Z2 Mini with
24 display for scale
p62_63_D3D_JUNE17_HPZ2.indd 63 30/05/2017 22:05

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PROFILE
WHERE
I WORK
KEVIN JENKINS
PROGRAMME LEADER
PRODUCT DESIGN AND
INNOVATION AT
PLYMOUTH COLLEGE
OF ART
F
ollowing a BA in Glass and
1 2
Ceramics from Stourbridge
College of Art and an MA
in Furniture Design from
Buckinghamshire Chiltern
University College, Kevin
Jenkins 20 year career as an interior and
product designer has spanned creating
ergonomic designs for office furniture
through to shop fits for brands such as
Harrods, Virgin Atlantic and RBS.
He set up his own product design
consultancy Box and Pad Ltd in 2009, 3 4
working for clients in furniture as
well as other product types, managing
design development projects for clients
including BT, the National Trust and
Hagen Dazs. In November 2016 he
joined Plymouth College of Art to set up
and run its BA (Hons) in Product Design
and Innovation.
boxandpad.com | plymouthart.ac.uk
What are your weapons of choice?

I would have to say Keyshot has made the 5 6
biggest difference to my design process.
What technology/product couldnt you

live without in your workspace?
I have been using a 3Dconnexion
SpaceMouse for some time, I couldnt
calculate how much time it saves , and
gives your left hand something to do.
What is missing from your toolset?

There will always be new tools and
equipment on the wishlist.

1 Kevin couldnt live
4 Setting up the new
Is there anything that would make your without his 3Dconnexion Anycubic deltaprinter in
design process run smoother? SpaceMouse the FabLab
2 A perspex candelabra
5 Ultimaker2+ portable
Im waiting for the day when we have
he designed 3D printers
drafting tables again only this time
as interactive screens operated with
3 Laser cutter in
6 But its not all about
Plymouth College of Arts the machines when it
gestures. FabLab comes to making
p65_D3D_JUNE17_where I work.indd 65 30/05/2017 22:06

THE LAST WORD
A couple of announcements this month

led Al Dean to think about how our digital
product design and simulation tools
focus on the visual but so far miss the
other key senses. Is a new era that
includes sound and touch coming?
I
n early May a press release came
through from Optis regarding a
project that it had undertaken
in conjunction with Airbus. If
youve not come across Optis
before, its a French outfit that has built
a reputation for providing high-end
visualisation technology, typically
used in the automotive and aerospace
industries. The project (which has
since become commercial) focussed on
combining the benefits of todays lower
cost, more immersive VR head mounted
displays (HMDs) with both haptic
feedback and audio simulation.
The end result is a system that not only
allows you to immerse yourself in the
visual representation of a virtual model
and environment but, with smart use of
haptic feedback and audio simulation,
allows you to walk around a product too.
This means you can gain feedback as your
digital fingers touch a hard surface as well
as experiencing the sound emitted from
that product. And the latter is not just an
accompanying sound file, but a truly 3D 1
simulated representation of the acoustic
quality of the product and its surroundings.
Considering Optis core market, this combination of how it feels in your hand this type of work that Optis and Airbus are
1 Optis HIM system
makes huge sense. As well as the exterior and how it operates. If theres a mechanical doing. Our digital design systems now allow featuring motion
looks of a car, the later stages of the sales action involved, it will be how that us to not only develop the geometry of the tracked visuals and
haptic feedback
cycle often focuses on the experience the mechanism feels when operated. part, but represent it near photorealistically enabled by ARTs
customer has of the cars performance Give me a rocker switch and Ill on screen. With the advent of affordable finger tracking
when sat in the drivers seat. happily sit there flicking it back and VR, were able to walk around and look system
Now, think about that experience, forth (probably till you take it away at that product in the same, visually rich
particularly during those first few from me), because the feel and sound manner. But can we yet truly experience it
moments. Its how it looks, how it is lit, reminds me of a Vauxhall Viva. Same immersively, with a sense of sound or touch?
the materials chosen etc. Then as is true of many things. That switch Not at present, but were quickly
you start to explore further, on a kettle or the different feel advancing to the point where this might
you become aware of of a lightswitch when become a reality. Itll start off at the
the interaction with the travelling overseas. high-end and become something that
console surrounding you. Granted, in these days only the largest companies with the most
Thats part visual, but of omnipresent touch at stake will adopt first. Then itll filter
also heavily influenced by screens, mechanical down, probably driven by adoption in the
how controls feel and how switches are becoming gaming industry (Call of Duty Smell-o-vision
they sound. few and far between but Edition anyone?) and well all have a richer
Weve all heard the stories I bet you feel the same (at experience.
of when Toyota set up its least, Im hoping so, otherwise Wont that be a fancy thing, eh?
Lexus division it studied how Im going to look a right ol plonker
the doors of a luxury car sounded when this comes out). The iPhone 6 still
with a view of replicating that sound of has a mechanical mute switch how long
quality. will that be around I wonder? GET IN TOUCH: Email me on al@x3dmedia.com or say hello on
And its not just cars. Think of a product So considering we use a combination of the twitter @alistardean Als now off to Maplin to stand in the
you love. Chances are that its not our senses when interacting with products, components aisle and flick switches till the security come and
simply just about how it looks. Itll be a its curious that we havent seen more of forcibly remove him.
p66_D3D_JUN17_LastWord.indd 66 30/05/2017 22:06

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JUNE 2017 ISSUE NO. 89

66 THE LAST WORD

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