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

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

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

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

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

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

From Left to Right: Jennifer Dennington, Juliana Martinelli, and Cheyena Davis

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

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

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

Cement Lab at the University of Brasília

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

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

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

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

Jennifer Dennington

Blog Post Author

re:3D Delivers First Gigalab to Engine-4 to Recycle Island Waste into Functional Goods

In a joint effort to transform plastic waste into valuable commodities, re:3D Inc is honored to announce that equipment for the first Gigalab has been delivered to Bayamon, Puerto Rico. Supported by funding from the Puerto Rico Science, Technology and Research Trust, this retrofitted shipping container manufacturing lab contains hardware to process plastic waste to be transformed into functional goods using a Gigabot X2 3D printer. The Gigalab also serves as a mobile workspace currently connected to the Engine-4 Foundation via shore power to support community-driven innovation. 

“The Engine 4 Foundation and its innovation lab, in collaboration with the company re:3D, envision the use of Gigalab as a platform to foster community-driven innovation. By utilizing 3D printing technology with recycled materials, they envision exploring potential projects centered around agrotechnology as a part of future research and development endeavors. This collaboration is poised not only to advance technological solutions in agriculture but also to promote sustainable practices that are crucial in the face of climate change. Through the amalgamation of community involvement, cutting-edge technology, and an emphasis on sustainability, they aspire to create a positive impact on the environment, establishing a precedent for future eco-conscious technological endeavors".
Luis Torres | Engine 4 Founder

The Gigalab is climate controlled & insulated. The re:3D team is also working with leaders in safety to ensure the layout and operations are optimized for the operator in mind. Final construction is underway to begin a formal demonstration through June 2024 during which re:3D Designer Michael C. Pujols Vázquez will test waste on the island for printability using designs made in collaboration with Puerto Rican communities.

“re:3D's Gigalab is a significant step towards innovative community solutions by repurposing plastic waste through 3D printing technology, crucial in Puerto Rico where waste management is a challenge. This initiative fosters sustainability and innovation, addressing local issues and setting a model for other regions with similar challenges. As a proud member of the design team at re:3D, the Gigalab allows me to turn creative visions into tangible solutions, positively impacting the community. The collaborative environment at The Engine 4 Foundation amplifies this mission, aiding the development of community-centric, technologically advanced, and environmentally responsible solutions. This setup is a gateway for exploring projects aimed at enhancing local sustainability. By merging creativity with action, I am well-placed to inspire change, lead impactful projects, and drive innovation aligned with community needs and environmental sustainability".
Michael C. Pujols Vázquez

Final steps include coating the Gigalab with a special paint to reflect heat, installing lettering to the container and optimizing the workspace for efficiency. In anticipation of the formal launch, Michael has been designing and 3D printing goods using a recycled PET pellet. re:3D is also receiving suggestions/introductions to manufacturers in Puerto Rico seeking a more sustainable option to reuse their waste locally, as well suggestions for objects that should be 3D printed from ground up plastic flake. Suggestions can be emailed to info@re3d.org.

re:3D looks forward to receiving your feedback as we #DreamBigPrintHuge in Puerto Rico!

Examples of prototype designs produced by Mike in Puerto Rico using rPETG pellets on Gigabot X2

About The Engine-4 Foundation:

Engine-4 Foundation is a non-profit based in Bayamón, Puerto Rico, dedicated to advancing innovative technologies like their 5G NB IoT Lab initiative, and promoting sustainability. They provide STEAM education to spark youth interest in science, engineering, and agro-technology, preparing them for a tech-driven future. They also engage in research and development in STEAM and agro-technology projects to enhance resilience and sustainability. By supporting Engine-4 Foundation, backers help foster cutting-edge technology, dynamic education, and a more sustainable future, allowing the foundation to continue making a positive impact.

About The Puerto Rico Science, Technology and Research Trust:

The Puerto Rico Science, Technology & Research Trust was established in 2004 to stimulate innovation, technology commercialization and the creation of high-technology jobs in Puerto Rico’s targeted industry sectors such as: Life Sciences, Alternative Energy, Environmental & Agricultural Sciences, Computer Science & Information Technologies, Medical Devices, and Aerospace & Aeronautics, among others.

2023 Gigaprize

Brookwood in Georgetown

And that is a wrap folks! Gigaprize 2023 is in the books, but our winner, Brookwood in Georgetown, is just getting started on their 3D printing journey! Brookwood in Georgetown is excited to use their Gigabot 4 to aid in producing ceramic molds and training for their vocational community that provides meaning work for adults with functional disabilities. Their final products the find their way onto the shelves at their award winning giftshop in Georgetown, TX.

GIGAPRIZE FINALISTS

We had many amazing applicants this year and it was an incredibly tight judging process, with our final 5 contestants (I Want That LegRe-InventaSew-PrintedCentro de Aprendizaje Educarte and Brookwood in Georgetown) being separated by less than a point. A huge thank you goes out to our wonderful judges – Khaalid McMillan, Sabine Berendse, Kameco de los Santos, Sonakshi Senthil, Josh Pridmore, Scott Austin Key, Jason Kessler, Sakshi Shah, Dr. Andrea Santos, Ama Fofie, Erik Hausmann, Lillian Ferrell & Lindsay Shwartz for bringing their expertise and industry experience to our judging process.

AMERICA MAKES

As a bonus, our Partner Organization AmericaMakes, will provide America Makes Education and Workforce development portfolio assets and training to the selected organization, meaning Brookwood in Georgetown will be onboarded into the AMNation! To learn more about America Makes, please visit their website at www.americamakes.us!

A MESSAGE FROM BIG, 2023 GIGAPRIZE WINNER:

BiG has a vision of an inclusive, empowering world for adults with special needs. This marks a paradigm shift in the way that society typically views these individuals. We provide training and support for our Citizens to succeed in modified job tasks, allowing them to experience the dignity and satisfaction of accomplishing real work. Winning the Gigabot will allow us to dream and create in new and innovative ways for our Citizens to succeed. From making molds for our clay enterprise to creating adaptive tools for our Citizens to participate in our pie making kitchen—the sky is the limit! We are beyond grateful!
Debbie Guinn from BiG

I am so thankful to have been a part of this journey, and cannot wait to see what amazing things Brookwood in Georgetown will do with our Gigabot! I hope that the runner up will continue to follow re:3D and apply for our next Gigaprize!

Ryan Murray

Blog Post Author

Engineering Updates June 2023

a 3d model of a touchscreen case seen from the inside.

Hello, Giga Friends! Happy summer from Texas! It’s been an amazing few months since we released Gigabot 4, Terabot 4 and GigabotX 2 at the start of the year. We’ve reconnected with many long-time Gigabot owners seeking upgrades, taking advantage of our free parts for older machines (don’t know about those? Get on our mailing list!) or purchasing new printers to add to their Gigabot family. We’ve also met many new owners doing fascinating projects with 3D printing as we continue to roll out our most advanced Gigabots, yet. 

The re:3D team has grown quite a bit, and on the engineering side, new teammates have taken on the task of putting fresh eyes on our parts and firmware to continue to iterate and improve our newest version, especially taking into account the feedback you have shared with us as beta testers and new owners. As such, we’re excited to share some updates with you on the progress of a few projects. As an open source company, we’re happy to report where we are in development of new tools and features for your 3D printers, stress testing and implementing them on Gigabot as they mature.

Touchscreen Case – Project Leads: Sami Hill and Alejandro Leal

With the release of the new versions of the 3D printers came the exciting addition of the full color, front mounted touchscreen, and it’s been a huge improvement for user interface over the previous VIKI controller. This is a work in progress update, and this case will be released as soon as it is fully tested. We’ve identified three main areas in which we’re iterating for an even better user experience:

  • Case Durability and Rigidity
  • Cable Connection to the Touchscreen
  • USB Drive Connection Point

Case Durability and Rigidity
We want this case to protect your touchscreen from bumps and falls as well as stay rigid when the touchscreen pivots on the mounting arm. As such we’ve thickened the case and bezel, putting more protective material around the sensitive electronic parts.

two touchscreen cases side by side. the white case is longer and wider than the black case
A size comparison of the current case(right) with the work-in-progress case (left).

Cable Connection to the Touchscreen
Inside the thickened case, there is new cable routing to make sure cable bends don’t exceed their minimum bend radius, and we have added a cable sleeve at the entry point to minimize abrasion on the cables as the case moves.

a 3d model of a touchscreen case seen from the inside.
Cable routing view from inside the touchscreen case.

USB Drive Connection Point
One of your common pieces of feedback is that the USB drive slot on the touchscreen is sometimes misaligned with the case. We’ve added internal bracing to that slot so the cable stays put and cleanly receives USB drives to load files onto the 3D printer.

Simplify3D v5 – Project Lead: Jordan Smith

The release of Simplify3D v5, our preferred slicing software, came with some great new features we’ve been testing on Gigabot. We’ve been most especially excited by the new infill and support patterns allowing quicker, cleaner support removal and morphing infill for stronger internal structures and better top layer finishes. Simplify3D v5 also added support for Klipper commands, which we’re excited to explore. Alongside the new software release we now have fully tested Simplify3D v5 FFF profiles available for your Gigabot 4 3D printers.

Klipper Software – Project Lead: Mitchell Mashburn

We have been diligently progressing on a new software update, v0.4.0 for Klipper stack, expected to be released soon. This update, based on your feedback, aims to offer a more optimized and up-to-date software experience for Gigabot owners. As part of this update, we have upgraded various components, including the Klipper firmware, Moonraker API, and Mainsail front-end interface. Detailed changelogs for each component are available via the links below.
While we conduct further testing before the release, we invite Gigabot owners running Klipper to participate in our alpha/beta testing program and gain early access to software to help us identify issues (apply here: https://forms.gle/2xe5Na3SHxK7Vqjx7).
Version 0.4.0 Upgrades Include:
Klipper (firmware): 0.10.0 -> 0.11.0 — See full changelog here: https://www.klipper3d.org/Releases.html
  • Improved error handling for the max31856 temperature sensor
  • New modules added, notably exclude_object which allows skipping an object on a multi-part print
  • Various bug fixes
Moonraker (API): 0.7.1 -> 0.8.0 — See full changelog here: https://moonraker.readthedocs.io/en/latest/changelog/
  • Data structure change
  • Improved update manager
  • Improved metadata parsing for Simplify3D V5.
  • Various bug fixes
Mainsail (front-end interface): 2.3.0-Beta -> 2.5.1 — See full changelog here: https://github.com/mainsail-crew/mainsail/releases
  • Option to change date & time format in settings
  • Add jobs to queue in batches
  • Send PAUSE at a specific layer change
  • Various bug fixes
Additional Changes & Features:
  • Webcam/timelapse integration
  • Simplify3D v5 thumbnails
  • Support for SD card looping to run continuous prints/gcode – M808 command
  • Removed screensaver on touchscreen
  • New and improved scripts to automate software upgrades and maintenance.
  • System dependencies upgrade
  • Image compression upgrade. (now not limited to balena etcher 1.5.15)
  • Update and version control improvements
  • Path changes.
  • Various bug fixes
  • Minor UI changes – macro placement, panels, etc
  • Updated README
We are committed to continuously improving Klipper and have several exciting features on our watch list, including automatic bed leveling, remote monitoring, control, and support, among others.
Have any questions or comments about these updates? We encourage you to add comments on our forum, or shoot us an email at info@re3d.org. Thanks, and happy printing!

Charlotte craff

Blog Post Author

re:3D® kicks off their 2023 Gigaprize Campaign, giving away an industrial 3D Printer to someone committed to uplifting their community.

FOR IMMEDIATE RELEASE

HOUSTON, June 1, 2023 — re:3D, Inc. is pleased to announce the kickoff of their 2023 Gigaprize campaign. For every 100 printers sold, re:3D donates a Gigabot 4* large-format, industrial 3D printer to an individual or organization committed to doing good in their community and/or society. Past Gigaprize winners include, among others, Magic Wheelchair out of Portland, OR, who provides 3D printed Halloween costumes for kids in wheelchairs, and Tunapanda Institute, incorporating region-specific 3D printing educational curriculum and opportunities to serve community needs in Kenya. The application for Gigaprize is live as of June 1st, 2023 via the re:3D website (www.re3d.org/gigaprize). Submissions will be accepted until June 30th, 2023 at 11:59PM CDT. Applicants will need to produce and upload a short 3-minute video explaining how a Gigabot 4* would help in furthering their mission and fill out a short questionnaire. Judging will take place during the first two weeks of July, and the winner will be announced mid-July. To remain impartial, re:3D will bring in external judges with a wide range of experience and expertise. All contestant videos will be uploaded to the official re:3D Youtube channel and a small percentage of the final score will be based on the number of “likes” each video receives. 

*Gigabot 4 or equivalent store credit towards another 3D printer.

ABOUT re:3D

re:3D® Inc. consists of a group of explorers committed to decimating the cost & scale barriers to industrial 3D printing. Having pioneered the world’s first and most affordable, human-scale industrial 3D printer, re:3D likewise is creating large scale, affordable 3D printers printing from pellets, regrind, and flake plastic waste. Beyond creating 3D printers for customers in over 50 countries, re:3D offers 3D printing contract services, consulting, design and education services. For more information on re:3D, visit www.re3d.org

 

Contact:

Ryan Murray

gigaprize@re3d.org

+1 (512)730-0033

Ryan Murray

Blog Post Author

The Catalyst: kitty crisis sparks innovation for Gigabot owner

Hey cat lovers! Do you have a feline furbaby? What about two? Maybe three? How about four?

Meet Julie Causse and her husband Guillaume Lecomte, the proud cat parents to Lucky, Isis, Naya, and Enja:

Four cats sit on a couch, two are black and two are brown stripped.
Four cats sit on a couch, two are black and two are brown stripped.

You might be thinking, “Wow, that is a LOT of cats! They must go through so much food and kitty litter… I would not want to clean up that litter box!” Julie and her husband will tell you, “Yes, we agree!” That’s where re:3D came in…

In 2016, Julie began looking for an automated litter box to purchase, specifically one that would clean the litter by collecting all excrement into a separate container that could be emptied in batches, instead of scooped out by hand every day. Julie couldn’t find one, so she decided to make it herself.

Through her research, Julie realized that 3D printing might be a good solution and came to the conclusion that she needed a large-format 3D printer, rather than a desktop-sized machine, to make her automated litter box. She and her husband found re:3D online and purchased our unassembled Gigabot 3D printer kit, which ships in separate, smaller flat-pack boxes. The Ikea of Gigabots, if you will. Because Julie and Guillaume live in France, the Gigabot 3D printer kit was not only more affordable for them, but easier to receive overseas than a fully assembled Gigabot. Once received, they built their Gigabot in their one-bedroom apartment, which is also home to four cats and two adults, but they make it work! They lovingly call their apartment their workshop. Samantha Snabes and Matthew Fiedler, two of re:3D’s co-founders, were honored to visit them and their cats in France, after speaking at “Hello, Tomorrow” in 2017. Samantha fondly remembers, “Julie and Guillaume embody the can-do, problem-solving nature of so many of our Gigabot owners. It’s been so exciting to see how they tackled this challenge and to keep in touch with them over the years.”

Guillaume and Julie are standing next to their Gigabot.
Guillaume and Julie standing next to their Gigabot.

Since then, Julie has continued her work on the automated litter box. Julie taught herself how to design CAD files and slice prints with Onshape. Having previously worked in office administration, Julie decided to go back to school, learned how to code, and is now a full-stack web developer! Her friend, Alex Guitton, also a software engineer, has been helping Julie program the litter box’s motors and sensors.

During the pandemic, Julie and Guillaume kept busy during lockdown by 3D printing logos for companies. Julie would design the logos and print them with PLA. Guillaume would post-process the logos, sand them to be smooth, and spray-paint them to the company’s color palette. A perfect team! They started by printing logos for their friends with businesses and then reached out to French social media influencers, creating eye-catching pieces they shared with followers. A few of the companies Julie and Guillaume printed logos for were Bbryance, dental hygiene and whitening specialists, SY&ME, a designer shoe brand designed by women for women, and Affranchis Music, a record label founded by French rapper Sofiane.

Julie and Guillaume's company is 3dLOG.

While Julie and Guillaume have since taken a break from 3D printing logos for businesses, they are in the process of making one more for re:3D, and we could not be more excited! Julie is continuing to work on her automated litter box and hopes to print a complete prototype this year. When it’s finished, we will be sure to get the scoop!

If you would like to contact Julie and Guillaume about their automated litter box or logos, you can email them at log3d@outlook.fr or direct message them on Instagram @3d_log or Facebook @3D LOG.

Le Catalyseur : la crise du chaton suscite l'innovation chez le propriétaire du Gigabot

Hé, amoureux des chats! Vous avez un félin? Et si vous en aviez deux? Peut-être trois? Et pourquoi pas quatre?

Voici Julie Causse et son mari Guillaume Lecomte, les fiers parents des chats Lucky, Isis, Naya et Enja:

Four cats sit on a couch, two are black and two are brown stripped.
Quatre chats sont assis sur un canapé, deux sont noirs et deux ont des rayures brunes.

Vous vous dites peut-être: “Wow, ça fait BEAUCOUP de chats! Ils doivent consommer tellement de nourriture et de litière… Je ne voudrais pas nettoyer ce bac à litière!”. Julie et son mari vous diront: “Oui, nous sommes d’accord!” C’est là que re:3D est intervenu…

En 2016, Julie a commencé à chercher un bac à litière automatique à acheter, plus précisément un bac qui nettoierait la litière en collectant tous les excréments dans un récipient séparé qui pourrait être vidé, au lieu d’être écopé à la main chaque jour. Julie n’en a pas trouvé, alors elle a décidé de le fabriquer elle-même.

Au cours de ses recherches, Julie a réalisé que l’impression 3D pourrait être une bonne solution et elle est arrivée à la conclusion qu’elle avait besoin d’une imprimante 3D grand format, plutôt qu’une machine de bureau, pour fabriquer sa litière automatique. Elle et son mari ont trouvé re:3D en ligne et ont acheté notre kit d’imprimante 3D Gigabot non assemblé, qui est expédié dans des cartons séparés et plus petits. Le Ikea des Gigabots, si vous voulez. Comme Julie et Guillaume vivent en France, le kit d’imprimante 3D Gigabot était non seulement plus abordable pour eux, mais aussi plus facile à recevoir à l’étranger qu’une Gigabot entièrement assemblée. Une fois le kit reçu, ils ont construit leur Gigabot dans leur appartement d’une chambre à coucher, où vivent également quatre chats en plus des deux adultes, mais ils y arrivent ! Ils appellent affectueusement leur appartement leur atelier. Samantha Snabes et Matthew Fiedler, deux des cofondateurs de re:3D, ont eu l’honneur de leur rendre visite, ainsi qu’à leurs chats, en France, après avoir pris la parole à “Hello, Tomorrow” en 2017. Samantha se souvient avec émotion : “Julie et Guillaume incarnent la nature capable de résoudre les problèmes de tant de nos propriétaires de Gigabot. C’était tellement excitant de voir comment ils ont relevé ce défi et de rester en contact avec eux au fil des ans.”

Guillaume and Julie are standing next to their Gigabot.
Guillaume et Julie à côté de leur Gigabot.

Depuis, Julie poursuit son travail sur la litière automatique. Julie a appris seule à concevoir des fichiers CAO et des impressions en tranches avec Onshape. Après avoir travaillé dans l’administration de bureau, Julie a décidé de reprendre les études, a appris à coder et est maintenant un développeur web complet ! Son ami Alex Guitton, également ingénieur en informatique, a aidé Julie à programmer les moteurs et les capteurs de la litière.

Pendant la pandémie, Julie et Guillaume se sont occupés pendant le confinement en imprimant en 3D des logos pour des entreprises. Julie concevait les logos et les imprimait avec du PLA. Guillaume se chargeait du post-traitement des logos, les ponçait pour les rendre lisses et les peignait à la bombe selon la palette de couleurs de l’entreprise. Une équipe parfaite ! Ils ont commencé par imprimer des logos pour les entreprises de leurs amis, puis ont contacté des influenceurs français sur les médias sociaux, créant des pièces accrocheuses qu’ils ont partagées avec leurs followers. Parmi les entreprises pour lesquelles Julie et Guillaume ont imprimé des logos, citons Bbryance, spécialiste de l’hygiène et du blanchiment dentaires, SY&ME, une marque de chaussures design conçue par des femmes pour les femmes, et Affranchis Music, un label fondé par le rappeur français Sofiane.

L'entreprise de Julie et Guillaume s'appelle 3DLOG.

Si Julie et Guillaume ont depuis fait une pause dans l’impression 3D de logos d’entreprises, ils sont en train d’en réaliser un autre pour re:3D, et nous ne pourrions pas être plus enthousiastes! Julie continue à travailler sur son bac à litière automatique et espère imprimer un prototype complet cette année. Lorsqu’il sera terminé, nous ne manquerons pas de vous tenir au courant !

Si vous souhaitez contacter Julie et Guillaume au sujet de leur bac à litière automatique ou de leurs logos, vous pouvez leur envoyer un courriel à l’adresse log3d@outlook.fr ou leur envoyer un message direct sur Instagram @3d_log ou Facebook @3D LOG.

Jennifer Dennington

Blog Post Author

Replicating the Natural World in Digital Design

Kate Reed is a Boston-based designer building wearable technology, leveraging principles of nature, to connect humans and computers. These wearables harness human biological input and output methods through the combination of unstable media, experimental interfaces, and augmented materials.

Kate built her first wearable when she was 13. Since then, she has designed, engineered and built over a hundred wearable computers. Her designs and inventions have been featured at the White House, New York Fashion Week, MoDA, the Hackaday Superconference, MIT Museum, and more.

In 2016, Kate visited President Obama at the White House to demonstrate the function of the 3D-printed hand drive wheelchair attachment she had created with her classmates.

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When Kate reached out for assistance, re:3D, Inc.was excited to help her complete her collection for the Fabricademy.

In a world where so  many of today’s wearable devices give off a sci-fi vibe, Kate’s goal was to create a wearable that looks and feels like it is a part of our planet. This wearable collection was designed using nature’s algorithms to not only feel natural to our body but natural to the planet as well.
One centerpiece of the collection is called Root, a shoe that is grown around the wearer’s foot. It uses mushroom differential growth logic to simulate real mushroom growth patterns. One interesting aspect of this design is that it was able to be 3D printed on a Gigabot XLT with virtually no support because this type of mushroom grows in nature in a way that naturally supports itself.

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Another one of my favorites is Sea sprouts, which shows what barnacle forms may look like if they grew on a human. The barnacles were parametrically grown using Rhino and Grasshopper, then 3D printed and paired with different organic counterparts like mushrooms or flowers. All of this together created living clothing that continues to evolve with the wearer. This beautiful piece was printed with PETG on a re:3D Gigabot XLT and took just over 230 hours to complete.

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“If we want to keep nature with us we need to actively incorporate it into the design process. Beyond Biomimicry is empowering nature through computational design and 3D printing to create wearable devices that bring nature with us.”
Kate Reed

To learn more about her work visit beyondbiomimicry.com

JODY COCHRAN

Blog Post Author

Full-Scale Additively Manufactured Training Aids for DOD

*Disclaimer: This article’s contents do not express or imply an endorsement by the Department of Defense, the Air Force, or the United States government

Executive Summary

This award was designed to fulfill requests from two Air Force Education and Training Command (AETC) organizations who presented the need to produce full-scale training aids for Augmented Reality (AR) and Virtual Reality (VR) training. The inert aids, however, were too heavy and inaccessible, and traditional production methods can be time and cost intensive. Existing Additive Manufacturing (AM) hardware that could produce training aids at high fidelity were too small, requiring the aids to be made in multiple small pieces and then assembled. re:3D explored how a digitally driven workflow could  drastically reduce these time, cost, scale, and quality factors.  re:3D also provided fully custom AM machinery (i.e. 3D printers) capable of producing single-piece, full-scale training aids at high quality. By implementing 3D scanning and a custom large-scale 3D printer, dubbed “Exabot” by re:3D, these groups were enabled to produce full-scale training aids on-demand at a 74% reduction in turnaround time and approximately 90% reduction in costs.

Client Snapshot

The 149th Fighter Wing, stationed on Joint Base San Antonio-Lackland, Texas is a part of the Air National Guard. As an F-16 training unit, its mission is to produce the finest airmen for global engagements and domestic operations while supporting its families and serving its communities. It’s sister unit is the 147th Attack Wing, at Ellington Field Houston, where they fly combat support missions with the MQ-9 Reaper.  

Needs and Challenges

For the AETC, there was a need to train Air Force (AF) technicians and operators in the precise assembly of GBU and JDAM kits. Technologies like AR/VR could have greatly increased training efficacy, but such a process still required the use of full-scale training articles. There were, however, certain drawbacks to using them. First, existing training aids were extremely heavy, requiring special rigging or equipment to transport. Second, traditional manufacturing methods for training aids were costly with respect to time, materials, and money spent. This could have been overcome by utilizing AM, but there were no existing AM platforms that could produce high precision parts at the scale of training aids being used. Even then, operators required a thorough knowledge of 3D printing for the greatest return on investment.

Solution

re:3D focuses on affordable, industrial scale AM, offering a much lower barrier of entry with respect to build volume and feature set as compared to industrial competitors (Fig. 1). All re:3D 3D printers are also designed for modularity and customizability, so older units always have the potential to upgrade. Through a Phase II Open Topic SBIR grant awarded by AFWERX, re:3D was able to work with the 149th FW and 147th ATKW to reverse engineer and produce full-size training aids from AM thermoplastic.

FIGURE 1 - re:3D’S FLAGSHIP PRODUCT, GIGABOT 3+. LEARN MORE AT https://re3d.org/gigabot/

During this process, re:3D explored the potential for savings in cost, time, and materials through the fabrication of training aids via digital fabrication tools. Specifically, a Creaform HandySCAN Black Elite 3D scanner was used to capture high resolution 3D geometry for multiple Guided Bomb Unit(GBU) and Joint Direct Attack Munition (JDAM) kits (Fig. 2). The scans were post-processed in Creaform VXmodel and Dassault Systemes SolidWorks for ease of 3D printing and assembly. From there, several test prints were produced (Fig. 3) on re:3D’s print farm, a collection of in-house Gigabot and Terabot 3D printers(Fig. 4), to optimize the printing parameters for best quality.

FIGURE 2 - SCANNING A GBU BODY WITH THE HANDYSCAN BLACK ELITE
FIGURE 3 - FULL-SCALE 3D PRINTED VERSION OF GBU BODY AND THE ASSEMBLED FULL-SCALE 3D PRINTED GBU12, RESPECTIVELY
FIGURE 4 - THE re:3D SHOWROOM IN HOUSTON, TX, WHICH HOUSES A PORTION OF THE COMPANY’S PRINT FARM

After exploring the workflow and implied cost savings of using 3D scanning and AM to produce training aids, re:3D designed a custom 3D printer catered specifically towards GBU and JDAM production (Fig. 5). This included an extension of the flagship products’ maximum printing height from 3 feet to 6 feet, allowing for printing entire GBU/JDAM models in a single piece. Training was provided to the customer to minimize the learning curve and achieve reliable, successful 3D prints faster. The development process began on a touchscreen add-on, which will provide a more intuitive and accessible control interface.

FIGURE 5 - EXABOT, FULLY ASSEMBLED PRIOR TO INSTALLATION AT THE 149th FW

Results

The first half of the work with the 149th FW and 147th ATKW consisted of the 3D scanning and print optimization work. With the 3D scanner, re:3D was able to capture and reverse engineer fully featured 3D models of multiple GBU/JDAM kits (Fig. 6). The test printing yielded multiple full-scale printed training aids delivered to both the 149th FW and 147th ATKW for their assessment. After this process, re:3D compiled a digital package consisting of post-processed 3D models, optimized printing profiles, and ready-to-print .gcode files (Fig. 7).

FIGURE 6 - GBU12 BODY BEING PROCESSED IN CREAFORM VXMODEL SCANNING SOFTWARE
FIGURE 7 - PREPARING THE GBU12 BODY FOR PRINTING WITH SIMPLIFY3D 3D PRINTING SOFTWARE

A fully AM GBU38B weighed 33 lbs (Fig. 8), with its real-world equivalent weighing in at over 600 lbs. This amounts to a weight reduction of over 90% by switching to an AM training aid that still maintains the same geometric features as the genuine article. There are also implied safety and logistical benefits as a result of the drastic weight reduction. Transportation and handling of the training aids would require less staff and equipment and be easier, safer, and cheaper as a result.

FIGURE 8 - FINISHED AND ASSEMBLED GBU38B. THE FULL LENGTH IS 94 INCHES OR ROUGHLY 2.4 METERS

Using traditional sourcing, for the 147th ATKW to acquire one of their GBU/JDAM units would cost $10,000. A spool of high quality PLA plastic filament for AM will typically cost $20 per pound. At roughly 30 lbs, a fully AM GBU/JDAM kit only uses about $600 in materials to produce (Fig. 9). This equates to a 94% cost reduction when comparing just the materials. Extra associated costs include electricity usage, printing set up and post processing (when necessary), but these do not nearly make up for the drastic cost difference. Primarily, the main cost advantage comes in the fact that the parts can be printed with minimal setup or supervision.

FIGURE 9 - SPOOL OF PLA FILAMENT, SIMILAR TO WHAT WAS USED TO MANUFACTURE THE FULL-SCALE TRAINING AIDS

Instead of acquiring engineering drawings of each and every piece of equipment and recreating the models in CAD, re:3D used a 3D scanner to quickly capture 3D geometry for the kits the 147th ATKW and 149th FW were interested in using. Each scanning session took approximately 2 hours, followed by a few hours of post processing for each model in order to fix any scanning artifacts or to modify geometry for ease of printing or assembly. From there, each model was ready to print as desired. The typical turnaround time for the 147th to acquire one of their traditional training aids can be around 3 weeks. On the other hand, one of these kits can be printed in its full scale in 130 uninterrupted hours. This equates to a 74% reduction in time to complete a fully 3D printed training aid

After the completion of the custom 3D printer, dubbed the “Exabot”, it was delivered directly to the 149th FW. With a build volume of 3 feet by 2 feet by 6 feet (Fig. 10), Exabot is perfectly suited for printing full-sized GBU/JDAM kits, or any other parts that fit within the build volume as the end users see fit. Compared to a typical re:3D Gigabot 3+, Exabot also sports a stationary bed, a gantry which moves in the X, Y, and Z directions, a heavy duty frame with leveling casters, and a counterweighted filament delivery tube for consistent quality no matter how tall the print (Fig. 11).

FIGURE 10 - SIZE COMPARISON OF TWO EXABOT FRAMES VERSUS ONE GIGABOT 3+
FIGURE 11 - EXABOT AFTER DELIVERY AT THE 149TH FW AND A COMPLETED 16 HOUR 3D PRINT OF A MODEL ROCKET

After the Exabot delivery, re:3D provided training to the 149th FW (Fig. 12). While the crew at the 149th FW were already very familiar with 3D printing, re:3D was prepared to train operators at all levels of experience. This included education in machine calibration, maintenance, and operation as well as Simplify3D software set up. At the conclusion of the training, the 149th FW crewmen felt comfortable with operating Exabot and excited at their new ability to 3D print full scale parts.

FIGURE 12 - ONSITE TRAINING WITH THE 149TH FW

Continuous Improvement

re:3D values continuous improvement for their products and is committed to building an upgrade path for all standard machines. For example, an early Gigabot 2 can be upgraded to the latest Gigabot 3+, affordably preserving common components from unnecessary disposal while improving the machine’s functionality. re:3D approaches Exabot with the same commitment, leveraging feedback from the 149th FW to inform improvements that all Exabot users will benefit from.

Improved Filament Feeding

One challenge of large scale 3D printing is managing the filament feed path. The first iteration of Exabot used counterweighted filament tubes, with a constant length of tubing that moved in and out of the frame depending on the height of the gantry (Fig. 13). After some use, however, the operators gave re:3D feedback about shortcomings with this design.

FIGURE 13 - EXABOT WITH COUNTERWEIGHTED FILAMENT TUBES

The 149th FW Exabot was updated with a frame holding the filament spools directly above the gantry (Fig. 14). This stores all filament inside the frame, minimizing the overall footprint. There was also a 70% reduction in the filament path, for more reliable feeding and less chances of grinding through filament, and more economical use of filament spools.

FIGURE 14 - EXABOT WITH THE FILAMENT SPOOL FRAME

Upgraded Build Volume

While the original bed size was driven by the size of the training aids used by the 149th FW, the gantry of Exabot could actually accommodate a slightly larger bed plate. A simple and straightforward improvement was to install a new bed assembly that was large enough to fit the full stroke of travel of the X and Y axes. The original bed plate was 24” x 30” while the new plate is 30.7” x 30.7”, for a 31% increase in build volume.

FIGURE 15 - NEW BED PLATE SUPERIMPOSED OVER THE OLD BED PLATE AS A VISUAL COMPARISON OF SIZE DIFFERENCE

Continued Engagement

re:3D continues to engage with the 149th FW for regular service and maintenance needs, and also to better understand their 3D printing workflow and collect valuable feedback. This information will inform the next generation of re:3D’s large scale 3D printing products. 

Call to Action

This grant opportunity awarded by the AFWERX open topic solicitation enabled active investigation of Air Force needs and resulted in an innovative solution that was immediately commercialized with global interest, which include requests for even larger custom form factors. As mentioned above, many areas were identified and addressed for cost reduction. re:3D has had subsequent conversations with  DOD stakeholders, identifying further needs that may be addressed through large scale 3D printing, whether through the flagship Gigabot, and now Exabot, or a collaborative, custom solution. 

If your organization is interested in an Exabot of your own, it is available for purchase via GSA (https://bit.ly/3eFLpa0). If your organization is interested in collaborating on a future SBIR grant opportunity, feel free to email info@re3d.org with your vision to #dreambigprinthuge. re:3D is happy to consider any SBIR Phase 1, Direct to Phase 2 and eventually even beyond into Phase 3 opportunities. If you are interested in purchasing one of re:3D’s standard 3D printers or service offerings, please send a message to sales@re3d.org.

Gigabot X is a Finalist in the 3D Pioneers Challenge!

Helen & the re:3D team are honored to learn that Gigabot X was featured alongside multiple products & technologies we admire for the 3D Pioneer Challenge- many of which are focused on sustainability & social impact! You can tune in with us to see the livestream on 22 June 2021, 5pm CEST at:  www.facebook.com/3DPioneersChallenge

For more information on the competition, we have reposted the press release below, taken from www.3dpc.io/en 🙂

The 3D Pioneers Challenge, an international design challenge for Additive Manufacturing and Advanced Technologies, has announced its finalists. Now in its sixth year, the focus of this year’s competition was not only on the core AM processes, but also on innovations in advanced technologies.

The group of participants included industry pioneers, young professionals, industry startups and students, coming from some thirty-two countries and spanning five continents.

The 2021 finalists seem to indicate a paradigm shift, explain the organisers: projects and products are being rethought through digital processes and technologies, with sustainability playing a major role in the new normal, both ecologically and economically. Socially-innovative concepts are taking steps into a progressive era of change.

The 3DPC-Digital Award Ceremony is scheduled to take place on June 22, 2021, and will be realised in cooperation with Jangled Nerves, Stuttgart, Germany, whose interdisciplinary team specialises in communication in space and the connection between the physical and digital worlds.

From now until the awards ceremony on June 22, the forty-three finalists can be viewed on the 3D Pioneers Challenge website and through its social media. Further information, including prize details, is available via the competition’s website.

www.3dpc.io/en

Samantha snabes

Blog Post Author

A Look at the Largest Makerspace in Puerto Rico

Our interview with Luis has been translated from Spanish into English for the purpose of this article.

Roughly a 20 minute drive from the bustle of Old San Juan is an old civil defense base which houses the largest makerspace in Puerto Rico. Engine-4 has been there for nearly four years, operating as a mecca for hardware and IoT startups on the island. 

Cofounder Luis Torres has a background in hardware development and wanted to create a space in his own backyard to encourage these types of startups, which tend to have less places to go for support in Puerto Rico. “We created a space where university students, professors, and tech companies are all working together under the same roof developing their ideas flexibly and inexpensively so that they can become future startups in the community.”

The building houses a lineup of tools well-suited for hardware fanatics: soldering stations, printed circuit board milling machines, laser cutters, oscilloscopes, and an array of 3D printers.

“Spaces like this encourage community relationships, creation, and innovation,” Torres says. “They send a message that – with the few tools we’ve been able to acquire – we’re able to create ideas that are making it out of Puerto Rico.”

The Meeting in a Storm

Engine-4’s Gigabot story starts, as many stories in Puerto Rico do these days, with Maria. 

As the hurricane battered the island, nearby Parallel18 moved their Gigabot to Engine-4’s more secure facility for safekeeping. Torres quickly sized up the machine, and the wheels began turning. “I saw the capacity of the printer and realized that, without a printer like Gigabot, there are a lot of prototypes we wouldn’t be able to make.”

As the resident companies at Engine-4 include a fair number of IoT developers, 3D printed housing for components is a common need. But they also house other companies with larger requirements, Torres says, like architectural firms working in urban development and startups building custom drones. These sorts of prototypes often dwarf the average desktop printer. He explains, “A printer like [Gigabot] gives us the capacity to print really large things that other, smaller printers just can’t.”

IMG-20200714-WA0002

Hardware development necessitates quick, agile development. As one local startup put it, “Prototyping is a daily activity.” Third party contract machining often means hefty price tags and long turnaround times, which simply aren’t an option for these companies as they move quickly from iteration to iteration. This is where the in-house fabrication equipment of a makerspace can play such a crucial role. 

Torres understands that there aren’t many machines out there that rival 3D printing in the world of rapid prototyping. “This is a part of our growth, and I understand that it’s an essential tool for the team,” he says. “To create prototypes, there really isn’t another device that you can use that’s not a 3D printer, and Gigabot’s capacity is more than any other machine.”

He’s been very satisfied with their decision to invest in such a large printer. “[The goal] was achieved since the first day we opened it,” he said.

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Favorite Projects

A common thread for many Puerto Rican entrepreneurs is the influence that Hurricane Maria has had on their business ventures, often spurring the creation of a company aimed at solving a problem laid bare by the storm.

True to form, some of Torres’s favorite projects that have come out of Engine-4 happen to be those associated with disaster response.

One such example is WATRIC Energy Resources, a company featured in a recent Gigabot story, who used the Engine-4 Gigabot to prototype a product which condenses drinkable water from moisture in the air. Their goal is to create units for homes and public spaces to reduce the reliance on the water grid in the event of another catastrophic disruption to the system similar to the aftermath of Maria.

Another favorite of Torres’s is a project involving mini weather stations in which Gigabot was used to 3D print the housing for a bundle of internal electronics. This was a part of Engine-4’s work on IBM’s Call for Code challenge, a competition to develop hardware prototypes for natural disaster aid. The units have been installed in different locations along the coast of Puerto Rico as well as atop Engine-4’s roof.

The Engine-4 Gigabot has also been put to work 3D printing custom components for drones to be used in a disaster-response format. In one example, drones carry and drop custom units from the air via remote control, transmitting an SOS signal to emergency responders. The idea is to use the drones to summon for aid in areas that may be impassable due to storm damage. 

Youth Program

One topic that Torres is particularly passionate about is his mentorship of the local youth.

In 2019 he started a free program called IoTeen ECO Bootcamp wherein he works with students from age 10-17 on tech skills, using cases involving sustainability and the environment. Over the course of the program, the group works with electronics like Raspberry Pi and Arduino, learns how to program in Python, and gets experience using 3D printers on projects like solar panels and smart farming. The whole program culminates in a hackathon.

“They don’t teach this in the schools here,” explains Torres.

He gives his students all the equipment they need to learn real-world technology skills and create functional products, guiding them along a path that may hopefully spark an idea of what they want to study in university. “They don’t have to wait until they’re in their final year of school to decide what it is they’re going to do,” he says.

The Importance of Community and Unity

When we spoke in late 2019, Torres had clear visions of growth for the future. His youth tech program was slated to double in size in 2020, Engine-4 was in the process of expanding into a new wing of the building, and he hoped to get more Gigabots for the space.

And then, as it has for countless others around the globe, COVID-19 entered the picture and made everything a little murkier. In many ways the island is still reeling from Hurricane Maria, and its healthcare system is in a vulnerable position due to persistent underfunding.

But in another sense, the crisis brought Engine-4’s sense of purpose as a hub for creation and innovation into sharp focus.

Torres and his team jumped immediately into action, putting their tools to use creating PPE for healthcare workers across the island. They began printing components to assemble face shields, and were able to fit up to 12 face shield prints on their Gigabot bed at one time. In the first wave of the pandemic in the spring, they were using nine printers to crank out 475 face shields a day. They have since donated 14,000.

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The words that he ended our November conversation with now seem to take on new meaning. 

“For the community, we need more unity between us. We need to take off our protagonist hats and focus ourselves on the same North Star, so that those who come after us can replicate [these spaces] and the community can grow like it’s grown in other parts of the world. This is my advice and my words for the community.”

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Morgan Hamel

Blog Post Author