3D Printed Rifleman Mech Steps into the Real World

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The popularity of Mechs doesn’t seem to fade away. Not a long time ago, we found out that one of our customers took Silver at Gen Con MHE painting competition with the Timber Wolf 3D miniature. And now, another Mech has been revealed by Alwin Chan, a fellow who has joined the 3D printing trend recently. It’s been a little bit longer than one year since Alwin started getting to the grips with the 3D printing and modeling.

Alwin doesn’t have special education and isn’t super skilled in handling 3D models or designing miniatures. But this has challenged him to try to learn it on his own from YouTube tutorials and videos.

Rifleman is Alwin’s special project, as it is one of his first 3D printing miniatures done from start to finish by himself in his pursuit of making 3D printing his hobby.

We contacted Alwin and asked him several questions about his experience with 3D printing and this is what he told us.

Alwin, you probably saw that a lot of our customers choose to 3D print Mechs. Could you let our readers know what is the reason behind this trend?

“I think many of us played MechWarrior or one of the old PC games when we were growing up. We also watched a ton of cartoons like Robotech / Macross where there were always these giant mechanical robots that could fly and shoot. Who wouldn’t want a Mech on their desktop? The hardest part was always finding a good model that was printable and had surface detail.”

How long have you been into 3D printing? Do you have any special education in this field?

“Believe it or not, I started 3D printing in September of 2016 so I’m in just over a year. I don’t have any design expertise but I am learning Fusion 360 because it is free and there’s many YouTube videos on it. I’m also planning on learning Blender too. I feel like I need to learn these to make some edits to models that I have as well as create models that aren’t available anywhere on the Internet.”

What was the first item you 3D printed and on what type of 3D printer did you do it?

“I funded the M3D Micro on Kickstarter and that was my first 3D printer and it was horrible. The very first item I printed was a Colonial Viper Mk2 from Battlestar Galactica.”

How was the result?

“Well, since it actually printed. I was amazed that it even worked. The layer height was high but it had the general shape of the model and seeing that for the first time. It’s great. It was like Star Trek was really happening.”

What 3D printer did you use to 3D print Rifleman? Does it have any specific settings that our audience needs to know before deciding to buy one? Would you recommend it for a beginner user?

“I used a Makerbot Replicator 5th Gen and a Makerbot Replicator 2X. I used 2 printers to cut the time in half to get all the parts done. I would suggest anyone printing these tune their printer first for the filament they are going to use and focus on retraction. Print at the highest quality your printer can handle, it will really bring out the details of the model and make post print processing a lot less of a headache.

How long did it take to have all parts 3D printed? Were there any failures? If yes, what kind and how did you deal with them?

“All in all, I think it took a total of 20 hrs. I had a couple of failures on the leg pieces because the support failed. I also had to chop the body to preserve the details on the bottom of the Mech’s body. If I didn’t do this, the support would have damaged the bottom of the model and that added a bit of time to the entire printing process. I also had to orient the parts to minimize support scarring and maintain as much detail as possible. I’d rather chop a part into 2 or 3 pieces than deal with the loss of detail.”

What type of printing material did you use? Tell us about your experience with using this material.

“I mainly print with PLA from Hatchbox which is pretty high quality and affordable. Since I use this brand a lot, I knew where my temperature and retraction settings should be to get the best possible model out of my printers. I think it’s important to test your material so you don’t waste hours and get a part that you’re not happy with.”

Your Rifleman is painted, as we can see. Tell us, did you do it yourself or prefer specialized services? What painting tools and techniques did you use to give it such a nice coat?

“I used automotive filler primer and then sanded and repeated until all the layers were hidden and smoothed out. After that, I airbrushed the entire model with Tamiya acrylic paints and then let dry. I added a matte clear coat and then started with the decals which I printed on an ink jet printer. After that, it took about 9 hours to add all the weathering and highlights. Since the model was large, I knew any surface flaws would show up so I had to spend the extra time to get it ‘right.’”

As you probably know, one of our customers, Kevin Witt, took part in Gen Con Convention and took silver for the painting competition. He entered with Timberwolf 3D model. Are you one of the guys who would consider participating next year in this competition?

“I saw that model and he did an awesome job! I would but it would all depend on how much time I had. There are a lot of very talented ‘professional’ model builders out there.”

How would you describe in a word your reaction at holding a 3D printed item in your hands?

“A kind of amazement that you had this vision of what the model could become and you made it happen. You have to resist just holding it and just daydreaming for a while. As you start the finishing process, I find myself doing that a lot. You can see the end and have to fight not to rush it and mess up.”

Are you now working on something special? Share with our audience.

“Yes, I’m working on the Starcraft Siege Tank. Ever since I played that game back in the mid-90s, I’ve wanted a model of that tank and I could never find one. I almost always played as Terran and I can’t thank Gambody enough for publishing it with the artist. This tank is going to take a while and I’m pushing the limits of my old printers!”

Alwin proves that perseverance and good printing material are the pillars to good results. His Rifleman Miniature is a good example to show to those who make their first steps into 3D printing.

Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts below.

Yurii Yefimov is the CPO of Gambody.

Indaero secures deals with Airbus suppliers after successful 3D printing of complex tools

Indaero, a Spanish aerospace and engineering company, has secured a deal with multiple Tier 1 and Tier 2 Airbus suppliers after it has successfully used FDM 3D printing to produce complex tools.

The company manufactures aircraft panels for key customers in the aerospace industry, as well as offering design, engineering, tooling, welding and painting services. After investing in a Stratasys Fortus 450mc Production 3D Printer, Indaero has been able to expand its offering to include lightweight tools with complex design that aren’t easily manufactured with traditional methods.

Manufacturing several production tools, Indaero is enjoying the ability to quickly design and produce complex curved geometries required to achieve the intricate shapes of the aircraft panels. Prior to its adoption of 3D printing, the company was forced to produce flat shapes which could affect the performance of the tool during its affixation to the panel by workers. Now though, with the Fortus 450mc and ULTEM 9085 material, also developed by Stratasys, Indaero says it is providing an even better service to its clients.

“Aerospace is unlike other industries, producing high volumes of tools,” said Dario Gonzalez Fernandez, CEO of Indaero. “To traditionally manufacture production tools, injection moulding or CNC machining would be used, but this would be very time-consuming and costly. With our Fortus 450mc 3D Printer we can service low-volume production quickly and cost-effectively, producing many different tools on-demand to accelerate the manufacturing process and ensure we meet customer delivery deadlines.

“The importance of the ULTEM 9085 material cannot be understated either. It has become an integral part of our production process, as it is certified for aerospace and well known by our customer, Airbus for a number of aircraft applications. With its unique combination of high strength-to-weight ratio and FST (flame, smoke, and toxicity) certification, we can 3D print robust, lightweight tools and respond to short run production of flying parts if required – giving us a unique advantage versus competition.”

Indaero has been harnessing the 3D printing technology to optimise a series of production tools for the manufacture of an Airbus NH90 Helicopter for Aernnova. One of these tools will be used to fix a slide box onto the interior panel of the helicopter wing. Traditionally, a tool of this kind has weighed around 12 kilos and required two operators to hold it in place against the panel while drill holes are marked. With the 3D printer in-tow, Indaero re-designed the tool with a curvature that perfectly fit the panel structure, weighing nine kilos lighter and capable of standing on its own. It’s this kind of enhancement that has Indaero thinking it has an advantage over its competitors, and is set to ensure better productivity for Airbus suppliers.

“The 3D printer has been a game-changer for us,” Gonzalez said. “The ability to 3D print curved production tools in robust materials made us realise the importance of having tools that perfectly fit the panels. Not only does it make the work of our operators much easier, it frees up resources and increases our overall productivity. This improvement was immediately recognised by a number of leading Airbus providers, such as Aernnova, who previously worked with our competitors and whose business we have subsequently secured.”

“FDM has long been an additive technology of choice for the aerospace industry, particularly for customised tooling applications,” added Andy Middleton, President EMEA, Stratasys. “Companies such as Indaero are leveraging high-performance materials, such as ULTEM 9085, to produce lighter weight, better performing tools on the production floor in less time and cost. It’s no surprise that these future-ready companies are improving business performance as a result.”

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EMJ Corporation has partnered with Branch Technology to build the world’s first 3D-printed house. EMJ will serve as the construction manager on record led by EMJ Special Projects and the EMJ Construction Technology department.

Branch Technology, a Chattanooga-based start-up, is home to the world’s largest free-form 3D printer and uses a technology called cellular fabrication, or C-FAB, to bring large-scale designs to life.

Founder and CEO Platt Boyd, who spent nearly two decades as an architect, developed the technology, which prints large structural shapes into cell-like matrixes for maximum strength, efficiency, and nearly limitless options—unlike traditional construction materials and/or designs that were once impossible to actually construct.

Branch gained national coverage when it announced its sponsorship of a design competition to construct the first 3D-printed house through its new technology. After reviewing submissions from 1,300 designers in 97 countries, Branch awarded WATG in Chicago with the winning design for its 1,000-square-foot, 1-bedroom, 1-bathroom house entitled “Curve Appeal.”

Printing and building a house piece-by-piece is unprecedented, but Branch has already tackled similar projects across the nation, including being involved in the world’s largest 3D-printed pavilion and the design for a 3D-printed habitat for NASA’s deep space exploration. Similarly, the house will be created by printed carbon fiber polymer matrixes, which will be filled with traditional insulation and then clad with dry wall.

“Branch is a world-class leader in bringing innovation to the construction industry,” says Jonathan Deming, Director of BIM and Construction Technology at EMJ. “This work has the potential to completely revolutionize the architecture, engineering and construction industries.”

Branch and EMJ are currently collaborating on the final plans for the house. This includes site logistics planning, phasing of prefabrication and installation, constructability and engineering of the design components.

“We are testing materials, mocking up options and reviewing scenarios to ensure the house is built to the highest quality standards,” said Jonathan Horne, EMJ Director of Quality, who is working alongside the EMJ Special Projects team and the Construction Technology Department to finalize the construction plans.

The house is expected to be completed in 2018 and will be built on the Chattanooga State main campus to be later used as an advanced technology demonstration space.

To learn more about plans for the 3D-printed house, click here, and see more about Branch’s C-FAB technology here.

Related articles:
Big ideas: 3D printing pioneer Branch Technology ‘doing things no one else is doing’
Behold: The World’s First Freeform 3D-Printed House Might Look Like This
See the Designs for the First Free-Form 3D-Printed House