Printing Physical Models with the Genisys Xs

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Printing Physical Models with the Genisys Xs
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Purpose of Rapid Prototyping

• Diagnostic tool
• pre-operative planning
• improve product quality
• reduce time-to-market
• communication
• early design flaw detection
• functional prototypes

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RP in a Research Environment

• Measure of realism
• Tactile feedback
• Macroscopic/microscopic or theoretical data
• Variation in structures difficult to detect using
  traditional visualization software

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What would I use it for?

• Molecular structures
• Cells, proteins
• Mathematical models
• Biological data, anatomical structures

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Suitability

• rp vs. machining
• Replacement parts

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Popular Systems

• Stratasys
• Genisys
• Z Corp
• Z402
• 3D Systems
• SLA-250
• ThermoJet

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Stratasys Genisys Xs

• Extrudes a bead of durable plastic polyester
  through a computer controlled pump head
• Models can be painted, drilled, finished
• Heat gun

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Genisys Xs

• 12x8x8 build area
• Pentium-based controller w/ local storage
• Paraffin-based polyester (P1500)
• Wafers
• Resolution 0.013 (.3302mm)
• Positional accuracy of 0.001
• Prints 4in/sec
• No post processing required

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Printer results
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Printer results

• Worst case clearance for one part to fit inside
  another
• ID 660 micrometers lt OD
• Problems with lower part of spheres
• Ridge

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Material (P1500)

• Tensile strength 2800 (psi) 19 (Mpa)
• Tensile modulus 120000 (psi) 896 (Mpa)
• Elongation 6
• Flexural strength 3900 (psi) 27 (Mpa)
• Flexural modulus 120000 (psi) 827 (Mpa)
• Hardness 62 (Shore D)
• Melting point 306-320 F

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AutoGen

• STL -gt JOB -gtCMB
• Viewable build area
• Rotate, scale, translate
• Fit
• Force print
• Units
• Estimated time print
• Sends file to printer

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AutoGen
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Magics Communicator

• More robust than AutoGen
• Lets you measure (from point to point, etc)
• IGES, STL, DXF, VDA
• Annotations
• Slide show
• Cross sectioning
• Cannot send files to Genisys

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Magics Communicator
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Cost

• Material cost 2.00/wafer
• Future costs undecided

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Successful Models

• Single object
• Surface
• Dxf vs. iges
• Rhino

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How to Print

• VMIL users
• STL file
• Autogen for preprocessing
• Print to moore
• Ask Jo