The Fastest Way to Create Tangible Color Models from CAD Data

Introducing Z Corporation High Definition, Low-Cost 3D Printers

Introducing Z Corporation

Introducing Z Corporation

• Z Corporation is the Growth and Innovation Leader in 3D Printing

• 2,500 customers worldwide

• Located in Burlington, MA USA (Boston Area)

• 125 distribution partners worldwide

• Quick facts from 2005

– Z Corporation’s 3D Printer shipments grew 60%, with revenue growth over 50%

– Z Corporation launched new products across the line-up in 2005, with more than 70% of revenue coming from new products by year end

– Z Corporation launched the award-winning Z510 Spectrum Full Color, High Definition 3D printer

• Z Corporation has created the category of high speed, low cost, full color 3D printing

Markets We Address

• We expect to be the 3D printer of choice for all forms of 3D Data

Product Design

Education

Architecture/

Engineering/

Construction

Medical

Entertainment

What is 3D Printing?

3D CAD File

A 3D Printer is an Output Device for 3D CAD Data

3D Printer 3D Model

How it Works

Spread Layer of Powder Print Cross-Section

1 2Spread Layer of Powder

3

• Software "slices" CAD file into thousands of thin layers

• Physical model is built one layer at a time

• Ink-jet print heads deposit binder into powder to create layers

Mainstream 3D Printing vs. Narrow-use Rapid Prototyping & Mfg.

“Rapid” Manufacturing

• Uses: short-run, end-use parts• Need: material strength, tooling-level

accuracy• Tradeoffs; very high cost, slow,

monochrome, difficult-to-use

Old “Rapid” Prototyping

• Uses: functional testing, late form & fit• Need material strength, tooling-level

accuracy• Tradeoffs; very high cost, slow,

monochrome, difficult-to-useMainstream 3D Printing

• Uses: – Design concept visualization– Early form & fit testing– Wide-ranging engineering,

sales, & marketing applications

• Needs– Very low cost for everyday use– Very fast print speed– High-definition resolution– Full-color, graphics, annotation– Easy to use

Mainstream 3D Printing vs. Narrow-use Rapid Prototyping & Mfg.

“Rapid” Manufacturing

• 3D Systems• Objet

Old “Rapid” Prototyping

• Stratasys• 3D Systems• Objet• Table-top CNCMainstream 3D Printing

Z Corporation

Proven Technology

Why Use 3D Printing?

Streamline the Design Process

• Create more prototypes, sooner

• Make ideas easier to visualize

• Make decisions faster by reviewing tangible options

• Identify form, fit, function errors early

• Improve clarity of communication with suppliers, vendors, prospective customers

• Output a single data file on printers in multiple locations. Instantly collaborate on design revisions

Physical Models Enable You to Communicate More Clearly

Jumpstart Sales & Marketing

• Create physical representations of concepts to win business even before the design process begins

• Create realistic prototypes for focus groups

• Affordably produce a variety of options, styles, fashions

• Develop and evaluate packaging options

• Begin selling before manufacturing delivers product

Explore Design Concepts

Evaluate Style, Fashion, Packaging, Feel, Size

Evaluate Form, Fit, Ergonomics, Assemblies

Improve Production Planning

Color-code assemblies, tooling components, or machining surfaces

to clearly communicate process steps

Display Engineering Analysis

Apply Cosmetic Finishes

Applications in Architecture

Applications in Architecture

Applications in GIS

Applications in Medical Modeling

Z Corporation Advantages

How to Evaluate 3D Printers

• How quickly do you need your parts?

– In the next hour?

– This afternoon?

– Tomorrow?

– Next week?

• How quickly does the person after you need their part?

• What can you afford to pay for each model?

– $10?

– $100?

– $1,000?

• Are your designs simple or complex?

All Prices in US $

Breakthrough Advantages of Z Corporation Technology

• High-definition resolution

• Only color printers available

• 5-10x faster than other technologies

• Lowest cost per-system and per-part

• Large enough for substantial models, or to print multiple models at once

High-definition for Exceptionally Realistic Parts

NY Museum of Modern ArtCelebrating 20 Years of Pixar

High Definition Parts are Museum Quality

Poor Definition of Other Technologies

Z Corp. High Definition

Others

Exclusive 24-bit Color

Why Color?

- More lifelike prototypes

- Shape and size are only two aspects of the design. Color is the third.

“ Color had a much bigger impact on our design process than we ever imagined. We knew it would save time and enhance communication, but it’s really been a giant leap forward for us. It won’t make monochrome prototyping obsolete, but it has dramatically accelerated our progress from simple sketches to success on the market”

Paul Bates – Reebok International

Real Product

Z Corp Part

Multi-Color Parts Without Paint

Labeling and Annotation

Breakthrough Speed

• Print a typical handheld part in < 2 hours

– 1-2 vertical inches (25-50 mm) per hour

• 5-10x faster than all other technologies

• Print multiple prototypes at one time

• Ability to service the queue

– When will the Nth engineer get his part?

Print Multiples in the Same Time Period

Z Corporation

Competition

The Value of Speed to a Team

Lowest Cost System-wide

• Lowest system purchase price in its class

• Lowest operating cost; $1.50 - $2.00/cubic inch ($0.10/cm3)

• Lowest cost/model (a typical handheld part costs $10)

• Lowest maintenance costs

– Features modular components for fast & inexpensive servicing

• Freely print parts on a low operating budget

All Prices in US $

Lowest Cost of Materials

Source: T. A. Grimm & Associates, May, 2005

Rapid Prototyping & Manufacturing Conference All Prices in US $

The Value of Combining Low Cost with High Speed

9,240$29,500120Others

1,080$7,200120Z Corp.

770$2,46010Others

90$60010Z Corp.

77$2461Others

9$601Z Corp.

HoursCost# PartsCost & time

to print this

32.5 in3 part

All Prices in US $

Why Stripped-down, Old RP Technologies Do Not Work in 3D Printing Applications

Dimension

• Models with MSRP

– BST 768: $18,900

– BST 1200: $21,900

– SST 768: $24,900

– SST 1200: $29,900

Stratasys Dimension –Low-end Rapid Prototyping

• 5-year-old technology at the end of its life cycle

• Painfully slow (the larger the part, the slower the build)

• Average-to-poor surface finish

• Lack of fine feature detail

Dimension; Dual-tip Extrusion (Hot Glue Gun)

• Like an old pen plotter

• Dual-tip design causes interference & distortion to adjacent vertical geometry

Breakthrough Speed

Time needed to print

this 32.5 in3 part

Z Corp.

9 HoursOthers

77 Hours

Dimension; Slow Print Speed

To complete this part would require 18 hours

Part after 2 hours using

Dimension

Identical part after 2 hours

using ZPrinter

Dimension; Slow Print Speed

This part requires 35

hours to print

Dimension; Poor Resolution

Dimension Specs: .012” tip x .010” layers

Spectrum Z510 Specs: 600 dpi x .003” layers (45x better resolution)

Dimension; Coarse Surface Finish

Dimension; High Cost to Own & Use

Dimension

ZPrinter 310

Cost of Printing Two 48-in3 models per week

All Prices in US $

Dimension Materials – 1000 in3

• $250/reel

• 58 in3 per reel

• You need support, so figure at least 30%

• 1300/58 = 22 reels

• 22 x $250 = $5,500

•$5,500

All Prices in US $

Materials Comparison – 1000 in3

•Z Corp: $1,650

•Dimension: $5,500

All Prices in US $

We are the Lowest Cost Solution

• Dimension BST

– $18,900

• Materials

– $5,500

• Training

– $1,000

• 90 Day Warranty

• $25,400 Package Price

• ZPrinter 310 Plus

– $19,900

– ZD5: $1,900

• Materials

– $1,650

• Training

– $1,000

• 90 Day Warranty

• $24,450 Package Price

All Prices in US $

We are the Lowest Cost Solution

• Dimension SST

– $24,900

– Tank: $3500

• Materials

– $5,500

• Training

– $1,000

• 90 Day Warranty

• $34,900 Package Price

• ZPrinter 310 Plus

– $19,900

– ZD5: $1,900

• Materials

– $1,650

• Training

– $1,000

• 90 Day Warranty

• $24,450 Package Price

All Prices in US $

ZPrinter® 310 ― Lower Cost of ownership than Dimension

$24,450 $25,400

Cost of Equipment + “first” 1,000 in3 (16,400 cm3) of material

All Prices in US $

Dimension SST Option

• $6K price-adder for SST 768 material print head

• $8K price-adder for SST 1200 material print head

• $3,500 additional for removal tank

– Not office compatible – requiring gloves & facilities to drain tank periodically

• Soluble supports

– Still requires some manual removal

– Phosphate bath must be replaced for every 30 cubic inches of material dissolved

– Supports dissolve in 3 hours, longer for larger parts

All Prices in US $

Dimension SST Option

• $6K/$8K addition for SST material head

• $3,500 additional for removal tank

– Not office compatible – requiring gloves & facilities to drain tank periodically

• Soluble supports

– Still requires some manual removal

– Phosphate bath must be replaced for every 30 cubic inches of material dissolved

– PS400 media (Water works liquid) has a PH rating falling between Ammonia and Lye. Heavy dilution and/ or chemical services needed for disposal

– Supports dissolve in 3 hours, longer for larger parts

– Occasional leakage of solvent into hollow part geometry

• (Keep parts on sponges, rags, and cloth for hours or days)

Dimension Support Structures

The Dimension process involves physical support

structures that must be painstakingly removed with tools

Dimension Tools for Removing Support Structures

• Exacto knife

– To cut away supports & base

• Sharp metal spatula

– To cut between the part & support structure

Dimension Part Processing

Step 1

Remove part with base and support structure from

Dimension printer

Support Structure = Waste

Base = Waste

Dimension Part Processing

Step 2

Attempt to tear part from support

structure. Support structure

cracks

Step 3

Cut support structure from the

rest of the base

Dimension Part Processing

Step 4

Begin removing support structure

Dimension Part Processing

Step 5

Continue to cut away support structure. Difficult because tools do

not reach all surfaces

Dimension Part Processing

Step 6

Remove base & discover more material to be removed

Dimension Part Processing

Step 7

Locate & unpack the correct size and number of picks, files,

tweezers, and other accessories included in Dimension Starter Kit

Dimension Part Processing

Step 8

Process continues …

Step 9

And continues …

Dimension Part Processing

Step 10

Conclude by sanding finish with 220/320-grit wet/dry sandpaper

included in Dimension startup kit

Case Studies

Case Study: Continental Tire

• #1 maker in Germany, sold worldwide as Continental, General Tire, Uniroyal

• Need – Multiple tread samples for timely product development decisions

• Solution; ZPrinter 310

• Results

– Rapid prototypes 5x faster

– Reduced prototype costs 50%

– Flexibility to develop, discuss, debate and refine tread designs

• “We’re making more money by making prototypes for our sales force, giving them something concrete and convincing to show major auto companies.” Matt Lamb, Tire Designer

Case Study: Black & Decker

• Global manufacturer of DEWALT®, Porter-Cable®, and Delta® tools

• Need – Fast, cost-effective early concept models

• Solution; ZPrinter 310

• Results

– Compressed design cycles

– Enhanced product aesthetics, ergonomics

– Improved resource utilization

• “We have been able to reduce model production time by as much as 75 percent. John Reed, Master Prototype Specialist

Case Study: Timberland

• Global leader in premium-quality footwear, apparel and accessories

• Need; More shoe prototypes, sooner, to evaluate comfort, performance, marketability

• Solution - Spectrum Z™510

• Results– Reduced prototype cost 80-fold

– Reduced prototype production time from one week to 90 minutes

– Reduce design time 33 percent

– Increased sales using 3D prototypes instead of 2D sketches

• “We can now quickly do innumerable iterations and variations, and the designers and marketing managers can really be sure the product is what [people on the street] are demanding.”

Toby Ringdahl, CAD Manager

Trinity Products

• $10 million manufacturer of remote-controlled cars

• Need – rapid prototypes for form, fit, function testing

• Solution; ZPrinter 310 for high-resolution parts (even 1/18 scale)

• Results– Prototypes now strong enough for

functional testing

– 80% time savings printing parts

– Cut design cycle 50%

– Eliminated earlier $800/part cost

• “ … the the single biggest step we’ve taken to improve the way we refine concepts, develop products, communicate with suppliers, and market products.”

Mike Wood, Chief Engineer

Case Study: Caterpillar Inc.

• World’s leading manufacturer of construction and mining equip.

• Need: Faster way to produce prototype castings to accelerate design changes.

• Solution: Z810 & ZCast process

• Results

– Reduced casting development time 70%

– Accelerated design changes

– Increased prototyping capacity 60%

– Reduced cost/prototype 50%

• “We can generally produce castings in a third of the time it used to take (5 days vs. 3 weeks), and at less cost.”

Joe Taylor, RP Team Leader

“ Architects just can’t collaborate around a napkin or computer file the same way they can around a physical model. Architects need to literally walk around a design, get their hands on it and maybe mark it up with a pen. This process is as vital as presenting to the client and just as rigorous?”

Al Vass – Associate VP

Case Study – Jerde Partnership

Case Study: Motorola V70

Motorola V70 Concept Testing

Motorola V70 Engineering

Motorola V70 Value

• No 3D data is released to create solid visual models without first making a model

• Mistakes caught before data released for tooling

• Designers work closer with engineers and human-factors teams when developing products

• Changes & revisions happen faster

Case Study: University of Michigan

• Broad curriculum support

• Study of EM wave propagation

• Plasma cutting template

• Study of ultrasound flow phantoms

• Architecture program

• Investment casting study

Case Study – Oliver Wolcott Technical School

• Machine Drafting students measure a real part & create that part in 3D CAD

– Part is made on 3D printer

– Students compare actual part with the Z Corp. part

• After completion of this project, students create their own 3D CAD design & “Zprint”

• All students trained on the Z Corp. printer & actively use it

THANK YOU