Computer Solutions
“The machine we are developing will produce parts with outstanding mechanical properties because every layer is fused using controlled heat and pressure. The process also has high processing speeds and excellent resolution.”
Materialise used one of its very large Mammoth stereolithography machines to build the model (Fig. 3). Because the build material is a liquid resin, the part must be supported as it is built; Materialise’s e-Stage software automatically generates these supports, but they are easily removed afterwards during the post-processing stage (Fig. 4).
Fig. 3. Materialise used one of its Mammoth stereolithography machines to build a model of Tutankhamun’ mummy for an exhibition.
Tutankhamun’s mummy
3D printing is now an extremely versatile process, with applications far beyond the creation of parts for product development purposes. For example, Materialise, the Belgium-based rapid prototyping bureau, has recently used stereolithography to create a replica of King Tutankhamun’s mummy for the Discovery Times Square exposition in New York. The operation was led by natural history and prehistoric model maker Gary Staab, of Staab Studios. The process began by importing CT (computed tomography)
scans of the Tutankhamun mummy into Materialise’s Mimics software to create an exact 3D model of the mummy. From there, 3-matic software hollowed the model. Hollowing is important because it reduces the amount of material used, speeds the build and makes the final product lighter. Once the digital model was ready, the team used its Magics software to fix the file and make the model ‘watertight’ - which is a crucial step in 3D printing.
Fig. 4. Materialise’s e-Stage software automatically generates a structure that supports the stereolithography part as it is built, but these supports are easily removed afterwards.
From Materialise’s facility in Belgium, Tutankhamun’s model was transported to the Staab studio in Missouri, where Gary Staab added detail, colour and texture to make the replica appear identical to King Tutankhamun’s mummy. While the mummy model is an extreme example of what 3D printing can achieve, companies wishing to implement 3D printing in an office or research and development environment can today take advantages of the latest generation of machines that are characterised by being faster, more user-friendly, and cheaper to buy and run, with the resultant models being robust and durable (Fig. 5). In many cases, the machines’ resolution can challenge that offered by rapid prototyping and manufacturing machines that, not long ago, were considered to be the state of the art. Indeed, today the boundaries between ‘office’ 3D printing and these other ‘high-end’ technologies are now becoming blurred. Furthermore, the ability to print with multiple materials offers users significant functional and aesthetic advantages. l
Fig. 5. The latest generation of office-friendly 3D printers, such as Z Corporation’s ZPrinter 350, are faster, cheaper to buy and run, and build robust and durable models.
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