3-D printed Shelby Cobra

This Shelby Cobra sports car, 3D-printed at Department of Energy's Manufacturing Demonstration Facility at Oak Ridge National Laboratory, will be on display this week at the Detroit Auto Show Technology Showcase. Credit: Image courtesy of Oak Ridge National Laboratory

With a 3-D printed twist on an automotive icon, the Department of Energy's Oak Ridge National Laboratory is showcasing additive manufacturing research at the 2015 North American International Auto Show in Detroit.

ORNL's newest 3-D printed vehicle pays homage to the classic Shelby Cobra in celebration of the racing car's 50th anniversary. The 3-D printed Shelby will be on display January 12-15 as part of the show's inaugural Technology Showcase.

Researchers printed the Shelby car at DOE's Manufacturing Demonstration Facility at ORNL using the Big Area Additive Manufacturing (BAAM) machine, which can manufacture strong, lightweight composite parts in sizes greater than one cubic meter. The approximately 1400-pound vehicle contains 500 pounds of printed parts made of 20 percent carbon fiber.
Recent improvements to ORNL's BAAM machine include a smaller print bead size, resulting in a smoother surface finish on the printed pieces. Subsequent work by Knoxville-based TruDesign produced a Class A automotive finish on the completed Shelby.

"Our goal is to demonstrate the potential of large-scale additive manufacturing as an innovative and viable manufacturing technology," said Lonnie Love, leader of ORNL's Manufacturing Systems Research group. "We want to improve digital manufacturing solutions for the automotive industry."

The team took six weeks to design, manufacture and assemble the Shelby, including 24 hours of print time. The new BAAM system, jointly developed by ORNL and Cincinnati Incorporated, can print components 500 to 1000 times faster than today's industrial additive machines. ORNL researchers say the speed of next-generation additive manufacturing offers new opportunities for the automotive industry, especially in prototyping vehicles.

"You can print out a working vehicle in a matter of days or weeks," Love said. "You can test it for form, fit and function. Your ability to innovate quickly has radically changed. There's a whole industry that could be built up around rapid innovation in transportation."

The Shelby project builds on the successful completion of the Strati, a fully 3-D printed vehicle created through a collaboration between Local Motors and ORNL.

The lab's manufacturing and transportation researchers plan to use the 3-D printed Shelby as a laboratory on wheels. The car is designed to "plug and play" components such as battery and fuel cell technologies, hybrid system designs, power electronics, and wireless charging systems, allowing researchers to easily and quickly test out new ideas.

Source: Oak Ridge National Laboratory

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Sculpting costumes with 3-D printers is 'the way theater is headed,' say theater education experts

Baylor junior Mackenzie Dobbs, a theatre performance major, in a witch's costume decorated with beans and mushrooms produced from a 3D printer. Credit: Drapers: Sylvia Fuhrken and Ryan Schapp, Photo by Jared Tseng

Three-dimensional printers, which already have churned out jewelry, prosthetic limbs and one fully functioning car, are taking the stage -- literally -- in another arena: live theater.

They allow greater speed, flexilibity, creativity -- and can appease directors who change their minds mid-rehearsal.

Synthetic beans and mushrooms -- accessories for the cursed, hump-backed witch in a Baylor University production of the musical "Into the Woods" -- recently emerged from a little machine tucked away in a corner of the costume shop at Baylor. And that's only the beginning for the new printer, says former Disneyland costume designer/wardrobe coordinator Joe Kucharski, assistant professor of theatre arts at Baylor.

Using his computer mouse and some free software, Kucharski tugged, flattened and pinched a digital "ball of clay" into the desired shapes: rotting vegetables, including two dozen beans and a dozen mushrooms. That done, the 3D printer heated and spun plastic cord into the delicate thread to create the costume elements for the witchy wardrobe.

Depending on the size and how complicated a design is, 3D printing may take 20 minutes to a couple hours.

"You can set a few buttons and walk away during printing," Kucharski said. "You can customize and print multiples, and you can use colors that are the whole range of the rainbow.

"Designers are always thinking, 'How can we design quickly but keep it adjustable so we're ready if the director says, 'Well, we're kinda there. . .'? We can go back and tweak quickly."

The printers have been used in film and fashion, and "it's a great application for scenic design in theater, too," he said. "You can use miniatures created on a small-scale model and save time instead of carving little details."

The 3D printer is rapidly becoming part of the "designer tool bag." While students still need to learn traditional drawing and creating, incorporating 3D technology into curriculum for costume and prop design can give them an edge in the job market.

"This is the way theatre is going," said Stan Denman, Ph.D., chair and professor of theatre arts at Baylor. "This even lets us create items that are no longer being produced -- like brooches or hatpins -- for period plays. Otherwise, because those things are antiques, the cost is prohibitive.

"This also can be helpful if you have an item that has to be broken in a scene," he said. "You can have multiple items to replace it for repeat performances."

Source: Baylor University

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Printing in the hobby room: Paper-thin and touch-sensitive displays on various materials

Paper- thin and touch-sensitive displays on various materials.
Credit: Image courtesy of University Saarland

Until now, if you want to print a greeting card for a loved one, you can use colorful graphics, fancy typefaces or special paper to enhance it. But what if you could integrate paper-thin displays into the cards, which could be printed at home and which would be able to depict self-created symbols or even react to touch? Those only some of the options computer scientists in Saarbrücken can offer. They developed an approach that in the future will enable laypeople to print displays in any desired shape on various materials and therefore could change everyday life completely.

For example: A postcard depicts an antique car. If you press a button, the back axle and the steering wheel rim light up in the same color. Two segments on a flexible display, which have the same shape as those parts of the car, can create this effect. Computer scientists working with Jürgen Steimle printed the post card using an off-the-shelf inkjet printer. It is electro-luminescent: If it is connected to electric voltage, it emits light. This effect is also used to light car dashboards at night.

Steimle is leader of the research group "Embodied Interaction" at the Cluster of Excellence "Multimodal Computing and Interaction." Simon Olberding is one of his researchers. "Until now, this was not possible," explains Olberding. "Displays were mass-produced, they were inflexible, they always had a rectangular shape." Olberding and Steimle want to change that. The process they developed works as follows: The user designs a digital template with programs like Microsoft Word or Powerpoint for the display he wants to create.

By using the methods the computer scientists from Saarbrücken developed, called "Screen Printing" and "Conductive Inkjet Printing," the user can print those templates. Both approaches have strengths and weaknesses, but a single person can use them within either a few minutes or two to four hours. The printing results are relatively high-resolution displays with a thickness of only 0.1 millimeters. It costs around €20 to print on a DIN A4 page; the most expensive part is the special ink. Since the method can be used to print on materials like paper, synthetic material, leather, pottery, stone, metal and even wood, two-dimensional and even three-dimensional shapes can be realized. Their depiction can either consist of one segment (surface, shape, pattern, raster graphics), several segments or variously built-up matrixes. "We can even print touch-sensitive displays," says Olberding.

The possibilities for the user are various: displays can be integrated into almost every object in daily life -- users can print not only on paper objects, but also on furniture or decorative accessories, bags or wearable items. For example, the strap of a wristwatch could be upgraded so that it lights up if a text message is received. "If we combine our approach with 3D printing, we can print three-dimensional objects that display information and are touch-sensitive," explains Steimle.

Source: University Saarland

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Smelly discovery challenges effectiveness of antimicrobial textiles

University of Alberta textiles scientist Rachel McQueen has found that anti-odor clothing may not be living up to its promise. Credit: University of Alberta

Anti-odour clothing may not be living up to its promise, and an ALES researcher is saying it could all be a matter of how the product was tested.

In two separate experiments, Human Ecology researcher Rachel McQueen and her team found that some antimicrobial textiles were far more effective at performing their advertised tasks in the lab than in testing on humans. In one experiment, the fabrics were designed to help lower the risk of infection; in the second, the fabric was treated with a silver compound, which can be marketed preventing odour in clothing.

"We aren't necessarily seeing the same results in the lab about antimicrobial activity translating into antimicrobial activity when we're wearing them next to our bodies in real life," she said.

The first experiment analyzed the effectiveness of three different textiles coated in antimicrobials triclosan, a zinc pyrithione derivative and a silver chloride-titanium dioxide compound. After putting the fabric on people's arms under plastic film for 24 hours, the silver-chloride titanium dioxide compound hardly eliminated any bacteria. Overall, they found the in vivo -- tested on humans -- results were not comparable with in vitro -- tested in the lab -- results in how they prevented microorganisms from surviving in the textile.

The second test had similar results, and tested whether polyester textiles treated with bioactive concentrations of an antimicrobial silver chloride compound reduced armpit odour and bacterial populations. Although lab testing showed antimicrobial activity, the treated fabrics did not lower odour or bacterial intensity in in vivo testing.

McQueen said that anything from sweat to the proteins in the human body can disrupt the antimicrobial properties of a fabric.

"In reality, when it goes to the point that it gets put on a textile... it may not have the same level of effectiveness as the ones they studied," she said.

McQueen said these findings highlight the importance of in vivo testing, which is less common than in vitro testing, in textile product development. But, because the textiles appear to be effective at reducing bacteria in the lab, she said they may be advertised as being anti-odourous, although they may not necessarily be so when actually worn.

So, for now, McQueen suggests thinking twice before trusting textile's advertised claims.

"It's just a real spectrum to how effective they may truly be. So I'd probably say, from a consumer's point of view, if you're actually buying something that says it's antimicrobial, it may not be," she said. "I think that's important to consider in relation to a lot of claims made about textiles, that is, to be skeptical about the claims marketers make."

McQueen's research was recently published in the International Journal of Clothing Science and Technology.

Source: University of Alberta

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