3D Printed Medal and Trophy

IMG_20181024 3D Printed Trophy Medal

As a product designer focused on 3D printing in my job at the University of Technology Sydney, it was no surprise that I found myself being asked to design some 3D printed awards for the end of year 2018 Vice-Chancellor’s Awards for Research Excellence. And while not receiving an award (yet!), I think it’s even more fun to get to be designing them – besides, now I can print them out for myself!

I was asked to design 2 different awards which you can see pictured above. The first were a set of 3 medals, and my only brief was to have them 3D printed in metal, and for them be approximately the size of previous medals given out for the awards. I based my design on a spinner concept which I’ve previously printed, with an important feature being the cone-like details which hold this assembly together when printed as a single part. There is no support material required, with one of my goals being to highlight through the design the capabilities of 3D printing in metal. For recipients, my goal was to create something playful and engaging, rather than most medals which are kept in a case and quickly forgotten. Thanks to my friend Olaf Diegel at Lund University for printing these in aluminium and sending them to us in time!

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For those familiar with metal 3D printing (Direct Metal Laser Sintering to be specific), you can probably guess there was a lot of manual post-processing of these medals to remove the base supports and polish the surfaces. Below you can see the medal as it comes out of the printer on the left (once cut from the build plate), and the final polished version on the right. All of the base support material you can see in the raw version had to be filed away while held in a vice, before going through a lengthy process of polishing. Slow, painful work, but you haven’t truly 3D printed in metal until you’ve gone through this process, it makes peeling away plastic support material from FDM prints seem like child’s play!

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The second award was a trophy which also continued with the 3D printed assembly concept. My only brief for this design was for it to be printed on our own HP Multi Jet Fusion 3D printer, which is very similar to SLS printing. Many of us have seen the “ball in a ball in a ball” type of prints which are often shown at 3D printing expos and events, and I built off this to incorporate a lattice frame to contain the balls. The basic design was done in Solidworks, however, the balls were just solid spheres at this stage. I then exported them into Meshmixer in order to apply a lattice structure to them, using 2 different geometries. All parts were then imported into Meshmixer in order to export them as a final fully assembled file ready for printing.

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A little bit of laser cutting and timber work by a colleague really helped bring the design to life, and again, the trophy encourages interaction and play. Congratulations to the winners and finalists, I hope you enjoy your awards as much as I did creating them. With any luck I might get to design them again in 2 years and bring one home myself for real! 😉

– Posted by James Novak

WTF, a low-poly goat?

20160322_3D Print Trophy

Yes, a low-poly goat. A few in fact.

These are 2 trophies that I’ve 3D printed for my second year class at Griffith University as awards for their current project designing lights for Yellow Goat. Nothing beats getting the students to work on real projects with industry, and adding an extra incentive with these trophies adds an extra competitive level and of course bragging rights for the winners! If you look back to one of the largest 3D printing projects I’ve tacked using desktop machines, the Mario Kart Trophy, you’ll see it’s not the first time I’ve used 3D printing to create a custom trophy. It’s turning out to be a great application of 3D printing since you can get really creative and produce them very cheaply (I wonder if trophy manufacturers are using 3D printing?). On the left is the trophy for the best design as picked by the team from Yellow Goat, and the trophy on the right is for the best team leader, chosen by averaging the marks of all team members and finding which team overall has the highest marks.

20160323_Rhino Low Poly

The 3D CAD modelling of this design was not as straight forward as most of the other designs on my website, so here is my workflow in case you’d like to try something similar (you don’t need the same software, just to understand the process):

  1. Trace the outline of the Yellow Goat logo (shown above right) in Adobe Illustrator. Export as a .dxf file, providing accurate 2D line-work to use in the 3D CAD model (you could just bring the image directly into your CAD software if you prefer).
  2. Import the .dxf file into Solidworks. Use this line-work to base your 3D modeling off. I also created some guide lines to ensure that my model would fit onto my desktop 3D printer without needing to scale later.
  3. Export the final model from Solidworks as a .IGS file.
  4. Import the .IGS file into Rhino. The model in the image above on the left is the imported model from Solidworks (yes you could just model the design in Rhino to begin with, however I knew I could get to this point much faster in Solidworks).
  5. Use the “Reduce Mesh” tool in Rhino to reduce the number of faces of the mesh. I reduced mine by about 93%, resulting in the low-poly model shown above. It’s also possible to do this type of low-poly conversion using the free software MeshLab, just click here to read one of my previous posts about how to do this.
  6. Because 93% is a huge reduction, the resulting mesh did have some gaps where the software didn’t know what to do, so was not watertight (manifold) and ready to 3D print. I manually cleaned up some of the edges and added some surfaces to fix this issue.
  7. Export as .stl and 3D print!

20160321_Yellow Goat

As you can see I still ended up splitting the large goat piece in order to minimise support material, printing the body piece upside down with the legs in the air and gluing the head back on later. It took a few prints to get the smaller goat right, the middle image above showing some of the messy surfaces I was getting from the Up! Plus 2 printer I used, surprising since it’s normally very good. The ABS seemed a little more sticky than normal as well, meaning the support material didn’t just peel away but had to be scraped and cut, making more of a mess. But third time lucky! I also downloaded the human figure from Thingiverse to again save some time, and it gives the effect I wanted anyway. A bit of chrome spray paint, a chipboard base and voila!

Check out the 3D model above for the full effect of the low-poly design!

– Posted by James Novak