I lead the design team responsible for the first object to even be printed from a Meteroite.
Planetary Resources, in collaboration with partner 3D Systems, have developed the first ever direct metal print from asteroid metals.
This spacecraft prototype was 3D printed from an actual asteroid that was pulverized, powdered, processed then printed on 3D Systems ProX DMP 320 metals 3D printer. The asteroid was melted under vacuum then gas atomized into powder by Allegheny Technologies, Inc. at their ATI Powder Metals research facility in Pittsburgh, PA.
Digital Silicone Tooling - some times known as eggshell molding - is an additive manufacturing process used for the creation of custom and complex silicone components though the printing of ultra thin single use 3D Printed Molds
This Lobbed Exhaust Mixer was design and optimized to print with the lightest structures possible. Printed in Incolne on a the 3D Systems ProX320. The DMP component is both easy to print and quick to post process enabling the users to spend more time doing whats fun, and less time cleaning parts.
The Figure 4 DLP print system is the fastest 3D Printer on the market. Deigned to optimize the dental industry among others, this small and fast printer reliably holds a 30um accuracy across a wide variety of models.
This new print system enables a wide variety of applications due to its innovative material library. Printing everything from medical devices to aerospace components is now quick and affordable.
Together with a variety of software partnerships we explored the cutting edge in topology optimization and mesostructural optimization.
These types of advanced design techniques are mainly used in aerospace applications the strongest and lightest components are critical.
We have also explored the latest 3D-printing and Investment casting techniques in further advance the field.
Most projects cant be shown due to ITAR requirements
A design exercise demonstrating the complexity that can be achieved with the correct application of the design for additive manufacturing mind set. These components were design specifically to be printed in Inconel and were optimized for the constraints of the printing process.
Not only are the internal structures optimized to reduce the sound, muzzle flash, and recoil. The exterior textures are applied digitally before the printing process occurs so that they can be quickly changed to a users needs without adding cost or time to the manufacturing process.
Designed with the intention of moving a traditionally manufactured metal box fan into the world of additive manufacturing.
The initial customers design would not print with out sever distortion that resulted in an unusable component. The design was re-engineered to minimize the distortion, while at the same time improving overall structural integrity and reducing its mass for improved efficiency.
QuickCast Diamond Structure is a long awaited improvement to a 3D Printed investment casting pattern process. Designed to reduce material consumption, while speeding up the build time. This isotropic structure elegantly eliminates many of the complex problems experienced in the investment casting industry.