.FLYINGHEAD COOL TOOL OF THE MONTH
.TITLE Got fab? Rapid fabrication (scan-modify-mill) solid objects right on the desktop
.AUTHOR Richard Siderits
.SUMMARY In this incredible article, Dr. Richard Siderits shows us how it’s possible to create an entire fab lab on the desktop. Using a shockingly inexpensive 3D scanner, along with a CNC milling machine and fourth-axis technology, he shows how we can scan, modify, and mill solid objects, all on the desktop. "I want it!" is a wild understatement.
.OTHER
In the medical field where I work, rapid prototyping can be essential for both research and patient treatment. Finding technology that supports this kind of need-it-now fabrication (NIN-Fab) is critical. At $2,500 the [[http://www.nextengine.com|NextEngine]] is a remarkable piece of technology. Scanning in at 127 micron (0.005 inch) resolution, it will do 360 degree scans of anything from bones to brains.
The setup is a breeze and takes takes about 4 minutes (if you stop to read the quick start instructions). Aside from being one of the coolest looking things on your desk, this scanner gives you unprecedented capabilities when combined with a small but robust suite of "MAKER-tools".
Figure A shows an image of the NextEngine scanner in its "native habitat", on the desktop. Compact and sleek the anodized aluminum surfaces conceal a powerful desktop 3D laser scanner. That’s a human finger bone on stage. The support arm is detachable for larger objects.
.FIGPAIR A Here’s an image of the NextEngine scanner in its "native habitat", on the desktop.
Teaming the NextEngine laser scanner with [[http://www.caligari.com|Caligari]] trueSpace 3D authoring software, the [[http://www.gravers.com/mdxcombo.html|Roland MDX15 CNC milling machine]], including the [[http://www.fourth-axis.com|Fourth Axis]] attachment gives you incredible flexibility.
.TEASER To learn how it all works, tap here.
.H1 How it all works
Use the NextEngine laser scanner to scan objects into your 3D graphics program for modification. Then output them to solid form using MDX15 CNC fourth axis milling machine. In other words Scan-Modify-Mill solid objects, all on your desktop!
Here’s a practical example of how we approach this aspect of rapid fabrication in our prototyping lab. laser scan an object with Nextengine.
Take the object into a program like trueSpace and subtract it from a block. Send the block with the subtracted void-space to the MDX15 to create a real world solid model of the block.
This solid model can be used to create a fast-set RTV (Room Temp Vulcanization) silicon rubber mold for quick castings in plastic or even low melting point metal. You can get liquid mold rubbers and liquid casting plastics from [[http://www.polytek.com|Polytek]] and all sorts of small metalworking goodies from [[http://www.micromark.com|Micro-Mark]].
Your imagination is the only limit.
[Editor’s note: Micro-Mark is a dangerous site. Whenever I go there, my heart beats faster, sweat beads on my forehead, and I want to buy everything. So, be forewarned. –DG].
Want to have some fun? On a less practical note, the image in Figure B is of a scanned peanut re-made into the ultimate peanut-gunship. Environmentals, lighting, "helbore" turret and remapped surface textures were added in trueSpace. An animation of "lift-off" and strafing run were also accomplished in trueSpace.
.FIGPAIR B Turn your peanuts into gunships.
.H1 Bottom line
There are many advantages to this setup. The color cameras capture full-color textured surfaces, the resolution is excellent (0.005"), scans are fast. Quick takes approximately 30 seconds while Fine takes about 2 minutes.
The scanner comes complete with an auto-positioner that does automatic indexing, which automates the process of performing 360-degree scans. Also, it has an "auto-alignment" feature which allows for alignment of turntable scans without any user input and "Refine-alignment" which uses geometric analysis to make alignment of adjacent scans more precise.
The software interface is intuitive and interactive with "future-state" online support.
There aren’t that many downsides. The memory requirement for the included software is (for an average PC) a fairly chunky 2 gigabytes of RAM and the files can get big. The data is so dense that you can usually decimate the resolution up to 4 times without noticing any difference.
Artist and designer Will Huff suggests using [[http://www.mootools.com/plugins/us/polygoncruncher/index.asp|Polygon Cruncher]]. I use it as a plug-in for [[http://www.mootools.com/plugins/us/index.asp|3D Photo Browser]], which can help manage the large number of triangles making up the surface of these big files without noticeable drop in resolution. The two programs together are $129. Will has written a [[http://www.nextengine.com/community/WillHuffHowTo.pdf|great story (PDF)]] on this, which is well worth your time to read.
So there you go. You can build your own 3D fab, which can live entirely on your desktop. It doesn’t get much cooler than this.
.BEGIN_SIDEBAR
.H1 Product availability and resources
Learn more about [[http://www.nextengine.com|NextEngine]].
Learn more about [[http://www.caligari.com|trueSpace]].
Learn more about [[http://www.gravers.com/mdxcombo.html|Roland MDX15 CNC milling machine]].
Learn more about [[http://www.fourth-axis.com|Fourth Axis]].
Learn more about [[http://www.polytek.com|Polytek]].
Learn more about [[http://www.micromark.com|Micro-Mark]]. Don’t forget to hide your credit card before visiting this site. Don’t say we didn’t warn you!
Learn more about [[http://www.mootools.com/plugins/us/polygoncruncher/index.asp|Polygon Cruncher]].
Learn more about [[http://www.mootools.com/plugins/us/index.asp|3D Photo Browser]].
Read [[http://www.nextengine.com/community/WillHuffHowTo.pdf|Will Huff’s overview (PDF)]].
.END_SIDEBAR
.BIO
