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The Fastest Way to Create Tangible Color Models from CAD Data

Introducing Z Corporation High Definition, Low-Cost 3D Printers

Introducing Z Corporation

Introducing Z Corporation
Z Corporation is the Growth and Innovation Leader in 3D Printing 2,500 customers worldwide

Located in Burlington, MA USA (Boston Area)


125 distribution partners worldwide Quick facts from 2005
Z Corporations 3D Printer shipments grew 60%, with revenue growth over 50% Z Corporation launched new products across the line-up in 2005, with more than 70% of revenue coming from new products by year end Z Corporation launched the award-winning Z510 Spectrum Full Color, High Definition 3D printer

Z Corporation has created the category of high speed, low cost, full color 3D printing

Markets We Address
We expect to be the 3D printer of choice for all forms of 3D Data
Entertainment

Medical Product Design

Architecture/ Engineering/ Construction

Education

What is 3D Printing?

A 3D Printer is an Output Device for 3D CAD Data

3D CAD File

3D Printer

3D Model

How it Works
Software "slices" CAD file into thousands of thin layers Physical model is built one layer at a time Ink-jet print heads deposit binder into powder to create layers

1
Spread Layer of Powder

2
Print Cross-Section

3
Spread Layer of Powder

Mainstream 3D Printing vs. Narrowuse Rapid Prototyping & Mfg.


Old Rapid Prototyping Uses: functional testing, late form & fit Need material strength, tooling-level accuracy Tradeoffs; very high cost, slow, monochrome, difficult-to-use

Mainstream 3D Printing Uses:


Design concept visualization Early form & fit testing Wide-ranging engineering, sales, & marketing applications

Needs
Very low cost for everyday use Very fast print speed High-definition resolution Full-color, graphics, annotation Easy to use

Rapid Manufacturing Uses: short-run, end-use parts Need: material strength, tooling-level accuracy Tradeoffs; very high cost, slow, monochrome, difficult-to-use

Mainstream 3D Printing vs. Narrowuse Rapid Prototyping & Mfg.


Old Rapid Prototyping Stratasys 3D Systems Objet Table-top CNC

Mainstream 3D Printing

Z Corporation

Rapid Manufacturing 3D Systems Objet

Proven Technology

Why Use 3D Printing?

Streamline the Design Process


Create more prototypes, sooner Make ideas easier to visualize

Make decisions faster by reviewing tangible options


Identify form, fit, function errors early

Improve clarity of communication with suppliers, vendors, prospective customers


Output a single data file on printers in multiple locations. Instantly collaborate on design revisions

Physical Models Enable You to Communicate More Clearly

Jumpstart Sales & Marketing


Create physical representations of concepts to win business even before the design process begins

Create realistic prototypes for focus groups


Affordably produce a variety of options, styles, fashions Develop and evaluate packaging options Begin selling before manufacturing delivers product

Explore Design Concepts

Evaluate Style, Fashion, Packaging, Feel, Size

Evaluate Form, Fit, Ergonomics, Assemblies

Improve Production Planning

Color-code assemblies, tooling components, or machining surfaces to clearly communicate process steps

Display Engineering Analysis

Apply Cosmetic Finishes

Applications in Architecture

Applications in Architecture

Applications in GIS

Applications in Medical Modeling

Z Corporation Advantages

How to Evaluate 3D Printers


How quickly do you need your parts?
In the next hour? This afternoon? Tomorrow? Next week?

How quickly does the person after you need their part? What can you afford to pay for each model?
$10? $100? $1,000?

Are your designs simple or complex?


All Prices in US $

Breakthrough Advantages of Z Corporation Technology


High-definition resolution Only color printers available

5-10x faster than other technologies


Lowest cost per-system and per-part

Large enough for substantial models, or to print multiple models at once

High-definition for Exceptionally Realistic Parts

High Definition Parts are Museum Quality NY Museum of Modern Art


Celebrating 20 Years of Pixar

Poor Definition of Other Technologies


Others

Z Corp. High Definition

Exclusive 24-bit Color

Why Color?
Real Product
- More lifelike prototypes - Shape and size are only two aspects of the design. Color is the third.
Color had a much bigger impact on our design process than we ever imagined. We knew it would save time and enhance communication, but its really been a giant leap forward for us. It wont make monochrome prototyping obsolete, but it has dramatically accelerated our progress from simple sketches to success on the market Paul Bates Reebok International

Z Corp Part

Multi-Color Parts Without Paint

Labeling and Annotation

Breakthrough Speed
Print a typical handheld part in < 2 hours
1-2 vertical inches (25-50 mm) per hour

5-10x faster than all other technologies


Print multiple prototypes at one time Ability to service the queue
When will the Nth engineer get his part?

Print Multiples in the Same Time Period


Z Corporation

Competition

The Value of Speed to a Team

Lowest Cost System-wide


Lowest system purchase price in its class Lowest operating cost; $1.50 - $2.00/cubic inch ($0.10/cm3) Lowest cost/model (a typical handheld part costs $10) Lowest maintenance costs
Features modular components for fast & inexpensive servicing

Freely print parts on a low operating budget

All Prices in US $

Lowest Cost of Materials

Source: T. A. Grimm & Associates, May, 2005 Rapid Prototyping & Manufacturing Conference

All Prices in US $

The Value of Combining Low Cost with High Speed


Cost & time to print this 32.5 in3 part

# Parts

Cost

Hours

Z Corp. Others

1 1

$60 $246

9 77

Z Corp. Others

10 10

$600 $2,460

90 770

Z Corp. Others

120 120

$7,200 $29,500

1,080 9,240

All Prices in US $

Why Stripped-down, Old RP Technologies Do Not Work in 3D Printing Applications

Dimension
Models with MSRP
BST 768: $18,900 BST 1200: $21,900 SST 768: $24,900 SST 1200: $29,900

Stratasys Dimension Low-end Rapid Prototyping


5-year-old technology at the end of its life cycle Painfully slow (the larger the part, the slower the build)

Average-to-poor surface finish


Lack of fine feature detail

Dimension; Dual-tip Extrusion (Hot Glue Gun)


Like an old pen plotter Dual-tip design causes interference & distortion to adjacent vertical geometry

Breakthrough Speed
Time needed to print this 32.5 in3 part
Z Corp. Others

9 Hours 77 Hours

Dimension; Slow Print Speed


Part after 2 hours using Dimension Identical part after 2 hours using ZPrinter

To complete this part would require 18 hours

Dimension; Slow Print Speed


This part requires 35 hours to print

Dimension; Poor Resolution


Dimension Specs: .012 tip x .010 layers

Spectrum Z510 Specs: 600 dpi x .003 layers (45x better resolution)

Dimension; Coarse Surface Finish

Dimension; High Cost to Own & Use


Cost of Printing Two 48-in3 models per week Dimension

ZPrinter 310

All Prices in US $

Dimension Materials 1000 in3


$250/reel 58 in3 per reel

You need support, so figure at least 30%


1300/58 = 22 reels

22 x $250 = $5,500

$5,500

All Prices in US $

Materials Comparison 1000 in3

Z Corp: $1,650

Dimension: $5,500

All Prices in US $

We are the Lowest Cost Solution


Dimension BST
$18,900

ZPrinter 310 Plus


$19,900 ZD5: $1,900

Materials
$5,500

Materials
$1,650

Training
$1,000

Training
$1,000

90 Day Warranty

$25,400 Package Price

90 Day Warranty

$24,450 Package Price

All Prices in US $

We are the Lowest Cost Solution


Dimension SST
$24,900 Tank: $3500

ZPrinter 310 Plus


$19,900 ZD5: $1,900

Materials
$5,500

Materials
$1,650

Training
$1,000

Training
$1,000

90 Day Warranty

90 Day Warranty

$34,900 Package Price

$24,450 Package Price

All Prices in US $

ZPrinter 310 Lower Cost of ownership than Dimension


Cost of Equipment + first 1,000 in3 (16,400 cm3) of material

$24,450

$25,400

All Prices in US $

Dimension SST Option


$6K price-adder for SST 768 material print head $8K price-adder for SST 1200 material print head

$3,500 additional for removal tank


Not office compatible requiring gloves & facilities to drain tank periodically

Soluble supports
Still requires some manual removal Phosphate bath must be replaced for every 30 cubic inches of material dissolved Supports dissolve in 3 hours, longer for larger parts

All Prices in US $

Dimension SST Option


$6K/$8K addition for SST material head $3,500 additional for removal tank Not office compatible requiring gloves & facilities to drain tank periodically

Soluble supports Still requires some manual removal Phosphate bath must be replaced for every 30 cubic inches of material dissolved PS400 media (Water works liquid) has a PH rating falling between Ammonia and Lye. Heavy dilution and/ or chemical services needed for disposal Supports dissolve in 3 hours, longer for larger parts Occasional leakage of solvent into hollow part geometry (Keep parts on sponges, rags, and cloth for hours or days)

Dimension Support Structures

The Dimension process involves physical support structures that must be painstakingly removed with tools

Dimension Tools for Removing Support Structures


Exacto knife
To cut away supports & base

Sharp metal spatula


To cut between the part & support structure

Dimension Part Processing

Support Structure = Waste Base = Waste

Step 1 Remove part with base and support structure from Dimension printer

Dimension Part Processing

Step 2 Attempt to tear part from support structure. Support structure cracks

Step 3 Cut support structure from the rest of the base

Dimension Part Processing

Step 4 Begin removing support structure

Dimension Part Processing

Step 5 Continue to cut away support structure. Difficult because tools do not reach all surfaces

Dimension Part Processing

Step 6

Remove base & discover more material to be removed

Dimension Part Processing

Step 7

Locate & unpack the correct size and number of picks, files, tweezers, and other accessories included in Dimension Starter Kit

Dimension Part Processing

Step 8
Process continues

Step 9
And continues

Dimension Part Processing

Step 10

Conclude by sanding finish with 220/320-grit wet/dry sandpaper included in Dimension startup kit

Case Studies

Case Study: Continental Tire


#1 maker in Germany, sold worldwide as Continental, General Tire, Uniroyal Need Multiple tread samples for timely product development decisions Solution; ZPrinter 310 Results Rapid prototypes 5x faster Reduced prototype costs 50% Flexibility to develop, discuss, debate and refine tread designs Were making more money by making prototypes for our sales force, giving them something concrete and convincing to show major auto companies. Matt Lamb, Tire Designer

Case Study: Black & Decker


Global manufacturer of DEWALT, Porter-Cable, and Delta tools Need Fast, cost-effective early concept models Solution; ZPrinter 310 Results
Compressed design cycles Enhanced product aesthetics, ergonomics Improved resource utilization

We have been able to reduce model production time by as much as 75 percent. John Reed, Master Prototype Specialist

Case Study: Timberland


Global leader in premium-quality footwear, apparel and accessories Need; More shoe prototypes, sooner, to evaluate comfort, performance, marketability Solution - Spectrum Z510 Results
Reduced prototype cost 80-fold Reduced prototype production time from one week to 90 minutes Reduce design time 33 percent Increased sales using 3D prototypes instead of 2D sketches

We can now quickly do innumerable iterations and variations, and the designers and marketing managers can really be sure the product is what [people on the street] are demanding. Toby Ringdahl, CAD Manager

Trinity Products
$10 million manufacturer of remote-controlled cars Need rapid prototypes for form, fit, function testing Solution; ZPrinter 310 for highresolution parts (even 1/18 scale) Results
Prototypes now strong enough for functional testing 80% time savings printing parts Cut design cycle 50% Eliminated earlier $800/part cost

the the single biggest step weve taken to improve the way we refine concepts, develop products, communicate with suppliers, and market products. Mike Wood, Chief Engineer

Case Study: Caterpillar Inc.


Worlds leading manufacturer of construction and mining equip. Need: Faster way to produce prototype castings to accelerate design changes. Solution: Z810 & ZCast process Results Reduced casting development time 70% Accelerated design changes Increased prototyping capacity 60% Reduced cost/prototype 50%

We can generally produce castings in a third of the time it used to take (5 days vs. 3 weeks), and at less cost. Joe Taylor, RP Team Leader

Case Study Jerde Partnership


Architects just cant collaborate around a napkin or computer file the same way they can around a physical model. Architects need to literally walk around a design, get their hands on it and maybe mark it up with a pen. This process is as vital as presenting to the client and just as rigorous? Al Vass Associate VP

Case Study: Motorola V70

Motorola V70 Concept Testing

Motorola V70 Engineering

Motorola V70 Value


No 3D data is released to create solid visual models without first making a model

Mistakes caught before data released for tooling


Designers work closer with engineers and human-factors teams when developing products

Changes & revisions happen faster

Case Study: University of Michigan


Broad curriculum support Study of EM wave propagation

Plasma cutting template


Study of ultrasound flow phantoms Architecture program Investment casting study

Case Study Oliver Wolcott Technical School


Machine Drafting students measure a real part & create that part in 3D CAD Part is made on 3D printer Students compare actual part with the Z Corp. part After completion of this project, students create their own 3D CAD design & Zprint All students trained on the Z Corp. printer & actively use it

THANK YOU

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