In the fourth assignment, Talents are challenged to come up with an end-product application and design for ‘Paper Rapid Prototyping’ (PRP).

PRP technology is at the moment only used for prototyping purposes and does not offer the same design freedom and strength as for example Laser Sintered (SLS) Polyamide. But with a significantly lower build material cost price, it can be up to 25 times cheaper than SLS. The paper printer that FOC uses is called Mcor matrix (WIRED publication). FOC has always tried to push the Rapid Manufacturing (RM) envelope, but has not yet explored the PRP opportunities fully.

Therefore the Talents are asked to come up with two things:
1.    One new PRP end-product application that is commercially interesting
2.    One design for the end-product application that has been selected

PRP design rules
•    The maximum build volume is 297x210x150mm. Just as with other 3D printing technologies multiple parts can be printed simultaneously in the build chamber.
•    The resolution is 0,1 millimeter (thickness of the paper sheet)
•    As long as it is A4 sized, different paper sheets can be used in one model. For example used paper or colored paper
File requirements
•    Closed geometry: All the objects that make up your model must be closed or “watertight”. It is important that the file has no interpenetrating bodies, no leaky manifolds and there is one continuous surface
•    Turn off smooth shading while modeling: Smooth shading is controlled by your software and hardware and changes the look of the geometry. If possible use a faceted shading method that allows you to see each polygon explicitly. This is really how smooth your physical model will be when printed
•    Feature size: In general avoid small perimeters perpendicular to the build axis. Thin walled features as small as 1mm can be built as long as the cross-sectional area of the part is sufficiently large to hold this feature. Small perimeters are generally difficult to successfully build due to the post weeding process
•    Structural strength: If a model needs to support its own weight or the weight of an object, consider the laws of physics and avoid very delicate features supporting mass

E-mail the following to [email protected] before December 1st 2010 at 11:59pm CET:
•    PDF-file explaining why the selected product application is perfect for PRP
•    3D-file of your design in STL-format
•    2 renderings of your design

General info*
First Prize: The winning Talent will receive €250,-.
Runners up: The best entries will be added to the FOC Online store. Royalties are 5%.

3d printing in paper

*Only submissions from pre-selected FOC Talents will be reviewed for this design brief! In exceptional cases FOC will invite additional Talents to the network. If you are an exceptional designer with advanced CAD skills and 3D Printing experience, you can apply by sending your portfolio to [email protected]