Computational Science

Computational Science | An emerging discipline that unites computer science and mathematics with disciplinary research in biology, chemistry, physics, and other applied and engineering fields. It is already being called the third science, complementing theoretical science and laboratory science. Computational science requires a collaborative effort across traditional academic disciplines. Work in computational science can lead to significant advances in areas such as structural biology, drug design, materials science, high energy physics and global climate change. One of the major focuses of computational science is on the knowledge and techniques required to perform computer simulation and modeling. In fact, in the design of automobiles and airplanes, simulation is being exploited in an effort to reduce the costs of prototypes, test models, and wind tunnel testing. Programs in computational science are widespread at Universities and Colleges, and are being introduced into the K-12 curriculum. The National Science Foundation supports computational science, claiming that it is “proving to be an effective way to generate new knowledge.” http://www. buffalo.edu/ccr.html

Program: Demonstrate excellent written and verbal communication skills. Show an aptitude of learning new skills and technologies. Enable research and scholarship by providing access to high-performance computing, data, and visualization resources. Provide a wide range of guidance and services to facilitate research including software development, data analytics, and parallel computing. Provide education, outreach, and training. Foster economic development and job creation in Sullivan County and NYS by providing local industry with access to advanced computing/data resources, including hardware, software and consulting services.

 

Gifted t Play: IOT Media Center

High-end visualization; prototype and  test models using 3D printing.

 

3D Printing is more than just prototyping. Today, 3D Printing offers transformative advantages at every phase of creation, from initial concept design to production of final products and all steps in between. Today’s competitive environment makes 3D printing creation more important than ever. giftedatplay.org

 

 

 

 

 

 

Concept Models

Improve the early design decisions that impact every subsequent design and engineering activity.

 

Selecting the right design path reduces costly changes later in the development process and shortens the entire development cycle, so you get to market sooner. Whether designing new vehicle components, power tools, electronics, architectural designs, footwear or toys, 3D printing is the ideal way to evaluate alternative design concepts and enable cross-functional input from all stakeholders so they can make better choices.

 

Functional Prototypes

As product designs begin to take shape, designers need to verify and test design elements to ensure the new product will function as intended.

 

3D printing allows design verification to be an iterative process where designers identify and address design challenges to spur new inventions or quickly identify the need for design revisions.  Applications may include form and fit, functional performance, assembly verification and aerodynamic testing, to name a few. Prototypes provide real, hands-on feedback to quickly prove design theories through practical application.

 

Pre-Production

In the final design, attention rapidly turns to manufacturing start-up.

 

This stage often involves significant investment in the tooling, jigs and fixtures necessary to manufacture the new product. At this stage the supply chain expands with purchase commitments for the raw material and other required components. Lead time for these required items can stretch out time to market, and 3D printing can, in a variety of ways, reduce the investment risk and shorten the time cycle for product launch.

 

Digital Manufacturing

3D printing technologies can print virtually unlimited geometry without the restrictions, providing designers greater design freedom to achieve new levels of product functionality.

 

Manufacturing costs are reduced by eliminating time and labor-intensive production steps, and reducing raw material waste typical with traditional subtractive manufacturing techniques. 3D printed components may be end-use parts or sacrificial production enablers, such as casting patterns, that streamline production flow. Leading companies in industries as diverse as jewelry, dental, medical instruments, automotive, electronics and aerospace have adopted 3D printing to produce end-use parts, casting patterns or molds. Doing so reduces manufacturing costs, increases flexibility, reduces warehouse costs and logistics.

 

File-to-Finished

Depending on the vendor and the specific 3D printing technology.

 

The ease-of-use notion is also a factor with a significant impact on the perceived and actual speed to obtain finished parts, with different levels of automation, involving a lower or higher level of manual labor skills and time. In most cases, the build preparation can be done from any workstation on the network. Software used by desktop and office environment printers allow a fully automated and fast print job setup and submission, with automated part placement within the build area and automatic support generation when required. Recent remote control and monitoring applications from tablets and smart phones further increase productivity and limit down times, with the same controls as onboard.

 

Cost

This is typically expressed in cost per volume, such as cost per cubic inch.

 

Costs for individual parts can vary widely even on the same 3D printer depending on specific part geometry, so be sure to understand if the part cost provided by a vendor is for a specific part or a “typical” part that is an average across a group of different parts. It is often helpful to calculate part cost based on your own suite of STL files representing your typical parts to determine your expected part costs.

 

Resolution

One of the most confusing metrics provided on 3D printers is resolution

 

Resolution may be stated in dots per inch (DPI), Z-layer thickness, pixel size, beam spot size, bead diameter, etc. While these measurements may be helpful in comparing resolution within a single 3D printer type, they are typically not valid comparison metrics across the spectrum of 3D printing technologies.

 

Accuracy

3D printing produces parts additively, layer by layer

 

using materials that are processed from one form to another to create the printed part. This processing may introduce variables, such as material shrinkage, that must be compensated for during the print process to ensure final part accuracy. Powder-based 3D printers using binders typically have the least shrink distortion attributable to the print process and are generally highly accurate. Plastic 3D printing technologies typically use heat and/or UV light as energy sources to process the print materials, adding additional variables that can impact accuracy.

 

Material

Understanding the intended applications and the needed material characteristics.

 

Each technology has strengths and weaknesses that need to be factored in. Claims about number of available materials should be viewed with caution as that does not guarantee the available materials will provide the real functional performance needed. It is vital that printed parts are tested in the intended application prior to making a purchase decision. Stability of parts over time and across various use environments are not discernible from standard published specifications, and they may lead to limitations in actual usefulness if not fully considered and tested.

 

Print

The Functional prototyping stage is critical to print full-size parts to test product functions.

 

Printing several iterations of the same part at once can also be beneficial to speed the product development cycle and improve product quality by testing more design options. The largest build volume is available with Stereolithography technology, with a printing length of up to 1500 mm, allowing engineers and designers to print complete dashboards, for instance.

 

Color

Depending on your applications, color may or may not be important to you.

 

If so, you’ll require a higher or lower level of color quality from a 3D printer. If you are printing conceptual models, architectural models, figurines, medical models, or artistic pieces, then clearly color is important to your models and their application. While it may only be necessary to label a certain area of the model one color, many designers want to be able to present their designs as the final product would look in real life, not just geometrically. Such a model is critical to their design process and is used to convey the concept of the final part.

 

3D printing

The entire creation process from initial concept design to final manufacturing and all steps in between.

Different applications have unique needs and understanding those application requirements is critical when choosing a 3D printer. Multiple systems may offer broader use opportunities than a single system. Thus, identifying your unique requirements within your entire design-tomanufacture process will help you select the ideal 3D printing technology and help you optimize the benefits of 3D printing: shorter time-to-market, improved product performance, streamlined and cost-reduced manufacturing, and improved product quality and customer satisfaction.

 

The most common technologies used in 3D printers are: 
• SLA (Stereolithographic Apparatus):

SLA printers use vats of liquid photopolymers that can be cured by UV light. A beam of UV light traces patterns on a layer of photopolymer, which solidifies and joins the layer below it. This allows for the creation of complex patterns and designs at relatively high speeds. 

• FDM (Fused Deposition Modeling):

In FDM printers, a thin filament of thermoplastics (i.e., plastics that melt when heated, solidify at room temperature) is fed into a nozzle. The nozzle heats up and melts the plastic, which is then deposited in successive thin layers to build 3D models. The low cost and relative simplicity of the FDM process makes it ideal for use in consumer 3D printers. 
      
• SLS (Selective Laser Sintering):

In this technology, a high-power laser is used to melt and fuse powdered plastic, ceramics or metals. The laser traces pre-determined patterns around the powdered material, which fuses together to create 3D objects. If the powdered material in question is a metal, the process is called direct metal laser sintering (DMLS). SLS can work with a range of materials, which makes it suitable for use in low-volume manufacturing and advanced prototypes. 

• PolyJet:

PolyJet technology was developed by Israel-based Objet Systems. It borrows elements from SLA and 2D inkjet printing technology. This involves jetting drops of liquid photopolymer on a build tray, which is subsequently cured via UV light. PolyJet technology is fast and can be used with a wide range of build materials.