On 12 July, Unitree unveiled its latest quadruped robot - the Unitree Go2, which features embodied AI technology, standard 4D ultra-wide LiDAR and GPT empowerment. This product is expected to revolutionize the consumer-grade quadruped robots industry, leading to a transformation of the sector.  

Revolution: A New Quadruped Robot of Embodied AI

Have you sacrificed many good product design features because you thought you could not make a specific precision part or it would be too expensive to outsource? That&rsquo;s ok because traditionally, it was the norm when we only had large, sophisticated, and expensive industrial machines. Not anymore since the introduction of the <a href="https://www.apsx.com/apsx-machines-compact" rel="noopener noreferrer" target="_blank">desktop machinery concept</a> hit the market. Let me explain further.In the rapidly evolving field of manufacturing, adopting advanced machining technologies is paramount for achieving precision, efficiency, and cost-effectiveness in manufacturing processes. While traditional, large-sized Swiss lathes have long been the standard for machining high-precision, turned small parts with small diameters, the emergence of desktop Swiss CNC lathes such as the APSX-NANO (costs less than $10K) has opened new avenues for machinists to expand their capabilities while simultaneously reducing outsourcing costs. This article delves deeper into the technical aspects and benefits of using a desktop Swiss CNC lathe over a traditional-sized Swiss lathe, focusing on reasons such as time savings, material efficiency through remnant utilization, extended tolerance ranges, and elimination of secondary operations.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574931645-Outsourcing-vs-In-House-Production.jpg" style="width: 428px;" class="fr-fic fr-dib">In addition to the advantages over traditional-sized Swiss lathes, a desktop Swiss CNC lathe offers compelling benefits compared to outsourcing part production to a machine shop. This article will also delve into the advantages of in-house production using a desktop Swiss CNC lathe, focusing on cost savings, increased control, flexibility, faster turnaround times, confidentiality and intellectual property protection, and the potential for innovation and skill development.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574953248-SwissCNCLathe-Large.jpg" style="width: 494px;" class="fr-fic fr-dib"><h3 id="isPasted">Why desktop size has advantages over regular-size Swiss lathes?</h3>Simplified Setup for Small Quantities: Small quantity needs can be too much hassle for large Swiss lathe setup and programming times. One significant advantage of desktop Swiss CNC lathes is the simplified setup process for small-quantity production runs. In contrast to traditional machining methods, which often involve complex and time-consuming setup procedures for large Swiss lathes, desktop Swiss CNC lathes streamline the setup and programming requirements. This enables engineers to swiftly transition from design to production, saving valuable time and resources.Time and Operation Efficiency: Time savings compared to regular CNC machines by reducing the number of operations and machine changeovers. Desktop Swiss CNC lathes are designed to save more time than regular CNC machines by minimizing the number of operations and machine changeovers. By integrating advanced automation features and efficient tooling, these machines can perform multiple operations within a single setup, significantly reducing production lead times. This enhanced efficiency empowers engineers to meet stringent project deadlines and improve productivity.Material savings by using remnants out of regular Swiss lathes: Using remnants from regular Swiss lathes is a significant advantage offered by desktop Swiss CNC lathes. In traditional machining processes, material remnants are often discarded due to insufficient length for further machining operations. However, desktop Swiss CNC lathes can effectively utilize these remnants, minimizing waste and optimizing material usage. This feature reduces material costs and contributes to sustainable manufacturing practices. You can also use precision ground bar stocks from the market. Even if you do not need to use the whole bar, you can spare it for another project.Good tolerance ranges for your precision targets: Desktop Swiss CNC lathes offer engineers ample tolerance ranges to meet their precision targets. Swiss machines&#39; distinctive sliding headstock and guide bushing enable precise machining of different diameters, complex holes, hex edges, slots, and threads without requiring multiple setups or additional equipment. This capability ensures that engineers achieve their machined components&#39; desired precision and dimensional accuracy, even for highly intricate designs.Eliminate secondary operations by using live tools for milling and drilling: The integration of live tooling in desktop Swiss CNC lathes allows engineers to eliminate the need for secondary operations. Live tools enable milling and drilling operations to be performed directly on the machine, eliminating the requirement for additional equipment or setups. This streamlining of processes saves time and enhances overall machining accuracy and consistency.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688574980383-APSX-NANO-CNC-SWISS_8.jpg" style="width: 300px;" class="fr-fic fr-dib"><h3 id="isPasted">Reasons to Opt for In-House Production</h3>One of the primary benefits of using a desktop Swiss CNC lathe in-house is the potential for significant cost savings. Outsourcing part production to a machine shop often incurs substantial costs, including markups on labor and materials, transportation expenses, and additional fees for setup and programming. By bringing production in-house with a desktop Swiss CNC lathe, these costs can be greatly reduced or eliminated altogether. The initial investment in the machine can be quickly recovered through long-term cost savings, especially for projects involving regular small-scale production runs.Increased Control and Flexibility: Maintaining control over the production process is crucial for ensuring quality, precision, and timely delivery of parts. Using a desktop Swiss CNC lathe in-house gives engineers and machinists full control over every aspect of production, from design to final machining. This level of control allows for greater flexibility in adapting to design changes, accommodating urgent orders, and making adjustments to meet specific requirements. Making real-time modifications and optimizations can result in higher-quality parts and improved overall performance.Faster Turnaround Times: Outsourcing part production to a machine shop often delays the production timeline. The need to communicate design specifications, coordinate with the machine shop&#39;s schedule, and account for shipping and delivery times can add significant lead times to the project. In contrast, using a desktop Swiss CNC lathe in-house allows for faster turnaround times. Design changes can be implemented immediately, and production can begin without external dependencies. This accelerated timeline enables engineers to meet tight deadlines and respond quickly to market demands.Confidentiality and Protection of Intellectual Property: Outsourcing part production may pose risks to intellectual property and design confidentiality. Sharing sensitive designs and proprietary information with external vendors can introduce the potential for unauthorized use or leakage of valuable intellectual property. By utilizing a desktop Swiss CNC lathe in-house, companies can maintain strict control over their designs and protect their intellectual property. This ensures that confidential information remains secure and minimizes the risk of competitors gaining access to proprietary knowledge.Potential for Innovation and Skill Development: Bringing part production in-house with a desktop Swiss CNC lathe presents an opportunity for innovation and skill development within the organization. Operating the machine internally allows engineers to explore new design possibilities, test innovative techniques, and iterate on prototypes more efficiently. The close proximity to the production process fosters a deeper understanding of the machining principles and enables engineers to enhance their skills and expertise. This continuous learning and development contribute to the company&#39;s long-term growth and competitiveness.<h3>Why a Swiss CNC is better than a traditional CNC lathe</h3>While traditional CNC lathes offer their own advantages, Swiss CNC lathes excel in specific areas in traditional and desktop sizes. Swiss turning is a process used for machining high-precision, turned small parts with small diameters. Swiss lathes&#39; sliding headstock and guide bushing system are key differentiating factors. Its sliding headstock and guide bushing set Swiss machines apart from other turning machines. The sliding headstock feeds the bar stock through a guide bushing (z-axis), which supports and stabilizes the bar stock near the cutting point. This helps prevent workpiece distortion and enables the machine to accurately create different diameters, complex holes, hex edges, slots, and threads without the need for multiple setups or additional equipment.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688575007394-20220112_FR_Render_Turning_Swiss_02-1024x576.png" style="width: 300px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688575017710-20220112_FR_Render_Turning_01-1024x576.png" style="width: 300px;" class="fr-fic fr-dib">In contrast, traditional CNC lathes lack the sliding headstock feature and are more suited for larger parts and different machining requirements.Swiss machines are also better suited for machining long parts than traditional CNC turning machines, as they are less likely to cause deflections. Industrial Swiss lathes can machine the other side of the part by using the secondary sub-spindle and chuck once the regular machining operation is done. The desktop Swiss CNC lathe may not have these capabilities.<h3>Industry applications for Swiss machining</h3>Swiss machining was initially used to create the tiny, intricate parts used in watches, and it&rsquo;s still used to create long, small, or slender turned components across various industries.In the defense sector, Swiss machining&#39;s high accuracy makes it ideal for manufacturing small, complex geometries with tight tolerances required for military hardware.The medical industry benefits from Swiss machining&#39;s precision capabilities in producing components such as electrodes, anchors, and surgical tools. Precision machining processes are well suited for components such as complex hinges, pull rings, anchors, and electrodes and components for various medical instruments and devices in the diagnostic, surgical, and drug delivery fields.Aerospace applications include the production of components with extreme precision, ranging from mechanical parts for spacecraft motors to electrical components for cockpit controls.The automotive industry utilizes Swiss machining for fabricating bushings, pins, brake systems, and suspension components.Additionally, the electronics industry relies on Swiss CNC machined parts for communication, defense, and electronic equipment, such as fine-threaded screws, lens housings, mounts, and connectors.&nbsp;<h3>The Cost Considerations for Traditional Large Swiss CNC Lathes</h3>Operating traditional Swiss CNC lathes can be cost-intensive due to their technologically advanced controls and high-precision capabilities. Additional expenses associated with regular-size Swiss lathes include:<ol><li>PREP WORK FOR THE GRIPPER: Bar stock diameter reduction and chamfering processes must be performed before loading into the machine.</li><li>CENTERLESS GROUND BAR STOCKS: The length of bars is too long and gets expensive to be grinded for precision ground operation. Otherwise, the entire Swiss CNC operation would stop in case of a small jamming instance. The bar can not be too small either because it will be wiggled inside the guide bushing, deteriorate the surface finish, or break the cutting tools.</li><li>WASTED MATERIAL DURING THE WARM-UP: Draft parts are typically produced during the warm-up phase, and most of them are discarded.</li><li>CLEANING THE CHIP TANKS: Regular cleaning of chip tanks is necessary to prevent clogging of pumps and avoid expensive repairs. The machining area must also be kept free of accumulated chips to prevent jamming.</li><li>OIL CONTAMINATION: The oil coolant used in Swiss lathes can adhere to parts, machine handles, and surfaces, requiring daily cleaning to maintain optimal performance.</li><li>UNNECESSARY SPEED FOR LOW-VOLUME PRODUCTION: The high speed of traditional Swiss lathes may not be cost-effective for low-volume production. The total cost of owning a Swiss lathe can be substantial, considering additional expenses such as transportation, mist collectors, oil drums, bar feeders, and pressurized oil systems. What if you make a part in 20 seconds in a traditional Swiss machine vs. in 60 seconds in a Swiss desktop lathe? Do your math to justify the cost of a machine. They can cost $300K minimum when you add optional items to operate efficiently. That&rsquo;s not always the end of the story. Things add up. You must also pay thousands of dollars for transportation to your job floor. The mist collector can be at least $5K. You pay about $2K for a drum of oil constantly. The bar feeder mechanism can cost you about $20K, which is required for a Swiss lathe. Another $10K for the pressurized oil system must be added to your system for a proper cooling process.</li><li>RISK OF FIRE: Machining materials like titanium and stainless steel using hot and pressurized oil coolant pose a fire hazard. Fire extinguisher systems may be required to mitigate this risk, incurring additional costs. You may be required to pay a minimum of $10K for a fire extinguisher system.</li><li>SETUP and PROGRAMMING TIME: Traditional Swiss lathes often require extensive setup time, including accurate programming, which can take days before production can commence.</li><li>LABOR COST: Skilled operators are needed to handle the entire Swiss lathe process, including programming, setup, machining, and <a href="https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators" target="_blank">troubleshooting</a>, resulting in higher labor costs.</li></ol>These cost considerations emphasize the potential financial and operational advantages offered by desktop Swiss CNC lathes, which may present a more cost-effective solution for engineering applications, especially for projects involving smaller quantities or specialized requirements. The labor cost, setup time, fire risk, contamination-free parts, and material waste savings are possible with desktop Swiss CNC lathes.<h3>Conclusion</h3>The emergence of desktop Swiss CNC lathes has opened up new horizons for engineering professionals seeking to enhance their capabilities and reduce outsourcing costs. With benefits such as simplified setup and programming, time and operation efficiency, material savings, good tolerance ranges, and eliminating secondary operations, desktop Swiss CNC lathes offer a compelling solution for engineers working with regular-sized Swiss lathes or traditional CNC lathes. While traditional-sized Swiss lathes continue to play a crucial role in precision manufacturing, the unique features and cost considerations associated with desktop Swiss CNC lathes make them an attractive option for engineering professionals aiming to optimize performance and reduce overall expenses.While the benefits of using a desktop Swiss CNC lathe over traditional-sized Swiss lathes are substantial, opting for in-house production with this portable machine also offers advantages over outsourcing to a machine shop. Cost savings, increased control and flexibility, faster turnaround times, confidentiality and protection of intellectual property, and the potential for innovation and skill development are key factors that make in-house production a compelling choice. By investing in a desktop Swiss CNC lathe, companies can streamline their production processes, improve quality control, and position themselves for long-term success. <h3 id="isPasted">References:</h3>What it takes to operate a Swiss lathe (<a href="https://youtu.be/F_HZS_QKNmE" target="_blank">https://youtu.be/F_HZS_QKNmE</a>)Complete guide to CNC Swiss machining (<a href="https://www.fastradius.com/resources/complete-guide-cnc-swiss-machining/" target="_blank">https://www.fastradius.com/resources/complete-guide-cnc-swiss-machining/</a>)5 Tips for Swiss CNC Lathe Operators (<a href="https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators" target="_blank">https://www.apsx.com/5-tips-for-swiss-cnc-lathe-operators</a>)Discover APSX Machines: COMPACT (<a href="https://www.apsx.com/apsx-machines-compact" target="_blank">https://www.apsx.com/apsx-machines-compact</a>)

The desktop Swiss CNC lathe will open a new opportunity window for you to expand your capabilities and reduce your outsourcing cost. 

The Advantages of a Desktop Swiss CNC lathe

With its reasonable print quality, heated bed, and tiny price tag, the Creality Ender 3 FDM 3D printer is the go-to machine for 3D printing hobbyists and DIYers. However, one of its main limitations is its fairly small build volume.Although Creality sells some larger printers such as the Creality CR-10, many users prefer the Ender 3 (and its V2/Pro variants) for its low price and familiarity. So they have naturally sought after ways to maximize or extend the build area of the budget machine via firmware and hardware modifications.This article looks at how to exploit the entire print surface of the Ender 3 without investing in a bigger printer.<h1 dir="ltr">Ender 3 dimensions</h1>According to Creality’s official website, the Ender 3 (and the V2/Pro) has a print area of 220 x 220 x 250 mm.[1] However, if you get out your ruler, you’ll find that the Ender 3 print bed dimensions are 235 x 235 mm.The full machine size of the Ender 3 varies by model:<ul><li dir="ltr">Ender 3: 440 x 440 x 465 mm</li><li dir="ltr">Ender 3 V2: 475 x 470 x 620 mm</li><li dir="ltr">Ender 3 Pro: 440 x 420 x 465 mm</li></ul><h1 dir="ltr">Difference between Ender 3 bed size and print area explained</h1>The difference between the Ender 3, Ender 3 Pro, and Ender 3 V2 bed size and print area is, as we can see from the dimensions above, 15 mm on both the X and Y axes. In other words, every edge of the bed has 7.5 mm of unprintable space. But why is this?<h2 dir="ltr">Clips</h2>The principal reason why the print volume of the Ender 3 differs from the actual dimensions of the build plate is clips.The Ender 3’s removable build plate is attached to the print bed with standard office binder clips, which encroach upon the usable area of the build plate. Accordingly, Creality has written the 220 x 220 mm print size into its firmware, helpfully preventing users from printing over those clips and getting failed prints.The problem here — and the reason why many Ender 3 users have been tackling this issue for years — is that you don’t have to use clips to attach a build surface if you swap out the Creality-supplied equipment with a replacement. In fact, the Ender 3 Pro actually ships with a magnetic build surface.It’s also possible to use clips that are more compact than binder clips, freeing up more potential printing space around the edges of the build surface. Alternatively, users may only put clips on two of the four sides of the bed, giving them something like 220 x 235 mm of potentially usable print area.<h2 dir="ltr">Extra allowance</h2>The other reason why Creality adds 15 mm of buffer on the X and Y axes is to anticipate misalignment and other errors that could cause the printhead to deposit material off the edge of the print bed.Just as a 2D printer prints within a margin to avoid printing over the edge of the page, a 3D printer works best when it isn’t instructed to print right up against the edge of the build surface.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc3MjIyNzAxNDMxLTNkX3ByaW50ZXJfbm96emxlLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="Ender printhead">The Ender 3 has a buffer zone so it doesn't print off the edge of the bed<h1 dir="ltr">How to increase the print area of the Ender 3</h1>If 220 x 220 mm won’t cut it for your prints, there are a few ways to increase the Ender 3, Ender 3 Pro, and Ender 3 V2 bed size (or simply exploit more of it), though the most effective ways may be unsuitable for beginners. The three possible strategies involve adjustments to firmware, hardware, and slicing software.<h2 dir="ltr">Firmware upgrade</h2>The Ender 3 print area of 220 x 220 mm is specified in the 3D printer’s firmware — the basic machine software that enables the hardware to function. This means that you can’t just tell your slicing software to print over and above these limits: the firmware will tell the machine that such an action is impossible.Fortunately, if you’ve made physical space at the edge of your build surface (by swapping the clips for smaller ones, for example, or replacing the build surface with a magnetic one), you can update your Ender 3 firmware to specify a larger build area, permitting marginally bigger prints.The Creality-installed firmware can’t be modified, so you’ll need to replace it with either Marlin or Jyers firmware. This is easier to do with the Ender 3 V2 because it comes with a pre-installed bootloader, but is trickier with the other models.The <a href="https://github.com/Jyers" target="_blank" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">Jyers Github page</a> contains several optimized versions of Marlin firmware that can be flashed onto the Ender 3 V2 using a micro SD card. This process replaces the Creality firmware with Jyers firmware, which permits changing of the print volume.Although it is possible to specify a print size of 235 x 235 mm, most users will stick to 230 x 230 mm, which still adds a significant 10 mm to the X and Y axes without running the risk of failed prints.<h2 dir="ltr">Physical bed extension</h2>If you’re desperately trying to squeeze another 10–15 mm out of your X and Y axes, chances are the Ender 3 bed might simply be too small for you.Fortunately, it is possible to modify the printer and physically extend its print bed. Again, this is much easier with the Ender 3 V2, as a physical bed extension will require a firmware upgrade and adjustment of parameters so the printer knows how much bed area it has to print on.Products like the Ender Extender and Endzilla are kits that allow for DIY replacement of the print bed, typically containing parts like a new build plate, frame parts, screws, washers, and nuts.With such a modification, the Ender 3 V2 bed size can be increased. Both the Ender Extender and Endzilla brands have kits that boost the Ender 3 (V2/Pro) bed size to 400 x 400 mm — much larger than the original dimensions, and also larger than any printer in Creality’s Ender range.One obvious drawback of this approach is the price of a bed extender. The Ender Extender 400 currently sells for $179, taking the total price of the printer plus the modification to almost $400. At that point, buyers might consider buying a larger printer.<h2 dir="ltr">Priming and skirt settings</h2>A slicer such as Cura can’t trick your Ender 3 into printing beyond its 220 x 220 mm boundary. However, if your settings aren’t configured the way you want them, you might be getting even less printing area than that.The key settings to look into here are skirt settings. In Cura, skirt parameters fall under Build Plate Adhesion settings in Print Setup. In 3D printing, a skirt is an outline of extruded filament that goes around the printed part but doesn’t actually connect to it. It is principally used to prime the extruder and ensure that the printhead is depositing material smoothly and evenly before it begins extrusion for the actual part.[2]Although useful, skirts reduce the printable area, because they must fully surround the printed part. Reducing the skirt line count to 1 or even 0 may be necessary in order to exploit the full size of the print surface.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjc3MjIyNzUyNTUyLXNraXJ0cy5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="skirts">Printed parts with thin skirts surrounding themRecommended reading: <a href="https://www.wevolver.com/article/ender-3-v2-max-speed" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-redirect" rel="noopener noreferrer">Best Ender 3 (Pro) Cura settings: temperature, speed, retraction, more</a><h1 dir="ltr">Creality 3D printers size chart</h1>Within the Creality Ender range, the larger build areas can be found in the various “Plus” and “Max” models. Newer models with the “Neo” tag tend to have a similar or identical build volume to their specific predecessor but with additional features.Within the wider Creality range, large-format printers like the CR-10 Max ( &nbsp; &nbsp;450 x 450 x 470 mm) offer even larger print areas but at significantly higher prices.<div align="left" dir="ltr"><table><tbody><tr><td> </td><td>Ender 3</td><td>Ender 3 V2</td><td>Ender 3 Pro</td><td>Ender 3 S1</td><td>Ender 3 S1 Plus</td><td>Ender 3 Max</td><td>Ender 5 Pro</td><td>Ender 5 Plus</td><td>Ender 7</td></tr><tr><td>Print area (mm)</td><td>220 x 220 x 250</td><td>220 x 220 x 250</td><td>220 x 220 x 250</td><td>220 x 220 x 270</td><td>300 x 300 x 300</td><td>300 x 300 x 340</td><td>220 x 220 x 300</td><td>350 x 350 x 400</td><td>250 x 250 x 300</td></tr><tr><td>Price ($)</td><td>189&nbsp;</td><td>208</td><td>236</td><td>329</td><td>529</td><td>259</td><td>399</td><td>579</td><td>489</td></tr></tbody></table></div><h1 dir="ltr">Key takeaways</h1>Hands-on users of the Ender 3 might feel that a firmware upgrade and small or large physical modification of the printer is well worth it to achieve larger builds. Beginners and casual users, on the other hand, might find it more trouble than it’s worth.Recommended reading: <a href="https://www.wevolver.com/article/petg-vs-pla-how-do-they-compare" target="_blank" class="atomseo-link atomseo-link-internal atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">PETG vs PLA: How do they compare?</a><h1 dir="ltr">References</h1>[1] Ender-3 3D printer [Internet]. Creality. [cited 2023Feb21]. Available from: <a href="https://www.creality.com/products/ender-3-3d-printer" target="_blank" rel="noopener noreferrer" class="atomseo-link atomseo-link-external atomseo-link-follow atomseo-link-highlighted atomseo-status-valid">https://www.creality.com/products/ender-3-3d-printer</a>[2] Dave HK, Patel ST. Introduction to Fused Deposition Modeling Based 3D Printing Process. Fused Deposition Modeling Based 3D Printing. 2021:1-21.

Creality Ender 3 users can extend their build area

The Creality Ender 3 and its V2/Pro variants have a stated print area of 220 x 220 mm, but the actual bed dimensions are 235 x 235 mm. So can you print right up to the edges or not?

Ender 3 (V2,Pro) Bed Size: What You Need to Know

Veco's Advanced Lithographic Electroforming process is a unique combination of unparalleled electroforming industry experience, advanced lithography technology and in-depth knowledge of metallurgy. It includes 6 steps.1) Cleaning A sheet substrate is cleaned and degreased. 2) Coating The cleaned metal "raw part" is then coated with a light-sensitive photoresist. 3) Exposure The metal sheet is then exposed to ultraviolet light which cures the photoresist layer. 4) Development After the image has been transferred by UV exposure, the substrate is developed, rinsed and dried. 5) Deposition An electrolytic bath is used to deposit metal onto the patterned surface. 6) Removal The electroformed part can be removed from the substrate after the material has been plated to the desired thickness. 7) Inspection Comprehensive inspection by experts.

Electroforming: Additive Manufacturing Atom by Atom

Electroforming is an additive manufacturing process specialized for the production of high precision metal parts. Its uniqueness is that you can grow metal parts atom by atom, providing extreme accuracy and high aspect ratios.

Advanced Lithographic Electroforming: process animation step by step

Julio Aleman, a Bioengineering PhD student at the University of Pittsburgh Swanson School of Engineering is performing research in microphysiological systems.Like many researchers, Aleman needed a microwell array system with individual wells that have a specific size, shape and density. In fact, Aleman needed two different microwell arrays that would support the injection moulding of hydrogels and serve as “master moulds” – the original moulds that he could replicate. In turn, these replicate moulds would be used for microwell fabrication. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869692139-PittsburghCaseStudy2.png">Hydrogel mould of 484-microwell arrayTo produce master moulds like this, photolithography (optical lithography or UV lithography) is often used. The process begins by spin coating a negative photoresist on a wafer to establish mould thickness and microwell depth. Photopatterning is achieved by light exposure through specialised high-resolution masks and finalised by chemical development of the master mould. Then, replicas of the master mould are made by casting pre-polymers over the negative template and polymerising them by thermal curing.Polydimethylsiloxane (PDMS) silicone is the biocompatible polymer that is most often used. Typically, the production of master moulds and masks requires specialised facilities and equipment. Micro-injection moulding can also produce master moulds, but the tooling is expensive and time-consuming to produce. <h1>An Alternative to Clean Room Photolithographic and Injection Moulding</h1>Projection Micro Stereolithography (PμSL) from Boston Micro Fabrication (BMF) allows for the rapid photo-polymerisation of a layer of resin with a flash of ultraviolet (UV) light at micro-scale resolution. PμSL offers an alternative to photosoft lithography, etching, deposition, micro-injection moulding, and other traditional microfabrication methods.PμSL, a form of micro 3D printing, can produce small components with fine features and tight tolerances that are otherwise impossible to create. PμSL is capable of achieving a resolution of 2µm~50µm and a tolerance of +/- 5µm~25µm, thus providing ultra-high-resolution that is mould-free and mask-free for fast prototyping and end-use parts.  <h1>Project Requirements for Two Master Moulds</h1>The University of Pittsburgh project needed master moulds for replicate silicone moulds that, in turn, would be used to make biomaterial-based microwells. Normally, master moulds require a cleanroom and can be challenging to characterise. Researchers can’t perform profilometer measurements until the moulds are baked, and a mould with the wrong dimensions means lost time and money.Julio Aleman’s project required fast turnaround times and high-volume production. Accuracy, resolution, and precision were critically important. Several PDMS replicas that were cured at 80° Celsius were needed and the repeated processes on the master mould had to have little to no impact on the dimensions while the master mould was also securely fixed in a substrate. Aleman knew that he would need moulds in two different sizes, and that the silicone moulds should allow for the bottoms of the hydrogel micro-wells to have constant and defined amounts of biomaterial once injected and polymerized onto a glass slide. After some preliminary discussions, he ordered parts from BMF.The master moulds that the University of Pittsburgh asked BMF to produce were square with a defined hole–pattern. The first mould was for a 64-microwell array. It had an overall area of 20 mm x 20 mm and a thickness of 1.65 mm. The diameter for each hole and the distance between holes was 600 microns, or 0.6 mm, and the base of each of the microwells had a height of 50 microns from the surface. The second mould was for a 484-microwell array. The overall area was the same as for the first mould (20 mm x 20 mm), but the thickness for the second mould was significantly less at 1 mm. There were also more holes – and the holes were smaller. These wells measured just 150 microns, or 0.15 mm, in diameter with a similar base height of 50 microns.3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869775020-PittsburghCaseStudy3.png">3D printed mould for 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869800497-PittsburghCaseStudy4.png">3D printed mould for 484-microwell array<h1>Expert Advice and Flexible Material Selection</h1>BMF’s application team reviewed the designs for the University of Pittsburgh moulds. They recommended increasing the thickness of the second mould to greater than 1 mm. Otherwise, a mould that is too thin may experience part distortion or internal stresses during the printing process. Aleman revised the thickness and BMF then created sample parts using GR resin, a high-performance engineering material that is black in colour, able to withstand temperatures up to 102°C, and that supports sterilising.Because the COVID-19 pandemic limited Aleman’s access to university facilities, the graduate researcher limited his mould evaluation to microscopy. In turn, this meant that parts made of a dark resin would be more difficult to inspect. To support microscopic techniques, Aleman needed a resin that would allow more light to pass through so that the features of the resin mould could be more clearly seen. The solution was to use an HLT resin instead. This yellow resin from BMF offers greater transparency but still provides good impact strength, heat resistance, and support for autoclave sterilisation.<h1> </h1><h1>Speed, Accuracy and More</h1>&nbsp;Julio Aleman was pleased with the quick lead time – the moulds were delivered in just two weeks. Instead of waiting months to get a single injection-mould, he could provide a master mould to each member of the research team. The moulds also exhibited dimensional stability and, unlike spin coating in photolithography, did not require multiple fabrication steps. After hard baking some master moulds in an oven overnight, Aleman attached them to a surface with double-sided electrical tape. The moulds experienced only a 10 to 20-micrometre reduction in size, and that may have been caused by pressing the moulds against the surface or the tape while the moulds were still malleable from baking.Aleman also reported that after approximately 10 cycles of PDMS moulding, the BMF master moulds did not exhibit any bending or deformation. To prevent sticking, the replicate moulds were salinated with Vapor Phase Deposition (VPD). This treatment, which is also used with the SU8 moulds in photolithography, permitted the easy detachment of the PDMS moulds from the BMF master moulds. Aleman reported that the master mould with the larger features was easily salinated over one hour of exposure while the mould with smaller features required five hours or overnight exposure.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869860170-PittsburghCaseStudy5.png">PDMS replica of 64-microwell array<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1605869888883-PittsburghCaseStudy6.png">PDMS replica of 484-microwell array<h1> </h1><h1>Proof-of-Concept for Your Next Project&nbsp;</h1>As the University of Pittsburgh project demonstrates, researchers can use micro 3D printing to speed microwell array fabrication. If your application requires proof-of-concept parts such as master moulds, BMF can harness the power of PμSL technology on your behalf. We can also help you with material selection and recommend the best microArch printer from our growing family of ultra-high resolution 3D printers.In an exclusive partnership with BMF, CREATE Education are sharing their knowledge, support and experience, to bring micro 3D printing technology to the forefront of their education community in the UK and Ireland, enabling breakthrough research and development.CREATE Education are committed to supporting educators, educational institutions, outreach and community programs with the aim to bring cutting edge technologies throughout the world, such as 3D printers, into education.To learn more about PμSL technology and micro 3D Printing for research, please contact <a href="https://bit.ly/ContactCREATEEd" rel="noopener noreferrer" target="_blank">CREATE Education’s specialists</a>.

Julio Aleman, a Bioengineering PhD student needed two different microwell array system with individual wells that would support injection moulding of hydrogels and serve as “master moulds”

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