Project Brief: Using the Ultimaker S5 Pro Complete System, we were able to print all night without fear of filament running out midprint and stopping our progress. The MHS automatically loads the next filament once a spool is empty. With Cura Connect, we queued up jobs for a few days allowing us to simply remove the build plate, insert the next one, and continue the next job with virtually no downtime. We ended up being 99% efficient with each spool as it gets used up until the very end, reducing part and set up cost.
Equipment Used: Ultimaker S5, Air Manager, Material Handling Station
Project Brief: The shortage of test kits has been a major problem worldwide. Retooling costs for injection molding has been met with resistance in the industry so 3D printing has become the perfect stopgap solution to the shortage. With no retooling costs, 3D printers can create the swabs on mass in proven Bio-compatible resins. They can be produced at a rate of 230-320 units per machine per day. The swabs can be autoclaved, and have been tested in Hospitals in the US.
Equipment Used: Formlabs Form 3B, Formlabs Surgical Guide Resin, Form Wash, Form Cure
Project Brief: We leveraged the power of the direct drive system and superior part cooling of the Pro2 to stack face shields up to 12 inches high. Stacking is a tough ask for any 3D printer and we found that the Pro2 was most reliable and allowed us to have a convenient cycle time of 24 hours. This method saved a ton of time cleaning build plates and resetting the printer for the next run. With the help of Raise3D cloud, we were also able to monitor print progress and stop the print if we saw issues from the comfort of our cellphone or laptop.
Equipment Used: Raise3D Pro2 Plus, Ultimaker S5, BASF Ultrafuse PLA Filament, Ultrafuse BVOH Water Soluble Support Filament, Ultimaker Breakaway Support Filament
Project Brief: the LC40 allowed us to prototype different PET face shield designs quickly and accurately. Within 10 minutes of lasering, we had five different versions of the shield to test for fit and function. Each iteration told us something different about the user experience and the final manufacturing process.
The LC40 makes even the slightest design changes real within minutes and facilitates rapid product development. We've arrived at the final product in under five days.
Equipment Used: Dremel LC40 Laser Cutter, Bofa AD350 Fume Extractor, PETG Sheets
Project Brief: The demand for N95 masks continue to be a problem. For industries unable to source masks, some have turned to scanning and 3D printing to create a better longer term solution in response to the shortage.
Utilizing scanning technology, Staff faces can be 3D scanned, and masks can be customized and printed out for individuals in TPU. The masks are customized to each person ensuring a perfect fit, while being flexible enough to be comfortable to wear all day. Lastly, TPU is sterilizable in heat without deformation resulting in a perfect custom form fitted mask that's reusable and sterilzable. Early trials have passed individual N95 tests (but this must be done individually due to the custom nature of the design)
Equipment Used: Einscan Pro2X Plus 3D Scanner, Ultimaker 3 3D Printer, Ulimaker Flexible TPU Filament
Project Brief: Due to the limited supply of respirator masks, we've decided to give our small but powerful vacuum former a shot. We made a negative of the respirator design so that we could vacuum form over it multiple times. The forming sheet is white PET which is biocompatible, sanitizable and cheap. The negative is made out of ABS to withstand the heat from the heating forks so that it can be used multiple times. PLA or PETG wouldn't work for this application as their HDT temperature is too low.
PS. Don’t use clear sheets as faces look odd inside of respirators
Equipment Used: Mayku Vacuum Former, Mayku form Sheets, Ultimaker ABS (for the mold)
Project Brief: Until now, we've had only a handful of applications for our dual head printers. Duplication mode was an option that wasn't used a lot until the COVIDSTOP.CA initiative. We have effectively used our Raise3D E2, BCN3D Sigmax R19, and BCN3D Epsilon as SIX different machines rather than only three. This means we were able to have double the throughput, making twice as many shields for the same amount of time.
Equipment Used: BCN3D Epsilon, Raise3D E2, BCN3D Sigmax R19, BCN3D Sigma R19
Project Brief: We've gotten used to the luxury features of cloud printing on our Raise3D, and Ultimaker machines. It is fantastic to have the option to queue and monitor jobs from the computer and cellphone. Unfortunately, older generation printers work using a simple USB or SD card. Astroprint activates the Ultimaker 2+ machines and brings them online. Allowing us to slice, monitor, and queue prints all from the cloud; we used the computer, cellphone and touch interface interchangeably whenever one was more comfortable than the other.
Equipment Used: Astrobox Touch, AstroPrint, Ultimaker 2+ Extended
Project Brief: Wearing a mask is mandatory to protect the people around you, but after a while our ears start to hurt... a lot! So we've decided to print ears savers for our selves and all the front line workers that want them. The great thing about this ear savers design is that it can be printed on any printer due to its small size and simple design. Most of our larger format printers were busy printing face shields, so we've used the Dremel and some of the Ultimaker 2+s instead.
Equipment Used: Dremel 3D45, Ultimaker 2+, LC40 Laser Cutter
Download the File: Surgical Strap .STL
Project Brief: If you're a home user wanting to help produce face shields, sometimes changing spools and/or worrying about filament running out mid print can be stressful and cumbersome. Enter the Mosaic Palette! You're able to now put 4 spools into your system, start a job and whenever a spool runs out, the next one is automatically spliced and fed in. Perfect for stacking prints, and using up every bit of filament around the house.
Equipment Used: Mosaic Palette 2S Pro, BASF Ultrafuse 1.75mm PLA