Design for Manufacturing

I was talking to a friend of mine today about a 3Dprinting project. He was unaware that I had a 15 year background in design for manufacturing, and I realized that maybe it would be a good idea to talk about CAD (Computer Aided Design), and how I integrate it with some of the work I create for 3Dprinting.

When creating an object that is to be manufactured, or that has to mate up with other components, It is critical to use CAD to make sure that all of your dimensions and tolerances are going to work. Much of my freelance work combines CAD with digital sculpting, allowing me the best of both worlds–especially when dealing with 3Dprinting.

Incendiary Tap Handle for Big Bridge Manufacturing

For this tap handle for Big Bridge Design, which is manufactured with resin 3Dprinting, the handle needs to mate up with a brass insert nut, so that the handle can be screwed onto the beer tap. Using Rhino I am able to utilize the clients 2D Illustrator file (.ai) to create a 3D model with the basic graphic design elements at the precise size, and also create the threads to receive the metal insert. The skulls are sculpted in ZBrush.

Turning the World of Calindria into a 3D model

This globe project was to create a 3Dprintable world for Noble Dwarf, the publisher of a tabletop role-playing setting Legends of Calindria. It is not too difficult to generate terrain based on the clients map, but it also needed to be printed in sections and have keys for assembly.

I created a globe in CAD and split it into sections. then used ARRAY commands to position all of the interlocking keys. The surfaces of the sections were subdivided and projected against the terrain in ZBrush to get the final shape.

Jewelry is also something that is a good opportunity to mix sculpted elements with CAD. This set of cuff links and pendant for 44th Legacy combined a relief sculpture from ZBrush with elements modeled in Rhino. The final pieces were created in bronze with the lost-wax process.