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Posted on April 27, 2016, by: James Barker This was my first year attending AMUG (Additive Manufactures User Group) and after attending RAPID last year in Long Beach, California, it exceeded my expectations.  Everyone I ran into last year at RAPID said that I HAD to attend AMUG since I am a user of both Stratasys Polyjet and FDM technologies.  Once I found out the dates I immediately asked my supervisor if I could attend this years AMUG that was held in good old St. Louis, Missouri!  I am so glad I was able to make it to AMUG.  Every day we had the decision to pick between 18 different presentations.  Not all of the presentations were repeated each day.  We had presentations from Universities, Aerospace, Defense, Medical, Manufactures of 3D printers and many more!  I needed a clone of myself because the decisions of choosing one presentation over another was way too difficult.  Luckily there were 5 representatives from PADT at this convention and we were able to share notes. Stratasysunveiled a new 3D printer on the first day of AMUG and it is phenomenal! It is called the .  The user has the ability to print with 6 different materials at the same time choosing between 360,000 different colors!  What other 3D printer is there that you can load Digital ABS, Tango (rubber), and different colors and build with them?  NONE!  Stratasys also revamped their print heads by doubling the amount of nozzles per material which results in better layer resolution!  All print modes have finer layers resulting in better aesthetics than any other printer previous with High Quality layers at 14 microns!  By teaming up with Adobe, the user can import a CAD file into Adobe Photoshop to assign a color pattern, picture, or even a texture to their CAD file.  To say I am excited about this printer is an understatement!  I need one now! STRATASYS WORKSHOPS: Carbon fiber soluble core workshop In this workshop we learned how to setup a soluble core, that was printed on a Stratasys Fortus 450MC using the SR-30 support, for a carbon fiber application.  This is a great application for the soluble support material. Turns out there are many customers using this application so that they don’t have to inventory expensive tools and can print on demand cores for their customers. During this presentation we learned that you will need to sand the part and then apply some sealing agent to the core/mandrel.  As for what type of sealing agent works best?  The answer is all.  They haven’t had any issues with different sealing agents from different vendors.  Several coats are needed.  When the part is building, you have the ability to setup pauses in the build so that you can add inserts or bushings to the part.  Because Aluminum dissolves in Sodium Hydroxide, you will want to use a different metal. If this is a application that you are interested in, please email me at and I will respond ASAP to you inquiries. Injection Mold 3D Printed Inserts  This application is a huge money and timesaver as well!  In this picture the inserts were 3D printed using a Digital ABS-Like material from a Polyjet printer.  The brackets and ejector plate were printed using the FDM technology and built out of Ultem 1010.    These builds took under 3 hours to build and allow the customer to quickly inject material to prove the design using the actual material required!  A few months ago we held a seminar in Utah at 2 different locations and taught this application with a Stratasys expert.  Here is a neat video Professor Jonathan George did showing this application in use: . Here is a video that Stratasys put out that shows their printers in use and the whole process as well.  ADDITIVE MANUFACTURING at GE AVIATION LEAP Engine Fuel Nozzle GE’s biggest success story is their LEAP Engine Fuel Nozzles.  For each LEAP engine manufactured there are 19 fuel nozzles needed.  Instead of assembling them by hand they are now all 3D printed.  10,000 engines have been sold to date since the engine wasintroduced in 2012.  By 2018, GE needs to 3D print 35,000 fuel nozzles and by 2020, they have estimated that they will need a total of 100,000 nozzles.  There is a 25% weight reduction and these parts are 5 times more durable than conventional manufacturing methods. T25 Temperature Sensor This housing is an inlet temperature sensor that was the 1st 3D printed part certified by the FAA to fly inside a GE commercial jet engine! GE Aviation is retrofitting 400 GE90-94B engines that power Boeing 777’s.  These sensors are subjected to all elements so there was rigorous testing done to ensure safety. The Center for Additive Technology Advancement CATA This facility is already open and running.  The goal is to advance Additive Manufacturing across all divisions of GE.  More information can be found .   XJET - NEW METAL TECHNOLOGY I have been operating 3D printers going on 7 years.  I am a huge fan of Stratasys/Objet 3D Printers so I made sure to attend the presentation by XJET. AMUG wasXJET’s unveiling of their new metal technology.  XJET was formed in 2005 by the inventors of Objet/Polyjet technology.  Since 2005 they have been able to raise $170 million to help spur their new idea.  They call it Nano Particle Jetting™.  The way it works is they take a nano particle of metal and suspend it in a liquid material that is then jetted from the print heads very similar to how Polyjet printers work.  Since the metal is infused in a liquid material there isn’t any harm dealing with powdered metals which eliminates the fear of dealing with a combustible powder metal!  The parts are built in a heated chamber which evaporates the liquid material that was holding the nano particle.  Another key part to their technology is the support material which is NOT the same material as the metal!  During the presentation, Dror Danai mentioned that there is no need to remove the support material with a mechanical process.  The parts will need to be annealed to remove stresses that occurduring the printing process.  While the part is being annealed the support material will be removed.  I am not sure how this is done, but it was hinted that the support dissolves or evaporates away. The print heads have 512 nozzles on each of them that can jet 18,000 droplets per second which helps achieve a layer thickness as fine as 2 Microns!!  Currently XJET has 7 machines that they are operating.  6 are in R&D and 1 is being used to print benchmarks for customers to help prove the technology.  Here is a link to their website showing how their technology works: If you would like to see this printer in person you can at RAPID which is in Orlando, Florida from May 16-19.  Here is a link to . CONCLUSION There are many other presentations and workshops that aren’t covered in this synopsis.  I focused on things that really excited me about the future of where this technology is headed.  If XJET technology is scalable, it can be revolutionary.  GE continues to be at the forefront of thistechnology and is continually pushing the limits of Additive Manufacturing.  The workshops I attended were mainly Stratasys driven because I was curious how you can make end-use production parts with their 3D printers.  Also the unveiling of the Stratasys J750 helps confirm that innovation is still taking part by one of the leaders in Additive Manufacturing in showcasing their new 3D printer that can print with 6 different materials! All in all I had a phenomenal time at AMUG and met some very interesting people that share my same passion for 3D printing.  If you have the opportunity to go to RAPID this  year in Florida, please let me know your thoughts of it.  I have heard there are some new materials coming out from Stratasys along with new 3D printers that will be showcased.  It is amazing where 3D printers have come from, and I am anxious to see where we are headed! If you would like to contact me with any questions then please email me at this email address: James Barker,Application Engineer Phoenix Analysis & Design Technologies

Posted on April 11, 2016, by: Eric Miller Many of you may have seen the recent launch of an Atlas V rocket from United Launch Alliance (ULA).  We are honored to have lent our expertise to ULA's 3D Printing efforts that resulted in the use of parts on that rocket made with additive manufacturing.   We will be talking about that and other ways we help the Aerospace Industry at the 32nd Space Symposium this week in Colorado Springs Colorado.  Please stop by! Read more in the .  A can be found here. Press Release: 3D Printing Expertise from PADT Advances Aerospace Industry Product design and development leader provides additive manufacturing support for United Launch Alliance Atlas V rocket COLORADO SPRINGS, Colo. - April 11, 2016 - -- Phoenix Analysis & Design Technologies Inc. (PADT), the Southwest's largest provider of Numerical Simulation, Product Development, and 3D Printing services and products, is highlighting its expertise this week at the 32nd Space Symposium,  the premierglobal, commercial, civil, military and emergent space conference. During the symposium, PADT experts in additive manufacturing will be on hand to discuss the company's technical expertise, logistics, sales and service capabilities in the exciting aerospace sector, which contributed to the successful launch on March 22 of a United Launch Alliance (ULA) Atlas V rocket. The Atlas V rocket made use of lightweight thermoplastic 3D printed parts, with the application of Stratasys technology supplied by PADT and consulting from PADT on how best to apply that technology to engineering, tooling, and production. Stop by and visit PADT's booth 1310 at the 32 nd Space Symposium, April 11-14, in Colorado Springs, Colorado.  . "PADT continues to be both a great supplier of both polymer and metal additive manufacturing technologies and an additive manufacturing technical consultant to ULA, supporting our Atlas V, Delta IV and future Vulcan Centaur launch vehicles," said Greg Arend, ULA manager,Additive Manufacturing. "By consulting with PADT, we were able to understand how these technologies enhance our design and manufacturing process, saving time, money and weight. PADT's knowledge of the use of both polymer and metal materials was instrumental in helping us achieve our success." In addition to supplying ULA with Stratasys' polymer 3D Printing machines, PADT consulted with them early on andled a tour of Oakridge National Labs to help them understand the state of the art for both metal and polymer applications and produced a technological roadmap for both technologies that has largely been followed.  Assisted by PADT, both companies made use of additive manufacturing for engineering prototypes, then advanced to the production of tooling for manufacturing and developed the confidence needed to move to flight hardware. The founders of PADT have been involved with additive manufacturing since the late 1980's and the company was the first service provider in the Southwest in1994.  Over the years, PADT has built a reputation for technical excellence and a deep understanding of how to apply various 3D printing technologies to enable real world applications.  Their sales team has shown the ability to sell sophisticated engineering products to companies large and small, and to provide excellent support to their customers. "3D Printing is not just about makers, nor is it just about engineering prototypes," said Rey Chu, co-owner, principal and director of Manufacturing Technologies at PADT. "Every day users are creating production hardware to produce usable parts that save them time and money. Ducts for rockets are a perfect application of 3D printed parts because they are complex, low volume, and can make single parts that need to be made in multiple pieces using traditional methods." About Phoenix Analysis and Design Technologies Phoenix Analysis and Design Technologies, Inc. (PADT) is an engineering product and services company that focuses on helpingcustomers who develop physical products by providing Numerical Simulation, Product Development, and Rapid Prototyping solutions. PADT's worldwide reputation for technical excellence and experienced staff is based on its proven record of building long term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because "We Make Innovation Work." With over 80 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at  -- End --  

place!  Even though I have been familiar with and worked with 3D printing for 20+ years, it is always nice to see the new technology, products, and the output of the products. " "... to see my son and all of the other kids so excited and amazed was truly awesome. Mason told me it was the best night of his life! And this morning his first words to me where thanking me for taking him to the event and when can we go back." "This is such a great opportunity for me to show my grandkids what I spent my life doing, and seeing them get so excited about it is wonderful”   The best part of the event for most of us here at PADT were the fantastic questions.  As one of our engineers said "for 2 hours I was just lost in the joy of positive human interaction."  We do love what we do here, but it was nice to share it with other people. Below are some pictures from the evening.  Make sure you to get invites to future events. We were pleased to be named a AZ SciTech Festival Signature Event   Atseveral points in the evening, the line was headed out the door.   The Demo room was full of 3D Printers and the kids loved handling the parts. Our office robot was a huge hit. The seminar room was turned into a hands-on lab for everyone to touch and feel the engineering tools we use. Some of the youngest attendees were able to give ANSYS AIM a literal spin and model the effect of a kid, a dad, and an elephant standing on a skateboard. Some people just took to a given tool, even advanced simulation. Students with exposure to engineering were able to ask our experts in-depth questions about technologies. The haptic device was a huge hit. It give real feedback as you edit and probe an object on the computer. Needless to say, kids adapted to it far faster than the adults. Engineering students were able to dive deep into the mechanics behind 3D Printing as well as its real world applications in industry. This is Ovid. He is PADT's new mascot. We hope to use him more in the future to helpexplain what we do here. This station shows how 3D Printing works, by stacking layers of material. Ovid doesn't look as good in low resolution. Scanning was a great way for everyone to see how we inspect and reverse engineer objects.

Posted on February 17, 2016, by: Joe WoodwardSo we have known for a long time that we can parameterize material properties in the Engineering Data screen. That works great if we want to adjust the modulus of a material to account for material irregularities. But what if you want to change the entire material of a part from steel to aluminum? Or if you have 5 different types of aluminum to choose, on several different parts, and you want to run a Design Study to see what combination of materials is the best? Well, then you do this. The process includes some extra bodies, some Named Selections, and a single command snippet. The first thing to do is to add a small body to your model for each different material that you want to swap in and out, and assign your needed material to them. You’ll have to add the materials to your Engineering Data prior to this. For my example I added three cubes and just put Frictionless supports on three sides of each cube. This assures that they areconstrained but not going to cause any stresses from thermal loads if you forget and import a thermal profile for “All Bodies”. Next, you make a Named Selection for each cube, named Holder1, Holder2, etc. This allows us to later grab the correct material based on the number of the Holder. You also make a Named selection for each group of bodies for which you want to swap the materials. Name these selections as MatSwap1, MatSwap2, etc. The command snippet goes in the Environment Branch. (ex. Static Structural, Steady-State Thermal, etc.) !############################################################################################################################### ! MATSWAP.MAC ! Created by Joe Woodward at PADT,Inc. ! Created on 2/12/2016 ! ! Usage: Create Named Selections, Holder1, Holder2, etc.,for BODIES using the materials that you want to use. ! Create Named Selections called MatSwap1, MatSwap2, etc. for the groups of BODIES for which you want to swap materials. ! Set ARG1equal to the Holder number that has the material to give to MatSwap1. ! Set ARG2 equal to the Holder number that has the material to give to MatSwap2. ! And so on.... ! A value of 0 will not swap materials for that given group. ! ! Use as is. No Modification to this command snippet is necessary. !############################################################################################################################### /prep7 *CREATE,MATSWAP,MAC *if,arg1,NE,0,then *get,isthere,COMP,holder%arg1%,TYPE *get,swapgood,COMP,matswap%ARG2%,TYPE *if,isthere,eq,2,then esel,s,holder%arg1% *get,newmat,elem,ELNEXT(0),ATTR,MAT !swap material for Body 1 *if,swapgood,eq,2,then esel,s,matswap%ARG2% emodif,all,mat,newmat *else /COM,The Named Selection - MatSwap%ARG2% is not set to one or more bodies *endif *else /COM,The Named Selection Holder%ARG1% is not set to one or more bodies *endif *endif *END MATSWAP,ARG1,1 !Use material from Holder1 forSwap1 MATSWAP,ARG2,2 !Use material from Holder1 for Swap2 MATSWAP,ARG3,3 !Use material from Holder1 for Swap3 MATSWAP,ARG4,4 !Use material from Holder1 for Swap4 MATSWAP,ARG5,5 !Use material from Holder1 for Swap5 MATSWAP,ARG6,6 !Use material from Holder1 for Swap6 MATSWAP,ARG7,7 !Use material from Holder1 for Swap7 MATSWAP,ARG8,8 !Use material from Holder1 for Swap8 MATSWAP,ARG9,9 !Use material from Holder1 for Swap9 alls /solu Now, each of the Arguments in the Command Snippet Details corresponds to the ‘MatSwap’ Name Selection of the same number. ARG1 controls the material assignment for all the bodies in the MatSwap1 name selection. The value of the argument is the number of the ‘Holder’ body with the material that you want to use. A value of zero leaves the material assignment alone and does not change the original material assignment for the bodies of that particular ‘MatSwap’ Named Selection. There is no limit on the number of ‘Holder’ bodies and materials that youcan use, but there is a limit of nine ‘MatSwap’ groups that you can modify, because there are only nine ARG variables that you can parameterize in the Command Snippet details. You can see how the deflection changes for the different material combinations. These three steps, holder bodies, Named Selections, and the command snippet above, will give you design study options that were not available before. Hopefully I’ll have an even simpler way in the future. Stay tuned.

Posted on February 16, 2016, by: Eric Miller Have you ever thanked an engineer?  In this week's TechFlash post I explore how we live in a world that has been transformed for the better (mostly) by engineers.  We are simple creatures who avoid the spotlight... but a thanks you would be nice. 

Posted on February 11, 2016, by: Kathryn Pesta PADT is excited to open our doors to the community and show you and your families what engineering is all about.  Bring the family down for a tour of PADT’s Tempe office and we will show them why engineering rocks. This family friendly event is a great way for kids to see what engineers really do all day.  Tour our 3D printing lab and check out how “We Make Innovation Work”.          WHEN: Wednesday, February 24th from 6:00pm to 7:30pm WHERE: PADT Headquarters   7755 S. Research Drive, Suite 110   Tempe, AZ 85284 The is a state-wide celebration of science, technology, engineering and math held annually in February and March.  Through a series of over 1,000 expos, workshops, conversations, exhibitions and tours held in diverse neighborhoods throughout the state, the Arizona SciTech Festival excites and informs Arizonans from ages 3 to 103 about how STEM will drive our state for next 100 years. Spearheaded by the , , the , , the and , theArizona SciTech Festival is a grass roots collaboration of over 700 organizations in industry, academia, arts, civic, community and K-12.

Posted on January 27, 2016, by: Eric Miller For this week's contribution to the PBJ's TechFlash blog I cover something that is near and dear to PADT - the replacement of testing with simulation, or virtual prototyping.  Learn why " "

Posted on January 26, 2016, by: Kathryn Pesta At PADT, we’re as big of a fan as anyone of the cool, trendy software and IT companies that run up billion dollar valuations in Silicon Valley and keep us all entertained and productive with their latest apps and platforms. But as an engineering product and services company, we’re hardware geeks at heart and one of our favorite conferences is coming up quick. It’s the Aerospace, Aviation, Defense and Manufacturing (AADM) Conference hosted by the Arizona Technology Council and Arizona Commerce Authority on March 3 at the Hilton Scottsdale Resort. Arizona has a rich history in this sector. TechAmerica's 2014 Cyberstates Report ranks Arizona fourth nationwide for jobs in the space and defense systems manufacturing industry, employing more than 8,300 people.  Industry giants such as Raytheon, Honeywell, Boeing, Lockheed Martin and General Dynamics all have a big presence here. Luke Air Force Base, Fort Huachuca and the Yuma Proving Ground allprovide ideal places for testing and flying in our cloudless skies and more than 300 days of sunshine. When you look at manufacturing, you’ll find thousands of varied companies located here that are propelling Arizona’s economy into the next era of growth. Industries leaders such as Intel, Microchip, and Frito Lay all have significant Arizona operations. Now in its fifth year, this conference has become the gathering place for Arizona’s AADM industry. You’ll not only have a chance to hear what the big companies are up to, you’ll meet potential suppliers and customers during the interesting presentations and well-attended cocktail reception. And for as little as $750 you can get a booth space and two conference tickets – that’s a deal you won’t find in New York City! The traffic at our booth always keeps us hopping and give us the opportunity to capture great leads. If you haven’t checked it out yet, get on it, check out the sponsorships and   . And don’t forget to stop by the PADTbooth. We’ll show you how we make innovation work!

Posted on January 14, 2016, by: Eric Miller There are so many aspects to numerical simulation worth talking about these days, and a lot of resources to get that information.  Applications, theory, how-to, and where it fits into the business of making stuff. Here on we tend to concentrate on practical hot-to things, and the magazine has focused on the application stories along with some how-to. What has been missing a a resource for how simulation impacts business, and how users of simulation are making other improvements in their business. Enter " ."  This new e-publication is from the same team that does the and  ANSYS Advantage, but it has a decided business slant - WAIT!!!.  I know, your an engineer, the world "business" scares you.  Don't worry, this is value added info, not a bunch of fluff. Take a look at the first issue .  I'll be honest, I kind of opened up expecting to page through going "whatever," "right, no one does that," and "who cares."  But I found myself skimming allof the articles with interest, and reading a couple completely.  There is some good stuff in here.  LIke an interview with Airbus engineers on about the challenge they face in designing their products. Or who Whirlpool uses social networking to facilitate communication between their users around the world. There is some simulation stuff in there, like how Siemens Power leverages simulation to make better power generation products.  And a lot more. Take a look, it won't hurt, I promise.  If you want something more technical, forward the link to your boss at least.

Posted on January 5, 2016, by: Eric Miller PADT's December contribution to the TechFlash column in the Phoenix Business Journal is a call to action for Arizona to step up their startup game. " " suggests the following actions: Work Together Make University IP Licensing Work Give Back by Taking More Risk Get Involved in Moving Startups Forward Stop Whining and Get to Work  

Posted on December 17, 2015, by: Eric Miller With PADT and the rest of the world getting ready to pile into dark rooms to watch a saga that we’ve been waiting for 10 years to see, I figured I’d take this opportunity to address a common, yet simple, question that we get: “How do I turn on HPC to use multiple cores when running an analysis?” For those that don’t know, ANSYS spends a significant amount of resources into making the various solvers it has utilize multiple CPU processors more efficiently than before.  By default, depending on the solver, you are able to use between 1-2 cores without needing HPC licenses. With the utilization of HPC licenses, users can unlock hyperdrive in ANSYS.  If you are equipped with HPC licenses it’s just a matter of where to look for each of the ANSYS products to activate it. ANSYS Mechanical Whether or not you are performing a structural, thermal or explicit simulation the process to activate multiple cores is identical. Go to Tools > Solve ProcessSettings The Solve Process Settings Window will pop up Click on Advanced to open up the Advanced Settings window You will see an option for Max number of utilized cores Simply change the value to your desired core count You will see below an option to allow for GPU acceleration (if your computer is equipped with the appropriate hardware) Select the GPU type from the dropdown and choose how many GPUs you want to utilize Click Ok and close Go the proper settings dialog Choose Advanced... Specify the number of cores to use Distributed Solve in ANSYS Mechanical One other thing you’ll notice in the Advanced Settings Window is the option to turn “ Distributed” On or Off using the checkbox. In many cases Distributing a solution can be significantly faster than the opposite (Shared Memory Parallel).  It requires that MPI be configured properly (PADT can help guide you through those steps).  Please see article by Eric Miller that references GPU usage and Distributed solve in ANSYS MechanicalTurn on Distributed Solve if MPI is Configured ANSYS Fluent Whether launching Fluent through Workbench or standalone you will first see the Fluent Launcher window.  It has several options regarding the project. Under the Processing Options you will see 2 options: Serial and Parallel Simply select Parallel and you will see 2 new dropdowns The first dropdown lets you select the number of processes (equal to the number of cores) to use in not only during Fluent’s calculations but also during pre-processing as well Default Settings in Fluent Launch Window Options When Parallel is Picked ANSYS CFX For CFX simulations through Workbench, the option to activate HPC exists in the Solution Manager Open the CFX Solver Manager You will see a dropdown for Run Mode Rather than the default “Serial” option choose from one of the available “Parallel” options. For example, if running on the same machine select Platform MPI Local Parallel Once selected in the section below you will see the name of thecomputer and a column called Partitions Simply type the desired number of cores under the Partitions column and then either click “Save Settings” or “Start Run” Change the Run Mode Specify number of cores for each machine ANSYS Electronics Desktop/HFSS/Maxwell Regardless of which electromagnetic solver you are using: HFSS or Maxwell you can access the ability to change the number of cores by going to the HPC and Analysis Options. Go to Tools > Options > HPC and Analysis Options. In the window that pops up you will see a summary of the HPC configuration Click on Edit and you will see a column for Tasks and a column for Cores. Tasks relate to job distribution utilizing Optimetrics and DSO licenses To simply increase the number of cores you want to run the simulation on, change the cores column to your desired value Click OK on all windows Select the proper settings dialog Select Edit to change the configuration Specify Tasks and Cores There you have it.  That’s how easy it is to turn on