While 3D building information modeling (BIM) and digital prototyping have taken away the need for physical shop-built models and created whole new workflows for architects and engineers, clients and authorities with jurisdiction still want physical models to exhibit at planning hearings and show to prospective commercial building tenants or condo unit buyers.
Until recently, most 3D printers cost upwards of $40,000. Burlington, Mass.-based Z Corporation recently introduced the ZPrinter 150 (grayscale only; $14,900) and ZPrinter 250 (CMYK color; $24,900). Compare those prices to Z Corp's own ZPrinter 450, at $45,000.
These new machines are aimed at small architecture studios and firms that want to print their own design iterations to enable closer study of design options while also enhancing communication between project team members and owners. AEC firms can now provide resin-printed 3D color models from any CAD file at greatly reduced cost, due to the lower prices of the latest 3D printers and their associated production materials.
Rather than using polymers or other manufacturing materials, Z Corp's machines use an inkjet printing system based on Hewlett-Packard technology. Here's how it works: A 3D CAD file is imported into the Zeditpro software (included with the printer). The software slices any CAD or BIM file into thin cross-sections and feeds them into the 3D printer. The printer creates the model one layer at a time by spreading a layer of gypsum-based powder and inkjet printing binder into the cross-sections of the model. The process is repeated until every layer is printed.
This is the only 3D printing technology that allows full-color CMYK printing. This method is faster than other additive processes and much, much faster than subtractive prototyping, in which a block of material is carved into shape. Other more costly 3D printing technologies employ either selective laser sintering, which uses heat to fuse metal or plastic elements, or digital light projection, wherein a liquid polymer is exposed to light from a DLP projector under safelight conditions to harden it into a plastic. One printer even uses fused sugar as its printing material.
"Both the ZPrinter 150 and 250 can use any CAD package that can export into the STL file format, and they offer everything the other machines do, just with a smaller package and a little more build time," said Joe Titlow, Z Corporation's VP of product management.
Titlow said the ZPrinter 250 "borrowed a lot" from the ZPrinter 450. "Since the 450 came out in 2007, we've come to understand how to further miniaturize its internal vacuum system, the internal feeder hopper, and its fluid systems, which are self-contained and cartridge-based. All of those technologies have been optimized for this lower-cost package."
One difference between the two generations of printers is that the 250 does not have a side-mounted de-powdering unit with a compressed-air blower, as the 450 does. The resin build material for a 3D model has also gone down in price over the last three years. Powder and binding materials for a Z Corp inkjet-style 3D printer would cost about $3-$5 per cubic inch for a machine owner, according to Impact 3D Models, a Chicago-based 3D modeling company that produces all of its models from a ZPrinter 650. That's down from more than $7 a cubic inch as recently as 2007.
"Everything in the build is variable from project to project," said Matthew Mondo, Impact's VP. "Some models that require more binding material can be more costly, and some shapes require more powder to make." Depending on the complexity of the model, he said, a finished product can run up to $30 per inch, "but it really all depends on what you're looking for."
Mondo said his firm is seeing an uptick in retail layout and MEP modeling work. Clients include TME, a Little Rock, Ark., MEP firm, and construction manager/general contractor Hill International.
Making the file exchange
Three-dimensional geometry is easily transferred from CAD and BIM applications to 3D printers because STL, the file format nearly all of these systems use, is a generic file interchange that many 3D modeling applications can produce and many software packages can consume. Software packages from a wide variety of manufacturers, including AutoCAD, Revit, Solidworks, and Bentley Microstation, can all be easily converted into STL files.
Autodesk has made a free STL exporter for its Revit BIM platform available as a technology preview on its Autodesk Labs testing website. The Revit STL Exporter automates the process of turning a Revit file into an STL file for any of the 2010 Revit family of products (Revit Architecture 2010, Revit MEP 2010, Revit Structure 2010).
Kelcey Lemon, senior technical marketing manager for Building AEC Solutions at Autodesk, said interest in 3D printing among AEC firms is growing, particularly to aid in the visualization and comprehension of design proposal.
Related Stories
Healthcare Facilities | May 6, 2024
Hospital construction costs for 2024
Data from Gordian breaks down the average cost per square foot for a three-story hospital across 10 U.S. cities.
Biophilic Design | May 6, 2024
The benefits of biophilic design in the built environment
Biophilic design in the built environment supports the health and wellbeing of individuals, as they spend most of their time indoors.
MFPRO+ Special Reports | May 6, 2024
Top 10 trends in affordable housing
Among affordable housing developers today, there’s one commonality tying projects together: uncertainty. AEC firms share their latest insights and philosophies on the future of affordable housing in BD+C's 2023 Multifamily Annual Report.
Retail Centers | May 3, 2024
Outside Las Vegas, two unused office buildings will be turned into an open-air retail development
In Henderson, Nev., a city roughly 15 miles southeast of Las Vegas, 100,000 sf of unused office space will be turned into an open-air retail development called The Cliff. The $30 million adaptive reuse development will convert the site’s two office buildings into a destination for retail stores, chef-driven restaurants, and community entertainment.
Codes and Standards | May 3, 2024
New York City considering bill to prevent building collapses
The New York City Council is considering a proposed law with the goal of preventing building collapses. The Billingsley Structural Integrity Act is a response to the collapse of 1915 Billingsley Terrace in the Bronx last December.
Architects | May 2, 2024
Emerging considerations in inclusive design
Design elements that consider a diverse population of users make lives better. When it comes to wayfinding, some factors will remain consistent—including accessibility and legibility.
K-12 Schools | Apr 30, 2024
Fully electric Oregon elementary school aims for resilience with microgrid design
The River Grove Elementary School in Oregon was designed for net-zero carbon and resiliency to seismic events, storms, and wildfire. The roughly 82,000-sf school in a Portland suburb will feature a microgrid—a small-scale power grid that operates independently from the area’s electric grid.
AEC Tech | Apr 30, 2024
Lack of organizational readiness is biggest hurdle to artificial intelligence adoption
Managers of companies in the industrial sector, including construction, have bought the hype of artificial intelligence (AI) as a transformative technology, but their organizations are not ready to realize its promise, according to research from IFS, a global cloud enterprise software company. An IFS survey of 1,700 senior decision-makers found that 84% of executives anticipate massive organizational benefits from AI.
Codes and Standards | Apr 30, 2024
Updated document details methods of testing fenestration for exterior walls
The Fenestration and Glazing Industry Alliance (FGIA) updated a document serving a recommended practice for determining test methodology for laboratory and field testing of exterior wall systems. The document pertains to products covered by an AAMA standard such as curtain walls, storefronts, window walls, and sloped glazing. AAMA 501-24, Methods of Test for Exterior Walls was last updated in 2015.
MFPRO+ News | Apr 29, 2024
World’s largest 3D printer could create entire neighborhoods
The University of Maine recently unveiled the world’s largest 3D printer said to be able to create entire neighborhoods. The machine is four times larger than a preceding model that was first tested in 2019. The older model was used to create a 600 sf single-family home made of recyclable wood fiber and bio-resin materials.