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
Giants 400 | Aug 13, 2019
2019 Science + Technology Giants Report: Operational flexibility is a must for S+T buildings
The science and technology (S+T) sector is arguably the industry’s most complex because it caters to a diverse clientele with specific priorities and imperatives, according to Building Design+Construction's 2019 Giants 300 Report.
Architects | Aug 12, 2019
AIA, NCARB help launch coalition to represent complex professions and licensing boards
Architects, registration boards, and others join effort to ensure a unified voice for professions in growing debate around licensure, regulation, and public safety.
AEC Innovators | Aug 9, 2019
Improving architectural designs through iteration
Computational design lets ZGF Architects see patterns that renderings and even models can’t show.
Giants 400 | Aug 8, 2019
Top 200 Office Sector Architecture Firms for 2019
Gensler, AECOM, Perkins+Will, Stantec, and HOK top the rankings of the nation's largest office sector architecture and architecture engineering (AE) firms, as reported in Building Design+Construction's 2019 Giants 300 Report.
Giants 400 | Aug 8, 2019
2019 Office Giants Report: Demand for exceptional workplaces will keep the office construction market strong
Office space consolidation and workplace upgrades will keep project teams busy, according to BD+C's 2019 Giants 300 Report.
Museums | Jul 29, 2019
A new museum debuts inside the Empire State Building
A $165 million, 10,000-sf museum opened on the second floor of the Empire State Building in New York City, completing the second of a four-phase “reimagining” of that building’s observatory experience, which draws four million visitors annually.
Multifamily Housing | Jul 23, 2019
Is prefab in your future?
The most important benefit of offsite construction, when done right, is reliability.
Healthcare Facilities | Jul 15, 2019
Can a kids’ healthcare space teach, entertain, and heal?
Standard building requirements don’t have to be boring. Here’s how you can inject whimsical touches into everyday design features.
Architects | Jul 10, 2019
9 picks from NeoCon 2019
Interior architect Mary Bartlett selects her favorite products and systems from the 2019 NeoCon show, Chicago, June 10-12, 2019.
BD+C University Course | Jul 8, 2019
Shadow box design: To vent or not to vent [AIA course]
A curtain wall shadow box is a spandrel assembly consisting of vision glass at the building exterior and an opaque infill at the interior side of the curtain wall system. This course is worth 1.0 AIA LU/HSW.