Microsoft has warned users of SharePoint Server that three on-prem versions of the product include a zero-day flaw that is under attack – and that its own failure to completely fix past problems is the cause.
In a July 19 security note, the software giant admitted it is “… aware of active attacks targeting on-premises SharePoint Server customers by exploiting vulnerabilities partially addressed by the July Security Update.”
The attack targets CVE-2025-53770, a flaw rated 9.8/10 on the CVSS scale as it means “Deserialization of untrusted data in on-premises Microsoft SharePoint Server allows an unauthorized attacker to execute code over a network.”
The US Cybersecurity and Infrastructure Security Agency (CISA) advises CVE-2025-53770 is a variant of CVE-2025-49706, a 6.3-rated flaw that Microsoft tried to fix in its most recent patch Tuesday update.
The flaw is present in SharePoint Enterprise Server 2016. SharePoint Server 2019, and SharePoint Server Subscription Edition. At the time of writing, Microsoft has issued a patch for only the latter product.
That patch addresses a different vulnerability – the 6.3-rated path traversal flaw CVE-2025-53771 which mitigates that flaw and the more dangerous CVE-2025-53770. While admins wait for more patches, Microsoft advised them to ensure the Windows Antimalware Scan Interface (AMSI) is enabled and configured correctly, alongside an appropriate antivirus tool. Redmond also wants users to watch for suspicious IIS worker processes, and rotate SharePoint Server ASP.NET machine keys.
CISA has also issued its own warning. “Conduct scanning for IPs 107.191.58[.]76, 104.238.159[.]149, and 96.9.125[.]147, particularly between July 18-19, 2025,” it said. “Monitor for POSTs to /_layouts/15/ToolPane.aspx?DisplayMode=Edit.”
[…] The alloy formed under the extreme conditions of metal 3D printing, a new way to make metal parts. Understanding this aluminum on the atomic scale will enable a whole new category of 3D-printed parts such as airplane components, heat exchangers and car chassis. It will also open the door to research on new aluminum alloys that use quasicrystals for strength.
What Are Quasicrystals?
Quasicrystals are like ordinary crystals but with a few key differences.
A traditional crystal is any solid made of atoms or molecules in repeating patterns. Table salt is a common crystal, for example. Salt’s atoms connect to make cubes, and those microscopic cubes connect to form bigger cubes that are large enough to see with the naked eye.
There are only 230 possible ways for atoms to form repeating crystal patterns. Quasicrystals don’t fit into any of them. Their unique shape lets them form a pattern that fills the space, but never repeats.
[…]
How Does Metal 3D Printing Work?
There are a few different ways to 3D-print metals, but the most common is called “powder bed fusion.” It works like this: Metal powder is spread evenly in a thin layer. Then a powerful laser moves over the powder, melting it together. After the first layer is finished, a new layer of powder is spread on top and the process repeats. One layer at a time, the laser melts the powder into a solid shape.
3D printing creates shapes that would be impossible with any other method. For example, in 2015 GE designed fuel nozzles for airplane engines that could only be made with metal 3D printing.
[…]
One of the limitations of metal 3D printing is that it only works with a handful of metals. “High-strength aluminum alloys are almost impossible to print,” says NIST physicist Fan Zhang, a co-author on the paper. “They tend to develop cracks, which make them unusable.”
Why Is It Hard to Print Aluminum?
Normal aluminum melts at temperatures of around 700 degrees C. The lasers in a 3D printer must raise the temperature much, much higher: past the metal’s boiling point, 2,470 degrees C. This changes a lot of the properties of the metal, particularly since aluminum heats up and cools down faster than other metals.
In 2017, a team at HRL Laboratories, based in California, and UC Santa Barbara discovered a high-strength aluminum alloy that could be 3D printed. They found that adding zirconium to the aluminum powder prevented the 3D-printed parts from cracking, resulting in a strong alloy.
[…]
The NIST team wanted to know what made this metal so strong. Part of the answer, it turned out, was quasicrystals.
How Do Quasicrystals Make Aluminum Stronger?
In metals, perfect crystals are weak. The regular patterns of perfect crystals make it easier for the atoms to slip past each other. When that happens, the metal bends, stretches or breaks. Quasicrystals break up the regular pattern of the aluminum crystals, causing defects that make the metal stronger.
[…]
“Now that we have this finding, I think it will open up a new approach to alloy design,” says Zhang. “We’ve shown that quasicrystals can make aluminum stronger. Now people might try to create them intentionally in future alloys.”
The Bigscreen Beyond is a small and lightweight VR headset that in part achieves its small size and weight by requiring custom fitting based on a facial scan. [Val’s Virtuals] managed to improve fitment even more by redesigning a facial interface and using a 3D scan of one’s own head to fine-tune the result even further. The new designs distribute weight more evenly while also providing an optional flip-up connection.
It may be true that only a minority of people own a Bigscreen Beyond headset, and even fewer of them are willing to DIY their own custom facial interface. But [Val]’s workflow and directions for using Blender to combine a 3D scan of one’s face with his redesigned parts to create a custom-fitted, foam-lined facial interface is good reading, and worth keeping in mind for anyone who designs wearables that could benefit from custom fitting. It’s all spelled out in the project’s documentation — look for the .txt file among the 3D models.
In two complaints, (1, 2, PDF) filed in the Eastern District of Texas, Marshall Division, against six entities related to Bambu Lab, Stratasys alleges that Bambu Lab infringed upon 10 patents that it owns, some through subsidiaries like Makerbot (acquired in 2013). Among the patents cited are US9421713B2, “Additive manufacturing method for printing three-dimensional parts with purge towers,” and US9592660B2, “Heated build platform and system for three-dimensional printing methods.”
There are not many, if any, 3D printers sold to consumers that do not have a heated bed, which prevents the first layers of a model from cooling during printing and potentially shrinking and warping the model. “Purge towers” (or “prime towers” in Bambu’s parlance) allow for multicolor printing by providing a place for the filament remaining in a nozzle to be extracted and prevent bleed-over between colors. Stratasys’ infringement claims also target some fundamental technologies around force detection and fused deposition modeling (FDM) that, like purge towers, are used by other 3D-printer makers that target entry-level and intermediate 3D-printing enthusiasts.
The 3D printing service Shapeways, originally from Eindhoven, is bankrupt, both in the Netherlands and the US.
Shapeways started in 2007 as a spin-off from Philips. The company let users design and upload their own 3D files, after which Shapeways could print the objects.
The company has been listed on the American stock exchange since 2021. At the time, sales were expected to grow to $250 million by 2024, but that was not achieved. In 2023, the company posted a net loss of $43.9 million, compared to a loss of $20.2 million in 2022.
The company already reported to the US Security and Exchange Commission in May that it did not have sufficient liquid assets .
In the Netherlands, the company was declared bankrupt on July 3 by the court in East Brabant.
Growing cartilage tissue in the lab could help patiens with injuries, but it is very hard to make the tissue grow in exactly the right shape. A new approach could solve this problem: Tiny spherical containers are created with a high-resolution 3D printer. These containers are then filled with cells and assembled into the desired shape. The cells from different containers connect, the container itself is degradable and eventually disappears.
[…]
A special high-resolution 3D printing process is used to create tiny, porous spheres made of biocompatible and degradable plastic, which are then colonized with cells. These spheroids can then be arranged in any geometry, and the cells of the different units combine seamlessly to form a uniform, living tissue. Cartilage tissue, with which the concept has now been demonstrated at TU Wien, was previously considered particularly challenging in this respect.
Tiny spherical cages as a scaffold for the cells
“Cultivating cartilage cells from stem cells is not the biggest challenge. The main problem is that you usually have little control over the shape of the resulting tissue,”
[…]
To prevent this, the research team at TU Wien is working with a new approach: specially developed laser-based high-resolution 3D printing systems are used to create tiny cage-like structures that look like mini footballs and have a diameter of just a third of a millimeter. They serve as a support structure and form compact building blocks that can then be assembled into any shape.
Stem cells are first introduced into these football-shaped mini-cages, which quickly fill the tiny volume completely.
[…]
The team used differentiated stem cells — i.e. stem cells that can no longer develop into any type of tissue, but are already predetermined to form a specific type of tissue, in this case cartilage tissue.
[…]
The tiny 3D-printed scaffolds give the overall structure mechanical stability while the tissue continues to mature. Over a period of a few months, the plastic structures degrade, they simply disappear, leaving behind the finished tissue in the desired shape.
First step towards medical application
In principle, the new approach is not limited to cartilage tissue, it could also be used to tailor different kinds of larger tissues such as bone tissue. However, there are still a few tasks to be solved along the way — after all, unlike in cartilage tissue, blood vessels would also have to be incorporated for these tissues above a certain size.
“An initial goal would be to produce small, tailor-made pieces of cartilage tissue that can be inserted into existing cartilage material after an injury,” says Oliver Kopinski-Grünwald. “In any case, we have now been able to show that our method for producing cartilage tissue using spherical micro-scaffolds works in principle and has decisive advantages over other technologies.”
When it comes to 3D printing, the orientation of your print can have a significant impact on strength, aesthetics, and functionality or ease of printing. The folks at Slant 3D have found that printing enclosures at a 45° provides an excellent balance of these properties, with some added advantages for high volume printing. The trick is to prevent the part from falling over when balance on a edge, but in the video after the break [Gabe Bentz] demonstrate Slant 3D’s solution of minimalist custom supports.
The traditional vertical or horizontal orientations come with drawbacks like excessive post-processing and weak layer alignment. Printing at 45° reduces waste and strengthens the end product by aligning the layer lines in a way that resists splitting across common stress points. When scaling up production, this orientation comes with the added advantage of minimal bed contact area, allowing the printer to auto-eject the part by pushing it off the bed with print head.
To keep the part stable while printing in this orientation Slant 3D designed a fin-like support structure attached to the back of the enclosure with small sprues. This wastes significantly less time and material than auto-generated supports, and snaps away cleanly, leaving behind minimal imperfections that are easily addressed. To improve aesthetics and hide layer lines, Slant 3D also recommend adding texture to the external surfaces of enclosures. On 3D printed parts this detail costs nothing, while it would have added significant costs to injection molded parts.
We’re intrigued by this creative twist on 3D printing’s capabilities—proving once again that a simple shift in perspective (or in this case, orientation) can unlock new design potentials.
The first metal 3D printer that will be used in space is on its way to the International Space Station. The Cygnus NG-20 supply mission, which is carrying the 180kg (397 lbs) printer, launched on Tuesday and is set to arrive at the ISS on Thursday.
Astronaut Andreas Mogensen will install the printer, which Airbus developed for the European Space Agency. The machine will then be controlled and monitored from Earth.
Polymer-based 3D printers have been employed on the ISS in the past, but metal 3D printing in orbit is said to pose a trickier challenge. The machine will use a form of stainless steel that’s often used for water treatment and medical implants because of how well it resists corrosion.
After the stainless steel wire is pushed into the printing area, the printer melts it with a laser said to be a million times more powerful than a typical laser pointer. The printer then adds the melted metal to the print.
The melting point of the metal is around 1,400°C and the printer will run inside a completely sealed box. Before the printer can operate, it needs to vent its oxygen into space and replace its atmosphere with nitrogen. Otherwise, the melted metal would oxidize when it became exposed to oxygen.
Given the higher temperatures that are employed compared with a plastic 3D printer (which heats to around 200°C), “the safety of the crew and the Station itself have to be ensured — while maintenance possibilities are also very limited,” ESA technical officer Rob Postema told the agency’s website. “If successful though, the strength, conductivity and rigidity of metal would take the potential of in-space 3D printing to new heights.”
Four test prints are scheduled. The printer will replicate reference prints that have been created back on Earth. The two versions will be compared to help scientists understand how printing quality and performance differs in space. Even though each print will weigh less than 250g (8.8 ounces) and be smaller than a soda can, it will take the printer between two and four weeks to create each one. The printer will only be in operation for a maximum of four hours each day, since its fans and motor are fairly loud and the ISS has noise regulations.
Mechanical engineers Shervin Foroughi and Mohsen Habibi were painstakingly maneuvering a tiny ultrasound wand over a pool of liquid when they first saw an icicle shape emerge and solidify.
[…]
Most commercial forms of 3-D printing involve extruding fluid materials—plastics, ceramics, metals or even biological compounds—through a nozzle and hardening them layer-by-layer to form computer-drafted structures. That hardening step is key, and it relies on energy in the form of light or heat.
[…]
Using ultrasound to trigger chemical reactions in room-temperature liquids isn’t new in itself. The field of sonochemistry and its applications, which matured in the 1980s at the University of Illinois Urbana-Champaign (UIUC), relies on a phenomenon called acoustic cavitation. This happens when ultrasonic vibrations create tiny bubbles, or cavities, within a fluid. When these bubbles collapse, the vapors inside them generate immense temperatures and pressures; this applies rapid heating at minuscule, localized points.
[…]
In their experiments, which were published in Nature Communications in 2022, the researchers filled a cylindrical, opaque-shelled chamber with a common polymer (polydimethylsiloxane, or PDMS) mixed with a curing agent. They submerged the chamber in a tank of water, which served as a medium for the sound waves to propagate into the chamber (similar to the way ultrasound waves from medical imaging devices travel through gel spread on a patient’s skin). Then, using a biomedical ultrasound transducer mounted to a computer-controlled motion manipulator, the scientists traced the ultrasound beam’s focal point along a calculated path 18 millimeters deep into the liquid polymer. Tiny bubbles started to appear in the liquid along the transducer’s path, and solidified material quickly followed. After fastidiously trying many combinations of ultrasound frequencies, liquid viscosity and other parameters, the team finally succeeded in using the approach to print maple-leaf shapes, seven-toothed gears and honeycomb structures within the liquid bath. The researchers then repeated these experiments using various polymers and ceramics, and they presented their results at the Canadian Acoustical Association’s annual conference this past October.
[…]
A crucial next step for sound-based printing would be to show how this process can function in real applications that meet the strict requirements of engineers and product designers, such as materials strength, surface finish and repeatability.
The research team will soon publish new work that discusses improvements in printing speed and, significantly, resolution. In the 2022 paper the team demonstrated the ability to print “pixels” that measure 100 microns on a side. In comparison, traditional 3-D printing can achieve pixels half that size.
Researchers at the Zurich-based ETH public university, along with a US-based startup called Inkbit, have done the impossible. They’ve printed a robot hand complete with bones, ligaments and tendons for the very first time, representing a major leap forward in 3D printing technology. It’s worth noting that the various parts of the hand were printed simultaneously, and not cobbled together after the fact, as indicated in a research journal published in Nature.
Each of the robotic hand’s various parts were made from different polymers of varying softness and rigidity, using a new laser-scanning technique that lets 3D printers create “special plastics with elastic qualities” all in one go. This obviously opens up new possibilities in the fast-moving field of prosthetics, but also in any field that requires the production of soft robotic structures.
Basically, the researchers at Inkbit developed a method to 3D print slow-curing plastics, whereas the technology was previously reserved for fast-curing plastics. This hybrid printing method presents all kinds of advantages when compared to standard fast-cure projects, such as increased durability and enhanced elastic properties. The tech also allows us to mimic nature more accurately, as seen in the aforementioned robotic hand.
“Robots made of soft materials, such as the hand we developed, have advantages over conventional robots made of metal. Because they’re soft, there is less risk of injury when they work with humans, and they are better suited to handling fragile goods,” ETH Zurich robotics professor Robert Katzschmann writes in the study.
ETH Zurich/Thomas Buchner
This advancement still prints layer-by-layer, but an integrated scanner constantly checks the surface for irregularities before telling the system to move onto the next material type. Additionally, the extruder and scraper have been updated to allow for the use of slow-curing polymers. The stiffness can be fine-tuned for creating unique objects that suit various industries. Making human-like appendages is one use case scenario, but so is manufacturing objects that soak up noise and vibrations.
MIT-affiliated startup Inkbit helped develop this technology and has already begun thinking about how to make money off of it. The company will soon start to sell these newly-made printers to manufacturers but will also sell complex 3D-printed objects that make use of the technology to smaller entities.
After nearly a decade in development, Ellie Weinstein’s Cocoa Press chocolate 3D printer kit is expected to start shipping before the end of the year. Derived from the Voron 0.1 design, the kit is meant to help those with existing 3D printing experience expand their repertoire beyond plastics and into something a bit sweeter.
So who better to host our recent 3D Printing Food Hack Chat? Ellie took the time to answer questions not just about the Cocoa Press itself, but the wider world of printing edible materials. While primarily designed for printing chocolate, with some tweaks, the hardware is capable of extruding other substances such as icing or peanut butter. It’s just a matter of getting the printers in the hands of hackers and makers, and seeing what they’ve got an appetite for.
So, why chocolate? It’s a pretty straightforward question to start the chat on, but Ellie’s answer might come as a surprise. It wasn’t due to some love of chocolate or desire to print custom sweets, at least, not entirely. She simply thought it would be an easy material to work with when she started tinkering with the initial versions of her printer back in 2014. The rationale was that it didn’t take much energy to melt, and that it would return to a solid on its own at room temperature. While true, this temperature sensitivity ended up being exactly why it was such a challenge to work with.
Have you ever wanted to see your own face on the body of a Power Ranger or a Ghostbuster? Thanks to an ingenious partnership between Hasbro and 3D-printing specialists Formlabs, now you can. The Hasbro Selfie Series will let would-be heroes take a scan of their face with their phone and have a custom-made, look-a-like action figure delivered at some point afterward. In this initial blast, you can opt to become an X-Wing Pilot, Ghostbuster, Power Ranger or Snake Eyes from GI Joe, amongst others.
It’s part of Formlabs’ growing project to turn 3D printing into a technological cul-de-sac into a viable way of making customized, mass-market products. The company has already teamed up with Sennheiser to make 3D-printed earbuds, and has branched out into making jewelry moulds, ventilator parts and false teeth. It also teamed up with Gillette to create customized razor handles which were manufactured using Formlabs’ industrial printers.
Hasbro’s Brian Chapman explained that, a few years ago, the company ran a competition at a comic-con to make custom action figures for five winners. They found the interest in the promo was so enormous that the company has always had an eye on developments in the 3D printing market.
Unfortunately, while it’s been announced today, the Hasbro Selfie Series won’t actually let you start scanning your head for a little while. In order to start, you’ll need to download Hasbro Pulse, the company’s dedicated mobile app, and get your face ready to be immortalized. Scans will open up closer to the expected ship date in the Fall, after which point you’ll be asked to pony up $60 (plus taxes) and wait for your six-inch, “collector-grade” figure to arrive. Unfortunately, for now, the offering is only available to customers in the US, but hopefully over time, we’ll see this make its way across the world.
Mount your Virpil Throttle and Stick to linear rails so you can slide them along your desk.
This allows you to move your HOTAS aside when you use the computer for other work.
When flying your aircraft or spaceship, a spring-loaded locking meachanism holds your HOTAS securely in place.
An adapter plate for Virpil Flightsticks (VPC WarBRD Base) is included (with and without a mounting option for the 15 button Elgato Stream Deck (MK.1). MongoosT Base untested.
Turn your pictures into 3D stl files of lamp lithophanes, flat lithophanes, night light lithophanes, and more by using the lithophane makers below. Learn more about how to use LithophaneMaker.com by watching my YouTube tutorials. Click on a lithophane picture or title to go to the tool that created that lithophane. Instructions on how to use the lithophane makers are on their page, and general instructions on how to 3D print a lithophane are on the 3D Printing page. Give me feedback by joining the Lithophane Maker User’s group on Facebook.
Heart Lithophane Maker
Turn your pictures into beautiful heartfelt gifts for your loved ones! The new user interface for this tool lets you crop your pictures on the first page, then click the button at the top that says CLICK HERE TO VIEW LITHOPHANE for you to see the lithophane and adjust its dimensions. You can lower the value by the rendering resolution to make the lithophane look more like the final product, or increase the value to make the lithophane render quicker.
Lithophane Lamp Maker
Turn up to four pictures into a lithophane lamp model using this tool. The tool provides an interface that will work will most lamps. A cutout cylinder with a ledge makes it possible to put the lamp lithophane directly over the lamp’s light socket and underneath the light. The default settings work for a lamp that I have at my own house, but I suggest you measure the light bulb socket that you’re going to put the lithophane lamp over.
Lithophane Light Box Maker
Turn your photos into a lithophane light box. The lithophane light box was designed to easily take light sockets like the ones you can find here. You can design a customized lithophane light box and crop your photos in just a few minutes using this tool.
Night Light Lithophane Maker
Click the picture above to access the night light lithophane maker. The default settings for the night light lithophane make the lithophane with night lights can be bought here. This webtool gives you the ability to design the night light lithophane to be able to interface with almost any night light!
Flat Lithophane Maker
Turn a photo into a hangable flat lithophane stl with this tool. This tool automatically surrounds the lithophane with a frame and some holes for hanging the lithophane. Some twine and suction cups can be used to attach the lithophane to a window, and pretty much any will work. We used this twine and these suction cups.
Lithophane Globe Maker
Design a spherical lithophane with an optional lunar background. The lithophane interfaces with a light bulb through a cylindrical base, and can have a hole at the other end if desired. You can select the aspect ratio of your picture and crop it in this tool as well.
Curved Lithophane Maker
This lithophane design tool creates curved lithophanes or completely round votive lithophanes. You can adjust the dimensions of the lithophane that are shown in the picture to get exactly what you want.
Ceiling Fan Lithophane Maker
This image to stl generator turns pictures into a ceiling fan lithophane. You can turn up to four pictures into a cylindrical lithophane that has hooks that fit into a circular lithophane that is also designed here. The circular lithophane has 1 or 2 holes that allow you to attach to the ceiling fan’s pull string fixture.
Circular Lithophane Maker
This tool with crop an image into a circle and create a flat 3d stl from your photo. The 3d model can have a positive or negative image, so that you can make a lithophane or inverse with this tool. The 3d model is designed to be printed horizontally, and the model comes with a hole for attaching it to a string, hook, collar, or whatever you have in mind!
Color Lithophane Maker
This lithophane tool turns a picture into a the stl files you need to print a color lithophane.
Christmas Tree Lithophane Maker
Turn your picture into a Christmas Tree Lithophane with this tool! These lithophanes can be placed on a table, or hung from a tree. I have found compared two lighting options. This tea light is bright enough to illuminate the lithophane in regular room lighting, but has a battery life of 30 hours and I recommend a clamp diameter of 28.5mm for it. This tea light lasts for 100 hours, but doesn’t illuminate the lithophane well in a dark room (but not a bright one), and needs a clamp diameter of 36mm.
Phys.orgreports scientists have developed a “living ink” you could use to print equally alive materials usable for creating 3D structures. The team genetically engineered cells for E. Coli and other microbes to create living nanofibers, bundled those fibers and added other materials to produce an ink you could use in a standard 3D printer.
Researchers have tried producing living material before, but it has been difficult to get those substances to fit intended 3D structures. That wasn’t an issue here. The scientists created one material that released an anti-cancer drug when induced with chemicals, while another removed the toxin BPA from the environment. The designs can be tailored to other tasks, too.
Any practical uses could still be some ways off. It’s not yet clear how you’d mass-produce the ink, for example. However, there’s potential beyond the immediate medical and anti-pollution efforts. The creators envisioned buildings that repair themselves, or self-assembling materials for Moon and Mars buildings that could reduce the need for resources from Earth. The ink could even manufacture itself in the right circumstances — you might not need much more than a few basic resources to produce whatever you need.
3D scanning and 3D printing may sound like a natural match for one another, but they don’t always play together as easily and nicely as one would hope. I’ll explain what one can expect by highlighting three use cases the average hacker encounters, and how well they do (or don’t) work. With this, you’ll have a better idea of how 3D scanning can meet your part design and 3D printing needs.
How Well Some Things (Don’t) Work
Most 3D printing enthusiasts sooner or later become interested in whether 3D scanning can make their lives and projects easier. Here are a three different intersections of 3D scanning, 3D printing, and CAD along with a few words on how well each can be expected to work.
Goal
Examples and Details
Does it work?
Use scans to make copies of an object.
3D scan something, then 3D print copies.
Objects might be functional things like fixtures or appliance parts, or artistic objects like sculptures.
Mostly yes, but depends on the object
Make a CAD model from a source object.
The goal is a 1:1 model, for part engineering purposes.
Use 3D scanning instead of creating the object in CAD.
Not Really
Digitize inconvenient or troublesome shapes.
Obtain an accurate model of complex shapes that can’t easily be measured or modeled any other way.
Examples: dashboards, sculptures, large objects, objects that are attached to something else or can’t be easily moved, body parts like heads or faces, and objects with many curves.
Useful to make sure a 3D printed object will fit into or on something else.
Creating a CAD model of a part for engineering purposes is not the goal.
Yes, but it depends
In all of these cases, one wants a 3D model of an object, and that’s exactly what 3D scanning creates, so what’s the problem? The problem is that not all 3D models are alike and useful for the same things.
3D Scanning Makes Meshes, Not CAD Models
Broadly speaking, there are two kinds of 3D models: CAD models, and meshes. These can be thought of as being useful for engineering purposes and artistic purposes, respectively. Some readers may consider that a revolting oversimplification, but it is a helpful one to make a point about how 3D scanning, 3D printing, and CAD work do (and don’t) work together.
Hackers designing parts are typically most interested in CAD models, because these represent real-world objects that get modified in terms of real-world measurements. But 3D scanning will not create a CAD model; it will create a mesh.
Typical CAD model editing example, showing a model as a solid object, altered in terms of geometric features and real-world measurements.
A typical mesh editing operation. The object is a network of points connected into a mesh, which can be manipulated and deformed.
Meshes can be used for engineering purposes — .stl files are meshes after all, and are practically synonymous with 3D printing — but a mesh cannot be modified in the the same ways a CAD file can. With a mesh, one does not extrude a face by a specific number of millimeters, nor does one fillet a corner to a specific radius. Meshes can absolutely be modified, but the tools and processes are different.
To sum up: 3D scanning makes 3D models from real-world objects, but the models that come out of the scanning process aren’t necessarily suitable for engineering purposes without additional work.
Options for the Home-based Hacker
At the beginning of this article I selected three typical intersections of 3D scanning, 3D printing, and CAD work to illustrate the various imperfect fits between them. Now I’ll go into those three use cases in more detail, and provide ways for the average hacker to use 3D scanning to make a project easier.
Using 3D Scanning to Create Copies
Photogrammetry is an accessible way to create 3D models, and free as well as paid options exist. Generally, the smaller and more complex an object, the harder it will be to obtain a result that preserves all the features and details.
Photogrammetry uses multiple photos of an object taken from a variety of different angles, and software interprets these photos to create a point cloud representing the surface of the object. A mesh 3D model representing the object can then be generated. Some cleanup or post-processing of the model is usually required, depending on the method and software.
This blog post from Prusa Research walks through how to get the best results with Meshroom, a free option for 3D scanning using photogrammetry.
OpenScan (and OpenScan Mini) is a DIY project by [Thomas Megel] aimed at using photogrammetry to scan small objects with high accuracy.
RealityCapture is non-free software with a number of useful features and well-made tutorials. Notably, they have a license model option aimed at occasional use and small quantities. Since most software subscription models rarely make sense for hobbyists and one-off projects, it can be worth a look.
Creating a CAD Model from a 3D Scan
Since 3D scanning will not generate a CAD model, it’s not a direct alternative to designing a part in CAD. Most CAD programs allow importing a mesh, but the imported mesh remains a mesh, which cannot be modified in the same way as other CAD objects. It might be useful as a guide for a new design, however.
A mesh converted to a solid will become an object made up of collection of triangular faces, identical to the ones that made up the original mesh. This is rarely what a novice CAD modeler expects.
One may wonder if it is possible to convert from one format to another. It is, but the conversion may not be what one expects. Converting a CAD model into a mesh is simple enough, but converting a mesh into a CAD solid is less straightforward.
If one’s goal is to use 3D scanning to make the creation of a CAD model easier and the conversion result shown here won’t do the trick, the next best thing is to use the 3D scan as a master and model a new part around it to match, using the imported mesh as a guide. One project that uses this approach is this custom trackball designed around a molded ergonomic prototype.
Some professional software suites have the ability to export to CAD, but the essential workflow is the same, with a scanned mesh being used as the reference for a new design.
3D Scanning to Digitize Inconvenient or Troublesome Shapes
This scan of a laser cutter’s panel is obviously only part of the whole machine, but the important part is present.
Sometimes an accurate 3D model of a shape is needed, and that shape isn’t easily modeled or measured by hand. The same photogrammetry tools mentioned earlier are useful here, but their purpose is different. Instead of modeling the object from top to bottom to make an accurate copy, often only part of the object is needed.
For example, modeling the shape of an equipment panel or dashboard requires only the relevant section to be scanned successfully. A person’s head can be scanned to ensure a precise fit for a helmet or mask, and there’s no need to get a full scan of the entire body. In general, fewer pictures are needed and post-processing and model cleanup is easier because there is a smaller area of interest. A size reference must be included somehow for scaling later, because most 3D scans do not intrinsically create 1:1 models.
An excellent example of this approach is this project to design a custom control panel intended to fit an existing piece of equipment. Unlike when scanning a whole object with the intent of duplicating it, there’s no need to capture difficult-to-reach places like the bottom or back. This makes both scanning and model cleanup easier.
Professional Scanning
Another option is to pay for a professional scan. Fancy scanners and software suites costing thousands, or tens of thousands, of dollars and aimed at engineering applications exist, and while they are out of the reach of the average hacker, paying for a company to do a scan or two might not be.
Accuracy and resolution can be beyond what’s possible with photogrammetry, and some of the professional software suites have fancy features like aligning multiple scans, accurate size references, or the ability to generate CAD models based on scan results.
A 1:1 model from a professional 3D scanning tool, the product of aligning and merging multiple separate scans from different angles to get a complete model. It is still a mesh, but it accurately represents the original in both features and scale.
Shown here is the model of a part I had professionally scanned with a Creaform HandySCAN Black 3D scanner, according to my invoice. It is an old wood grip from an antique firearm. The scan still created a mesh, but it was an accurate 1:1 model of the original that I was able to use to print replacements on an SLA 3D printer.
When getting a quote for professional 3D scanning, be sure to ask about fee structure and be clear about your needs. In my case, it was cost-effective to scan multiple similar objects under a single setup fee.
Know What 3D Scanning Can (and Can’t) Do
3D scanning is getting better and more accessible all the time, but the fact that it generates a mesh means it doesn’t always fit smoothly into a 3D printing and CAD part design workflow. That doesn’t mean it can’t be useful, but it does mean that it’s important to know the limitations, and how they will affect your needs.
Of course, one can always dig out the calipers and manually model a part in CAD, but not all parts and shapes are easily measured or reverse-engineered. 3D scanning is a great alternative to modeling complex, real-world objects that would be impractical or error-prone to create by hand.
Have you successfully used 3D scanning to make a project easier, or have a favorite method or tool to share? We definitely want to hear all about it, so please take a moment to share with us in the comments.
In jade waters off Hong Kong’s eastern shoreline, scientists are thrilled to spot a cuttlefish protecting her eggs inside an artificial, 3D-printed clay seabed helping to restore the city’s fragile coral reefs.
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Around 84 species of coral are found in Hong Kong’s waters, scientists say, more diverse than those found in the Caribbean Sea.
Most can be found on remote inlets, far from the sediment-filled Pearl River Delta and its busy shipping channels.
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They have begun using 3D printed tiles that work as an artificial bed for corals to latch onto and thrive, with promising results.
“The first time we put down the tiles, there were a few fish around,” she told AFP on a recent inspection by University of Hong Kong (HKU) researchers.
Now the artificially produced reef laid down last summer is teeming with wildlife, including the cuttlefish, something Yu described as “very, very exciting”.
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Corals are colonies of billions of living polyp invertebrates and are hugely sensitive to temperature changes.
When they get too hot, they lose their vibrant colour and die.
Repopulating a dead or damaged reef requires suitable ground for the remaining coral larvae to latch onto and build a new home—and the printed tiles have so far proven dependable.
“3D printing allows us to customise a tile or a solution for any type of environment and I think that’s the real potential that the technology brings,” David Baker, an associate professor at HKU’s School of Biological Sciences who led development of the technology, told AFP.
Tiles carrying 400 coral fragments have been laid on a 40 square-metre (430 square-foot) section of sea floor in the marine park.
“The corals now on the tiles definitely survive better than the traditional way of transplantation,” said Yu, putting the success rate at around 90 percent.
Some projects around the world have deliberately sunk ships or concrete onto the sea floor to encourage coral growth. And while those methods have had some success, they can change the chemistry of the water.
The tiles used in the Hong Kong project are made with terracotta, minimising the environmental impact.
“Clay is basically soil, so soil you can find everywhere on earth,” said Christian Lange, an associate professor from HKU’s Department of Architecture.
It leaves water chemistry unchanged, Lange added, and if a tile fails to spawn a new colony it will simply erode without leaving a trace.
Holograms aren’t new, but a desktop machine that spits them out could be available soon, presuming LitiHolo’s Kickstarter pans out. The machine will have a $1600 retail price and fits in a two-foot square. It can generate 4×5 inch holograms with 1mm hogels (the holo equivalent of a pixel).
The machine allows for 23 view zones per hogel and can create moving holograms with a few seconds of motion — like the famous kiss-blowing holograms.
Of course, you’ll also need a special self-developing film and a way to get 3D images into the printer such as software or a camera set up to do a 3D scan. In the 4×5 size, the film runs about $13 a plate which will create one hologram.
Since 5 inches is 127 mm the hogel resolution of the result is about 101×127, and the samples on the website and the video below certainly don’t look like they are in HD.
Will people pay $1600 for low-resolution holograms? More importantly, is there a market for grainy holograms that would let you earn back the investment? Maybe not, but that hasn’t stopped us from buying 3D printers and other workshop toys. Plus, if this catches on, what will be available in ten years time?
The California-based business isn’t the first or only company taking advantage of this growing 3D printing tech. But unlike other companies, Mighty Building’s upcoming project in Rancho Mirage, California will have the title of “world’s first planned community of 3D printed homes,” according to its maker.
To create this first-of-its-kind community, Mighty Buildings partnered with development-focused Palari Group, a working relationship that first started from other property designs in September 2020.
In December of last year, Palari Group officially ordered Mighty’s “Cinco” models for the Rancho Mirage, California housing development.
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The tech-forward housing development will consist of 15 homes across five-acres. This $15 million project will be built using the Mighty Kit system, which utilizes prefabbed panels to create custom homes.
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The development will be completed next spring, and Mighty Buildings is already in talks with a “number of developers” for potential future communities.
Forget glue, screws, heat or other traditional bonding methods. A Cornell University-led collaboration has developed a 3-D printing technique that creates cellular metallic materials by smashing together powder particles at supersonic speed.
This form of technology, known as “cold spray,” results in mechanically robust, porous structures that are 40% stronger than similar materials made with conventional manufacturing processes. The structures’ small size and porosity make them particularly well-suited for building biomedical components, like replacement joints.
The team’s paper, “Solid-State Additive Manufacturing of Porous Ti-6Al-4V by Supersonic Impact,” published Nov. 9 in Applied Materials Today.
The paper’s lead author is Atieh Moridi, assistant professor in the Sibley School of Mechanical and Aerospace Engineering.
“We focused on making cellular structures, which have lots of applications in thermal management, energy absorption and biomedicine,” Moridi said. “Instead of using only heat as the input or the driving force for bonding, we are now using plastic deformation to bond these powder particles together.”
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The particles were between 45 and 106 microns in diameter (a micron is one-millionth of a meter) and traveled at roughly 600 meters per second, faster than the speed of sound. To put that into perspective, another mainstream additive process, direct energy deposition, delivers powders through a nozzle at a velocity on the order of 10 meters per second, making Moridi’s method sixty times faster.
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“If we make implants with these kind of porous structures, and we insert them in the body, the bone can grow inside these pores and make a biological fixation,” Moridi said. “This helps reduce the likelihood of the implant loosening. And this is a big deal. There are lots of revision surgeries that patients have to go through to remove the implant just because it’s loose and it causes a lot of pain.”
While the process is technically termed cold spray, it did involve some heat treatment. Once the particles collided and bonded together, the researchers heated the metal so the components would diffuse into each other and settle like a homogeneous material.
“We only focused on titanium alloys and biomedical applications, but the applicability of this process could be beyond that,” Moridi said. “Essentially, any metallic material that can endure plastic deformation could benefit from this process. And it opens up a lot of opportunities for larger-scale industrial applications, like construction, transportation and energy.”
The team, from the John A. Paulson School of Engineering and Applied Sciences (SEAS), created a 3D-printable material that can be “pre-programmed with reversible shape memory.” The wool-like material can remember old forms and morph back into those, or transform into different shapes when a certain stimulus is applied.
It’s made using keratin extracted from recycled wool. Keratin is a fibrous protein that’s found in hair, which, of course, has a habit of returning to its natural form.
The researchers shaped a single chain of keratin into a spring-like structure. They twisted two of those together and used many such “coiled coils” to assemble large fibers. When a stimulus is applied to the material or it’s stretched out, those structures uncoil and the bonds realign. The material stays that way until it’s triggered to return to its original state, which is programmed with a solution of hydrogen peroxide and monosodium phosphate.
In one test, researchers programmed a sheet of keratin to have an origami star as its permanent shape. They dunked the sheet in water to make it malleable and rolled it into a tube. But when the team put that tube in the water again, it unrolled and reformed as the origami star.
The researchers believe the material could help reduce waste in the fashion industry. They suggested it could be used for truly one-size-fits-all clothing that stretches to fit the wearer, or bras “whose cup size and shape can be customized every day.” Consumers could save as well if they don’t have to replace stretched-out clothes quite so often.
“This two-step process of 3D printing the material and then setting its permanent shapes allows for the fabrication of really complex shapes with structural features down to the micron level,” Luca Cera, a SEAS postdoctoral fellow and first author of a paper on the material, said in a press release. “This makes the material suitable for a vast range of applications from textile to tissue engineering.”
Whether the goal is to find a treatment for COVID-19 or another disease, scientists often have to conduct preliminary tests on animals to determine whether the drug is safe or effective in people. It’s not always a one-for-one comparison, but The New York Times reports there may be a new way around that step going forward: 3-D printing.
For example, Anthony Atala, the director of the Wake Forest Institute for Regenerative Medicine, and his team are using 3-D printers to create tiny replicas of human organs, including miniature lungs and colons, which are particularly affected by the coronavirus. They send them overnight for testing at a biosafety lab at George Mason University.
The idea predated the coronavirus — Atala said he never thought “we’d be considering this for a pandemic” — but it could come in handy and help expedite the experimental drug process, especially since Atala said his Winston-Salem, North Carolina-based lab can churn out thousands of printed organs per hour. “The 3-D models can circumvent animal testing and make the pathway stronger from the lab to the clinic,” said Akhilesh Gaharwar, who directs a lab in the biomedical engineering at Texas A&M University. Read more at The New York Times.Tim O’Donnell
KFC announced on July 16 it would test chicken nuggets made with 3D bioprinting technology in Russia this fall.
The chain partnered with 3D Bioprinting Solutions to create a chicken nugget that will mimic the taste and appearance of its original nuggets at a fraction of the environmental cost.
The release will be the first time a major chain will sell a lab-grown meat product and may serve as a proof-of-concept for the much-hyped cell-based meat industry.
KFC will test chicken nuggets made with 3D bioprinting technology in Moscow, Russia, this fall, the chain announced in a July 16 press release.
The chicken chain has partnered with 3D Bioprinting Solutions to create a chicken nugget made in a lab with chicken and plant cells using bioprinting. Bioprinting, which uses 3D-printing techniques to combine biological material, is used in medicine to create tissue and even organs.
The 3D-printed chicken nuggets will closely mimic the taste and appearance of KFC’s original chicken nuggets, according to the press release. KFC expects the production of 3D-printed nuggets to be more environmentally friendly than the production process of its traditional chicken nuggets. The fall release will mark the first debut of a lab-grown chicken nugget at a global fast-food chain like KFC.
With select bucket seats from the 911 and 718 as well as various classic car parts—including clutch release levers for the 959—already being produced using 3D printing, Porsche is more familiar with the technology than most. Now, the automaker is taking things even further, 3D printing entire pistons for its most powerful 991-gen 911, the GT2 RS.
Although it doesn’t sound like these 3D-printed pistons will actually be found in many production Porsches anytime soon, they represent a bit more than just an engineering flex. There are some very real mechanical benefits here. For starters, they weigh 10 percent less than their forged equivalents and feature an integrated and closed cooling duct in the piston crown that’s apparently unable to be reproduced using traditional manufacturing methods. The decrease in weight and temperature results in an extra 30 horsepower on top of the GT2 RS’s already mighty 700.
Porsche
“Thanks to the new, lighter pistons, we can increase the engine speed, lower the temperature load on the pistons and optimize combustion,” said Porsche advance drive senior engineer Frank Ickinger. “This makes it possible to get up to 30 [horsepower] more power from the 700 [hp] bi-turbo engine, while at the same time improving efficiency.”
Produced in partnership with German auto part maker Mahle and industrial machine manufacturer Trumpf, the pistons are made out of a high-purity metal powder developed in-house by the former using the laser metal fusion process, essentially a laser beam that heats and melts the metal powder into the desired shape. The end result is then validated using measurement technology from Zeiss, the German optics company best known for camera lenses.
With the advent of electric cars, it’s only a matter of time before internal combustion engines become a novelty rather than the default. It’ll be interesting to see how much efficiency (and, in turn, time) 3D-printed components buy for the internal-combustion engine as a whole.
LOS ANGELES — The world of 3D printing has come so far that scientists can actually produce biological products like bone, skin and blood vessels. Of course, there are numerous safety risks involved in using 3D-printed body parts in human patients. There is progress on that front, though. Scientists have developed a method for printing body parts that will make procedures involving 3D-printed tissues much safer.
Typically, when scientists print tissues, they transplant them into their patients after being printed. Thanks to a research team led by researchers at the Terasaki Institute, tissues can now be printed directly into a patient’s body.
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“This bio-ink formulation is 3D printable at physiological temperature, and can be crosslinked safely using visible light inside the body.” says first author Ali Asghari Adib, Ph.D, in a media release.
Like squeezing icing onto a cake
Researchers also created a groundbreaking 3D-printing nozzle and an “interlocking” printing technique to use with their bio-ink. Bio-ink can be squeezed through the nozzle of the printer like cake icing is squeezed through a tube. The nozzle also punctures the tissue it’s about to print on so some bio-ink can fill the gaps the nozzle created and serve as an anchor for the 3D-printed tissue
“The interlocking mechanism enables stronger attachments of the scaffolds to the soft tissue substrate inside the patient body,” adds Asghari Adib.
