Raised-Relief TopO & Tactile Maps for Park Visitors

Fabricating Raised Relief Terrains from Global mapperBlue Marble Users Group 2015Combined Presentations from John Lee (ABC Imaging) and Michael Higgins (Summit Terragraphics, Inc.)

3-D Printing Color Raised-Relief Terrains from Global Mapper

By John LeeBMUC October 2015

3D Services at ABC Imaging

3D print management

ABC3DPickup or delivery from local ABC 3D print center

Laser cutting & CNC routing complimenting 3D printing

3D scanning of buildings & structures to document existing conditions ABC3DSERVICES

CAD/BIM data repair and conversion

ABC 3D Service Hubs

SeattleIrvineBay Area (Concord)New York CityWashington DC Chicago (opening soon)

US ShopsInternational: Shanghai, London3D, Frankfurt, Dubai3D

3D Print Hub

Dimensions FDM on ABS

CJP Color Jet PrintingABC Imaging 3D printing options

High Resolution w/ diverse polymer resins

Why fabricate RRMs?

Some people have trouble visualizing in 3D from renderings. Tactile maps foster interaction.Easy mark-up and viewing from all angles.Can be an artistic installation in the office, a lobby or home.

3-D Printing is the popular marketing term for Additive Manufacturing.

Additive manufacturing is defined as the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. (ASTM F2792)

Conventional manufacturing techniques are mostly subtractive.You start with a block or panel of material and cut, route, etch and grind away material to make your object. Or sheets of material are deformed around a mold.

Additive not Subtractive

MIT Professor Neil Gershenfeld: Additive fabrication technologies are to subtractive technologies as potters are to sculptors.

Among the advantages in many industrial niches and design practices:

Complex geometry with internal cavities impossible to fabricate by any other method.Setup/Tooling cost and time needed for a new unique design is much less.Generally less material waste.Manufacture parts on demand, as needed. No need for keeping inventory and shipping. Local manufacturing.

Some Limitations of AM

Not for mass production; its for mass customization.

The flip side of the quick setup and low tooling cost is that if you want to mass produce a design, the 1,000th copy costs essentially the same as the 1st copy in terms of materials and machine time. No economies of scale.

Poor substitute for traditional manufacturing in some cases. Earliest 3D Printers were used for rapid prototyping mostly.

While theres great freedom of geometry, there is a limit to the shapes that the various 3D printing processes can make.

High material costs can make larger parts prohibitively expensive. Razor and Blades business model pervades the industry. With few exceptions you must buy proprietary materials from the machine manufacturer.

Learning CurveThe more capable the machine, the higher the learning curve.File preparation is especially intensive for detailed architectural scale models.Every type of AM process has a post-processing step. Mostly this involves removing support material (scaffolding) and may involve applying infiltrate hardeners. Can be labor intensive for large and detailed model parts. Often requires additional equipment like lab ovens, ultraviolet light ovens, water pick stations and bathing units

Learning CurveThe more capable the machine, the higher the learning curve.File preparation is especially intensive for detailed architectural scale models.Every type of AM process has a post-processing step. Mostly this involves removing support material (scaffolding) and may involve applying infiltrate hardeners. Can be labor intensive for large and detailed model parts. Often requires additional equipment like lab ovens, ultraviolet light ovens, water pick stations and bathing units

AM Machine Categories & ClassesPer ASTM International Committee F42:Seven AM Process Categories

Binder Jetting* (multi color capable)Directed Energy DepositionMaterial ExtrusionMaterial JettingPowder Bed FusionSheet Lamination* (multi color capable)Vat Photopolymerization

And within some of the categories, there are three classes of machine models.ProductionProfessionalPersonal

Production Class AM Machines$100k to $1 millionInstallation area may need HVAC and electrical outfitting.Chamber sizes up to around 3 feet x 3 feet x 2 feet. Operator training required.Used mainly by large engineering firms and service bureaus located in industrial areas of mid-sized cities.

Professional Class 3-D Printers$20k to $80kDesigned to be office friendly, to varying degrees.Chamber sizes typically not more than 14 inches in any dimension. Service contracts are offered. Proprietary robust driver software.Used mainly by design professionals, universities and service bureaus located in large cities.

Personal Class 3-D Printers$1k to $3kFor hobbyists and tinkerers. Mainly the material extrusion process. Only simple massing models are possible. Some simple end-use mechanical parts can be made. No onsite machine service is available. Driver software is open source in many cases. Not as reliable as pro-level or production level machines.

Binder Jettingan additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materialsColor-Jet Printing (Zprinting) is one of the two multi color/texture map capable processes. Production and Pro level machines only. Some processes use powdered stainless steel and plastic powderGood speed and entire layer is solidified in several gantry passes can nesting multiple models both horizontal and verticalCan even nest parts inside of larger hollow parts Raw parts are porous. Intricate geometry is possible.

Binder Jetting/End-use architectural hardwareExOne metal process can be used for custom architectural fixtures like door handles, murals and fixtures.

3D Systems Color-Jet Printers

Advantages of Color-Jet PrintingFastest 3D printer build time on the marketLowest cost material and operating costsDetailed models convey your design effectivelyModel parts can be infiltrated with different resins depending on the application Potential to print in multi color including texturesCan create several iterations of the same design quickly nested in the same build cycle

VIDEO: Color Jet Printing (CJP)

CJP- City of Rockville, MD

CJP + Dry-Mounted 2D Plot

CJP Permitting Model

CJP from contours

CJP from DEM

CJP from CAD+Ortho

Reagan Natl Airport

CJP Shaded Terrain

Geologic Model-Dam Abutment

Dam Abutment Major Joints

Dam Abutment Major Joints Mesh PrepSeveral removal pieces connect by dowels.

Hydro-electric dam abutment joints model assembled.CJP

Hydro-electric dam abutment joints model assembled.CJP

Sheet Lamination

an additive manufacturing process in which sheets of material are bonded to form an objectMCOR process uses common office paper and is multi color capable. Capable of simple massing models only.Some other industrial machines weld very thin metal sheets with ultrasonic vibration.

MCOR Paper 3DP Video #1

MCOR Paper 3DP Video #2

MCOR

File formats from Global Mapper for color 3DPVRML (.wrl) Export web format menuOrPLY (polygon file) Export 3D format menu.Before you send the file: See scale, vertical exaggeration and other design considerations in the Summit Terragraphics presentation.

Raised-Relief Maps & Solid Earth ModelsWhy, Examples, Workflows, Design ConsiderationsPresented by:Michael HigginsSummit Terragraphics Inc.

BMUCOctober 2015

www.summitmaps.com

2D Methods for Showing TerrainFlat methods of presenting terrain can be very effective as shown in the samples below. But at times using a 3D model greatly eases interpretation of complex terrain, particularly for the untrained eye.

Contour LinesShaded ReliefElevation Color-Ramp

Combined Topo Shaded Relief

Why raised-relief and 3D models?

The original National Park Service 2D flat map of Glacier Bay National Park is shown at right. Summit very effectively converted this map to a raised-relief format shown below.Notice on the raised-relief map how easy it is to quickly understand and interpret the complex and rugged terrain.

Summit Terragraphics IncSampling of products:

At left, the National Park Service Denali map, converted to 3D raised-relief map format.At right, a raised-relief map of a private property in North Carolina.

Summit Terragraphics IncSampling of products:

At right, a raised-relief map of Kabul, Afghanistan and surrounding area, produced for the US Army.At right, a large raised-relief map of the Arctic Circle, modeling the ocean bathymetry as well as the land topography.

Summit Terragraphics IncSummit is a leading designer and manufacturer of thermoformed raised-relief maps and Solid Earth Models for National Parks and recreation areas, government/military, corporations, and individuals.

Up to 50 x 35 3D area.Up to 3 4 of relief.

Key Technology -- 3D printed thermoform terrain molds extreme resolution and accuracy with economical cost.Key Advantage low cost 3D map production once design/tooling is complete.

Raised-Relief Map Manufacturing Methods3D Printed Solid Earth Models

Pros: Very high terrain shape fidelity particular in steep/deep areas Very good image-terrain registration.

Cons: Significant cost for each model.Limited print resolution and color.

Raised-Relief Map Manufacturing MethodsPrinted & thermoformed plastic sheets

Pros: High print image quality. Accurate terrain modeling.Low per map production cost.

Cons: Significant tooling costs.Image registration & deep valleys/canyons challenging at times.

Raised-Relief Map WorkflowTypical Work Flow for a Summit Terragraphics Thermoformed Raised-Relief Map Project

Customer Requirements Extent, Scale, FormatSource/Generate Map ImageEarth-Imagery Base layerColor-Illustrated Base LayerVector Graphic Overlays Collect/Process Elevation DataNED, SRTM, Lidar, Construct Terrain Thermoform Mold (3D printing/ composite lamination)Print - Review Map Wide-format digital printing on flat vinyl sheetThermoform Prototype Raised-Relief MapCustomer Prototype Review -- adjust graphics as needed.Print & Thermoform Production Raised-Relief Maps2 Weeks2 - 4 Weeks1 Week1 - 2 WeeksCustomer Print Image Review -- adjust graphics as needed.

Solid Earth Model WorkflowTypical Work Flow for a Summit Terragraphics 3D Printed Solid Earth Model Map Project

Customer Requirements Extent, Scale, FormatSource/Generate Map ImageEarth-Imagery Base layerColor-Illustrated Base LayerVector Graphic Overlays Collect/Process Elevation DataNED, SRTM, Lidar, 3D Print Color TilesPrint - Review Map Wide-format digital printing on paper, full size.2 Weeks2 Weeks1 Week1 - 2 WeeksCustomer Print Image Review -- adjust graphics as needed.Composite Reinforce and Laminate Tiles into full model

Raised-Relief Map Design ConsiderationsHorizontal Scale: Summit Terragraphics has worked across a wide range From 1:4,000 (Torrey Pines, to right)To 1:5,700,000 (Arctic Circle, below)

To 1:33,000,000(Mini US map, toLeft) Most

Most of Summits projects are: 1:50,000 to 1:500,000

Raised-Relief Map Design ConsiderationsVertical Scale and Exaggeration: Summit Terragraphics has worked across a wide range.

From .80x(private ranch, shown at right)

To 15x (Arctic Circle)

To 35x(mini US Map)

Raised-Relief Map Design ConsiderationsThe optimal vertical scale and exaggeration are dependent on both terrain geometry and scale. The data points plotted below show the vertical exaggeration selected for a variety of map projects.

High ExaggerationAverage ExaggerationLow Exaggeration

Most often 1.5x to 3x

1x

11,000 drop over 8 miles =.26 Height/Rad2x3x4xMt Rainier

6x

Kauai Raised-Relief Map and Solid Earth Model Project

1:60,000 horizontal scale2x vertical exaggerationHawaii State Plane 4 projection10m sat image base layer10m NED DEM

Kauai Raised-Relief Map and Solid Earth Model Project

Thermoformed Plastic RRM40 x 303D Printed Solid Earth Model20 x 15