3D E-Mail

3D E-Mail

Some time ago, we talked about our future zillions of years from

now. The experts in the field seemed to indicate mankind”s only

hope for survival was to somehow use the “Scotty, beam me up”

approach to reconstruct ourselves in another universe. This

certainly will be a formidable task, especially since we aren”t really

sure there is such a thing as another universe! It was only natural

that I was intrigued by an article in the February 2000 issue of

Discover magazine about a small step in this direction. The

article, titled “Behold, the 3-D Fax”, describes a beam-me-up

process that is now a reality, at least insofar as certain kinds of

inanimate objects are concerned. Ok, you can”t beam the

inanimate object to another universe but you can transmit it from

New York to London or to New Jersey, which, in the view of

some New Yorkers, is equally distant from “The City”. Ok again,

you can”t transmit the object itself but you can transmit a three-

dimensional replica of sorts.

My memory is a bit rusty on the details, but I remember being

quite impressed by something I saw when I worked for NACA”s

Lewis Flight Propulsion Lab in Cleveland some 40 years ago. It

was a machine that could be programmed to carve out a wooden

or possibly a plastic model of such things as an experimental

design of an airplane wing. I don”t know how the programming

was accomplished but it was not a common thing in those days.

Today, we have the next step and the subject of the Discover

article, the three-dimensional replicator (3-DR) or, as termed by

its inventor, stereolithography. Let”s stick with 3-DR.

Our hero is Charles Hull, who was working for a company that

made ultraviolet lamps used to harden special plastic coatings of

some sort. In 1984, Hull was fooling around in his lab and

decided that he could use these lamps to make solid plastic

objects. What he did first was to dump a bunch of gooey plastic

in a basin. Now he wanted to harden certain specific areas of the

plastic. So, he designed a computer system that could guide a

beam of the UV light in the desired pattern on the surface of the

plastic. This hardened a layer of the goo where the light hit the

plastic. Hull then lowered a platform just below the surface the

basin. I”m assuming that the hardened plastic stuck to the

platform. By lowering the platform just a tad, a thin layer of goo

covered the hardened layer of plastic. This process of patterned

illumination and lowering of the platform was repeated until Hull

had built up a solid object. He then raised the platform to reveal

his first creation, a blue plastic cup about an inch tall.

Three years later, he revealed his invention to the engineering

world and it was a hit! Hull founded a company called 3D

Systems in California. The field is now known as solid-imaging

and also can be termed three-dimensional printing. You have a

choice of just about any name for this generic machine, which of

course was long anticipated by the usual cast of characters, the

science fiction writers. Those in the solid-imaging field expect

that in the future you”ll be able to download the software to make

all kinds of objects on your home 3-DR. A comb or a plastic doll

should be duck soup to make.

The article mentions a computer-graphics show last summer at

which hundreds of attendees submitted to laser-scanning of their

heads. Each walked away with a two-inch high, very precise

sculpture of their face. Designers from multi-national companies

can e-mail their designs to their counterparts” solid-imaging

machines to turn out models for inspection anywhere in the

world. There are now ink-jet printers that print, not ink, but little

dots of hot plastic that can be built up into 3-D objects. The

machines, which cost about $65,000, have drawn fans in the

jewelry business where they are used to make wax molds in which

to cast the jewelry. Medical applications currently include making

models of such items as heart valves, dentures, and molds for

making replacement parts such as artificial hip joints.

Archaeologists can use X-ray or other techniques to model

images of the skull or other parts of mummies without

unwrapping them.

The future holds the promise of ink-jet printers that will spit out

dots of not just plastic, but combinations of plastic binders with

ceramics or metals that can be fused together to make complex

shapes and compositions of materials. Laser-sculpting can copy

all kinds of objects. Who knows, you might want to have a copy

of the Venus de Milo or the David in your living room? Instead

of going to a foundry with your model to be cast in bronze, you

might just sketch out your object on your computer and then farm

out the software instructions to your local solid-imaging

equivalent of Kinko”s. This assumes you can”t afford your own

home 3-DR.

An unrelated article in the American Chemical Society”s

publication Chemistry last summer may actually eventually blend

in with the above subject. The short abstract of a paper in April

1999 issue of Nature deals with a property known as

superplasticity. This is a pretty simple concept, it just means that

you can stretch a chunk of a material without breaking it, just like

pulling taffy. Brings back memories of the time as a child when

our family lived in Atlantic City. Do they still have salt-water

taffy? But back to superplasticity. Metals and alloys have what

are known as grain structures, which you can see typically by

polishing and/or etching a sample. These grains are essentially

little crystals. Unless you have the rare single crystal (which you

do have in most semiconductor devices), a metal or alloy object is

composed of many grains of various sizes. What has been found

now is that by reducing the size of these grains or microcrystals

down to the nanocrystal size (really, really small crystals), the

same metal or alloy can be pulled without breaking at much lower

temperatures than for the ordinary, larger grain materials.

What amazed me was that a nickel alloy with aluminum was one

that was mentioned in the article. When I was at Bell Labs, I

once foolishly thought that a nickel-aluminum alloy would make a

good electrode material for a battery. I had a sample the size of

my thumb made up and was going to form it into an electrode. It

turned out that sucker was the hardest most unbreakable,

unbendable, unfile-able, uncrushable piece of stuff that I”ve ever

handled. I couldn”t do anything with it. At any rate, these fine-

grain superplastic materials, with their property of superplasticity

at much lower than normal temperatures, result in more

economical fabrication of objects ranging from aircraft turbine

blades to biomedical prosthetic devices.

To sum up, the world of fabricating materials into 3-D objects is

one that is evolving into forms that even the recent plethora of

millennial prognosticators might consider quite revolutionary.

Now if we can find that other universe, maybe there”s still hope

for our future.

Allen F. Bortrum