Honey, I Shrunk the Pyramids: Met Museum, Proto Labs Create Model of Ancient Egypt

For the Metropolitan Museum of Art’s exhibition, “Ancient Egypt Transformed: The Middle Kingdom,” on view at the New York museum through Jan. 24, 2016, exhibit planners decided to reconstruct the pyramid complex of King Senwosret III in both a virtual and physical model.

The scale model of the pyramid site is displayed in the Metropolitan Museum of Art’s galleries.

The physical 1:150-scaled model of the site is based on a 3D virtual model that was produced first, and modeled after 3D-printed prototype parts that were created by Proto Labs. For perspective, the main pyramid of the original complex was more than 206-ft.high. In the scaled model, it is 1.5 feet. The creation of the model, which is intended to bring this important Middle Kingdom era to life for visitors to the exhibition, involved a process that was an intriguing blend of traditional and digital methods. This process included traditional sculpting, model-making, mold-making, casting, carpentry and faux painting, plus digital methods of fabrication, specifically 3D printing. The additive manufacturing process by Proto Labs served as the Met’s prototyping phase that helped replicate the unique parts of the model. Continue reading

3D Printing Fully Functional Parts with Selective Laser Sintering

Selective laser sintering (SLS) is an industrial-grade 3D printing process. It builds durable nylon prototypes and functional parts using a laser that “draws” slices of a CAD model in a bed of material, fusing micron-sized particles one layer at a time. The result is fully functional plastic parts that might have been otherwise challenging to manufacture using machining or injection molding.
This month’s tip discusses:

  • Properties and applications of various nylon materials
  • Managing the SLS build process
  • Design elements to improve eventual moldability
  • Surface finishes and post-processing
  • Maximum part size, achievable tolerances and other considerations.

Read the full design tip here.