Manual

Door handles made easy

i.materialise stainless steel door handles v1.1

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Contents

Introduction - 3

Design Kit - 5

Tips and Tricks - 10

3D Printing - 15

Design by PeLi Design

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i.materialise is a 3D printing service for everybody with an eye for design and a head full of ideas.

We want you to focus on the creation of designs –made by you– that add value to people’s lives, while we do the manufacturing.

We want to be the power behind your design.

There’s something special about physically holding a design you’ve spent so many hours on.

Door handles? Really?Yes… 3D printed door handles! Personalize your door handles and welcome people into your sense of style at the same time they enter your house.

Inspired by PeLi Design’s groundbreaking door handles, we’ve created a design kit allowing you to create 3D printed stainless steel door handles of your own. These unique door handles are sure to impress any visitor, and with this kit, we ensure that you get the design that suites you best…your own.

Design by PeLi Design

Design by PeLi Design

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How does it work?It’s simple.

We offer you a building volume with fixed dimensions for your handles and rosettes. With our design kit you can prepare your file for production.

We ‘ll offer you the following items: (from left to right)

2 rosettes with 4 screws for attaching the rosettes,

2 handles with 2 fixation screws for the handles,

a locking mechanism with the connection box and 4 screws

a small installation guide.

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building volumes

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Download the Design kitOn the website, you can select the software program you want to design in. In these files you’ll find the different layers with aids, and guides that will help you with make your design printable.

You can chose from the following file types:

Google SketchUp .skp

Rhino .3dm

3ds Max .3ds

Wavefront .obj

Content Design kitOpen the design kit in your 3D modeling program and you will find:

A reference door and lock

Bounding boxes for one rosette and one door handle

An example set of door handles with handles, rosettes, a fixation screw, and rosette screws

A star shaft that needs to be subtracted from the lever

Elements which remain in the model: the fixation screw

References for the rosette screws

A guide of tolerances for a Teflon ring on the lever and rosette

example of set

TIP Once you’ve selected and downloaded the kit, you can get started. but it’s best to read through the manu-al to get to know the do’s and don’ts.

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Step 1 - Size handle and rosette

Bounding box handleFor a fixed price we offer you a so called bounding box. This means that your design has to fit inside of this box. So it’s good to start looking at this size when starting to design in order to avoid hav-ing to rescale your design afterwards.

For your ease we have split up the bounding box of the rosette and the lever.

A box of 55mm x 10mm x 55m is the maximum you can use for one rosettes.

For the handle the maximal size would be 140mm x 90mm x 35mm.

ExampleTo help you design your door handle set, we have added an example in one of the layers. You use it as a template or just a reference. The choice is yours. The example also serves a checklist to see what needs to be included when uploading the file to our 3D print lab.

In the kit we have also included a standard size door and locking mecha-nism, to making it easier to get an idea of how your design would look in the end. You’ll find them in the layer called “reference door & lock”’.

TIP Designing within the bounding boxes is obligatory since non conform sizes will be re-jected. Please pay attention to this

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Star ShapeThe reason we want you to use a star shape is that it allows you to use the doorhandle for both of the standards on the market.

If you already have a locking system in place, you can check which standard you have. But in principle, this doesn’t change anything on your design. The star shaped hole in the handle will allow both options to be used. This means if you move or want the doorhandle on a different door, this should be possible.

The first standard has a neutral position with a horizontal square shaped hole.

In the the second standard this square hole is turned by 45 de-grees.

This is the option that we will ship in our package.

Step 2 -Shaft leverThe second step is all about making sure your doorhandle can fit on to the locking system. This means that you need to substract the star shaped volume that we provide in the design kit

Subtracted volumeMake sure that the star shaped volume is in the correct position when you subtract it from your design, and that your handle has a wall thick-ness of at least 3mm at least around this shaft. You can find the star shaped box in the “boolean difference‘‘ layer

With the star shape subtracted the box shaped shaft can be slid on for the 2 standards, as you can see.

Also, for the second standard, the lever can be slid on without any problems.

This flexibiltiy is the main reason this type of shape is used.

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Step 3 - Screws

Handle screw The next step is forseeing a fixation for the lever. This screw needs to be inserted to attach the handle to the connector box that will be inserted in the lock. Since this is a screw, holes need to be made and a thread needs to be created. Due to the technology used and the strength needed, it is better to create the hole and thread after the level is built. Therefore, the only thing you need to ensure in your 3D file is that there is enough space for the screw to be inserted after printing. If you keep enough wall thick-ness of minimum of 3mm around this cylinder so the hole and thread can be made without any problems. You can find the cylinder in the “keep in model”’ layer.

Rosette screwsIn order to attach the rossettes to the door, you need to foresee holes for the screws in both sides of the rossettes. Depending on your choice, the screws can be positioned either horizontally or vertically.

�xation screw

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Step 4 - TolerancesThe final step before uploading is making sure that the lever and rosette have good toler-ances in order to ensure the handle works without any issues. When putting your set of doorhandles together we will insert a teflon ring between the handle and the rosette. Therefore, it’s important to leave enough room between the 2 components.

In the layer called “tolerances”you can see what size the component should be.

te�on ring

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Step 5 - ChecklistDesign guide

Check the general design rules of Stainless steel on our webpage.

Content uploadDelete the references before up-loading. Keep the fixation screw in your model, and make sure to subtract the star shaped shaft.

Check the example layer to see what we expect you to upload.

ErgonomicsTry to imagine the use of your door handle. In everyday use, ergonomics are important.

Wall thicknessCheck the wall thicknesses. For your door handles you should have a minimum of 3mm.

Only then, a part will be strong and durable enough to be used as a door handle.

Minimum

3mm

Building volumeMake sure your design fits inside the building volumes. If your model is too big, rescale it, but make sure you don’t lose too much wall thickness by doing so. Also, make sure that the dimensions of the star shaped shaft are correct. If you rescale the design, it’s pref-erable that you redo the boolean dif-ference of your lever with the star shaped volume.

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Go over the following items to verify whether your design is ready for uploading.

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Step 6 - UploadUpload

In order to have your design recognized as a door handle set you need to upload it via the door handles page.

Once you have selected your file and pressed open, your file will be up-load to our 3D print lab.

PreviewWhen the upload is completed, a preview will be generated. This way you can see if the upload was done correctly.

Material

The material will automatically be selected since we only offer the door handles set in Stainless Steel. It is not possible to choose another material.

ColorYou can now select the color you want your door handle set to be. Note that the entire set has to be the same color..

CheckoutIf you are happy with everything, you can complete the order by press-ing the checkout button.

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Stainless steelModels made in stainless steel are printed in stainless steel powder that is infused with bronze.

Stainless steel is the cheapest form of metal printing, very strong, and suitable for very large objects like doorhandles.

TextureDue to the building process, which adds material layer by layer, lines will be visible on your door handle. Some of the lines will be polished away by tumbling.

If an area of your model is inaccessible during the tumbling process, because it is a recess or is covered, it will be dark black in color.

Check the stainless steel page on our website for more information, design guides, and images.

ColorsThere are three options when selecting a color in stainless steel.

Check our Flickr for more examples

Tips and tricks

Old Silver Medieval Pewter

Wheat Pewter

Design by PeLi Design

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Example: Doorhandle by PeLi Design

1 PeLi has designed a set of door handles and would like to have a real life model of it. He down-loads the i.materialise door han-dle kit.

2 Peli uses the different layers and references to adjust his design to the building volume, places the screws, subtracts the star shaped shaft and uses the tolerances provided.

3 Once he is happy with the model, he presses the upload button. and selects his 3ds file. His file is quite big, so he visits other websites while waiting for the upload. The progress bar keeps him updated on the status of the upload.

4 Once the model is uploaded, he selects the color of his choice - Old Silver- and confirms his order.

5 When the model is uploaded on the i.materialise website, PeLi proceeds through the necessary steps and orders his model. PeLi receives his 3D printed door handles in the mail. They look awesome, and are exactly what he wanted!

Design by PeLi Design

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3D P

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How Pro Metal technology worksEx One technology works by creating a 3D physical model directly from digital data, layer by layer, turning concepts and ideas into real, physical 3D mod-els that you can hold, examine, and evaluate.

3D printing technology by

1 A 3D CAD file is imported into the system software. The software slices the file into thin cross-sectional slices, which are fed to the 3D printer.

3 The process is repeated un-til every layer is printed and the part is complete and ready to be removed.

2 The printer creates the model one layer at a time by spreading a layer of metal powder and inkjet printing a binder in the crosssection of the part.

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1 PrintBinder is selectively dispensed using inkjet printing technology.

2 New LayerThe build platform is lowered by a set increment..

3 SpreadA new layer of powdered metal is spread.

4 RepeatSteps 1-3 are repeated, until the part is built.

5 FinishingUnbound metal is removed. Metal parts are thermally processed..

Powdered Metal

recoater applies the powdered metal on the build platform.

Bound Metal

The printhead selectively dispenses the resin in to the powdered metal. This temporarly builds the part until it can be sintered to the specified density.

Forming ProcessPrint functional parts in hours directly from CAD.

Metal parts are built in a layered fashion. Each layer is comprised of two materials added sequentially:

3D printing technology by

Enjoy your 3D printed door handles

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