DESIGN AND 3D PRINTING OF CUSTOM-FIT PRODUCTS WITH FREE ONLINE SOFTWARE AND LOW COST TECHNOLOGIES. A STUDY OF VIABILITY FOR PRODUCT DESIGN STUDENT PROJECTS C. Rodrigo Corbatón 1 , M. Fernández-Vicente 1 , A. Conejero 1 1 Universitat Politècnica de València-Escuela Técnica Superior de Ingeniería del Diseño (SPAIN) Abstract This case study analyses the viability of an efficient modeling approach using Grasshopper as a parametric Computer Aided Design (CAD) application in combination with low-cost digitizing devices and low-cost Additive Manufacturing (AM) printers for customization design and manufacturing of a product: sunglasses. The aim of the study was to enabling design students to utilize the advantages of three-dimensional (3D) scanning, CAD and AM for bespoke design. Face geometry features were captures using free photogrammetry software. An automated modeling procedure was developed and applied to model a concept of sunglasses that fits to the user face. The resulting virtual sun glasses was manufactured with two AM printers, a previous prototype low-cost printed in ABS and a final functional version in Nylon manufactured with a SLS technology sanded and painted with the lens assembled . An initial economic study indicated that the presented approach offers a feasible alternative to the current practices and proves the possibility for design students for custom-fit design with an affordable low-cost process Keywords: Innovation, low cost technology, 3D printing, Custom-fit design, 3D digitizing, additive manufacturing. 1 INTRODUCTION In the past few years, AM technologies has started to be used as Rapid Manufacturing (RM) – the production of end-use parts from Additive Manufacturing systems to produce end-use parts 1 . The principal advantage of the Additive Manufacturing processes is the ability to manufacture custom parts directly of complex geometry entirely without the need for tooling, being this application one of the most given use 2 . Therefore the opportunities for product design and manufacturing are immense 3 . Thanks to RM and other technologies such as 3d digitalization of customer anthropometric data it is now possible to create individualized products. These bespoke products, configured to personal use, could provide an alternative direction for consumer purchasing behavior in the future 4 . In this sense the production of custom design hearing aids by Siemens Hearing Solutions and Phonak Hearing Systems are the first examples of this approach. Using CAD software, the contours of a patient’s ear conduct are digitized and custom-made hearing aid shell is produced via 3D printing 5 . More recently, other cases such as the printed New Balance running shoe 6 or the custom prosthetics of Bespoke Innovation 7 , who invites the user to choose from a variety of graphics, patterns, finishes or even add text or tattoos. Another example related to this study is the custom 3D printed glasses service that offers the company Protos located in San Francisco. The uniqueness of their business is based in the way that customers place their orders. Their service is based on a website where anyone with Internet access is a potential customer. After choosing a base model, the website makes a series of photos of the user to modify and fit the chosen mount 8 . These processes used by new emerging companies producing custom fit products commonly involves: a) 3D scanners to capture anthropometric data, b) CAD applications to 3D modeling and c) AM to build the product. This process implies the acquisition of software and equipment that in the majority of cases are unaffordable for designers. However, the combination of innovative and emerging free design software and low-cost 3D printing bureau services compared with traditional methods, has the potential to emerge as a new bespoke industrial design methodology. Furthermore, an opportunity whereby there will be the ability for individuals to cost effectively control the design and manufacture of individual customized products 9 .