Rapid Prototyping Presentation 3D Printers

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    Rapid Prototyping

    Laminated Object Manufacturing

    Selective Laser Sintering

    StereolithographyFused Deposition Modeling

    Solid Ground Curing

    3D Printing

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    What is Rapid Prototyping

    Builds parts Layer-By-Layer

    Class of technologies that construct physical

    models from CAD data

    Some what like a 3-D printer

    An Additive process Visual Aids or Design Testing

    Rapid Tooling or Rapid Production of parts

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    The Basic Process

    Create a CAD model of the design

    Convert the CAD model to STL format

    Slice the STL file into thin cross-sectional

    layers

    Construct the model one layer atop another Clean and finish the model

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    CAD MODEL

    Build a Model

    Solid Modeler Packages

    Such as Pro-Engineer tend to represent objects

    more accurate then wire frame packages

    Yield better results

    Existing CAD or Create a model for RP

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    Conversion to STL

    STL Format

    Establish consistency

    ****.stl stereolithography, the first RP technique

    Represents a 3-D surface in an assembly of planar

    triangle

    Like facets of a cut jewel

    Planar elements Can not represent curve surfaces exactly

    Accuracy vs. manageability

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    Conversion to STL

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    The Slice

    Pre-processing program

    Prepares STL file for build

    Most program allows user to adjust the model

    Size

    Location

    Orientation

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    The Slice

    Orientation

    Weaker and less accurate in the Z direction then

    in the x-y plane

    Orientation partially determines the amount of

    time for build

    Higher in the Z

    lot more time to build Place shortest dimension in the Z

    Reduces the number of layers

    Layers are slices from .01mm to .7 mm (technique)

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    The Slice

    Auxiliary Structure

    Supports the model during build

    Useful for delicate parts

    Some time difficult to remove

    Damage to Model

    Poor surface finish

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    Layer by Layer

    Construction of the part

    Several Techniques

    Builds part one layer at a time

    Polymers

    Paper

    Wax Powdered Metal

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    Clean and Finish

    Final Step is post-processing

    Removing prototype

    Detaching supports

    Curing (if needed)

    Minor Cleaning

    Surface treatment

    Sanding, sealing, painting and so on

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    Clean and Finish

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    Rapid Prototyping Techniques

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    Laminated Object Manufacturing

    Called LOM. (Helisys)

    Paper is coated heat-activated glue so it will stick.

    (spool)

    Paper is bonded with last piece with heated rollers.

    Design is cut out of paper with a laser.

    The excess paper is cross hatched for removal. Produces large parts.

    Wood like texture

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    LOM Process

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    LOM Examples

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    Selective Laser Sintering

    Called SLS. (DTM Carl Deckard)

    Melts powdered material a layer at a time.

    Uses leveling rollers

    Laser is used to melt powdered material.

    Traces part and sintering metal powder

    Makes functional parts.

    Many different powders can be used.

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    SLS Process

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    SLS Examples

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    Stereolithography

    Called SLA. (3D Systems first 1986)

    Photosensitive liquid resin hardens when

    exposed to a laser. Low-power high focused UV laser

    Traces out layer, solidifying resin

    Liquid epoxy or acrylate resin

    The part is created layer by layer. The part needs to be cured after it is created.

    Great accuracy and surface finish.

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    SLA Process

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    SLA Examples

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    SLA Examples Cont

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    Fused Deposition Modeling

    Second Most Widely Used

    Filament of heated thermoplastic is extruded from

    the tip X-Y plane

    Like decorating a cake

    Platform lowered and head deposits a second layer

    upon the first

    ABS, PC, Casting Wax, Polyphenolsulfone

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    FDM SAMPLES

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    Solid Ground Curing

    SGC - (Cubical)

    Similar to stereolithography

    Uses UV light

    Selectively hardens photosensitive polymers

    Cures entire process at a time

    Photomask Printed on glass plate

    UV light passes through the mask to the polymer

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    SGC

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    3D Jet Printing

    Entire class of machines

    3D Printing (3DP MIT, Soligen Corp.)

    Powder (excess is blown off)

    ZCORP 3D (Z corp.)

    Powder (excess is blown off)

    Thermo-Jet (3D systems)

    Molten wax or polymer (no excess)

    The model is built up layer upon layer at a time. Ink-jet printer head technology

    Different materials can be used.

    Versatile

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    3D Printing Process

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    3D Printing Examples

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    3D Printing Examples Cont

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    3D Printing Examples Cont

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    Source Credit

    http://home.att.net/~castleisland/lom_int.htm http://www.milparts.net/lom.html

    http://www.ind.tno.nl/prototyping/rapid_prototyping/lom.html

    http://www.bath.ac.uk/~en7bnd/rp/lom.htm

    http://home.att.net/~castleisland/sls_int.htm

    http://www.materialise.com/mt.asp?mp=ps_laser http://www.cs.hut.fi/~ado/rp/subsection3_6_3.html

    http://home.att.net/~castleisland/lom_int.htmhttp://www.milparts.net/lom.htmlhttp://www.ind.tno.nl/prototyping/rapid_prototyping/lom.htmlhttp://www.ind.tno.nl/prototyping/rapid_prototyping/lom.htmlhttp://www.bath.ac.uk/~en7bnd/rp/lom.htmhttp://home.att.net/~castleisland/sls_int.htmhttp://www.materialise.com/mt.asp?mp=ps_laserhttp://www.cs.hut.fi/~ado/rp/subsection3_6_3.htmlhttp://www.cs.hut.fi/~ado/rp/subsection3_6_3.htmlhttp://www.materialise.com/mt.asp?mp=ps_laserhttp://home.att.net/~castleisland/sls_int.htmhttp://www.bath.ac.uk/~en7bnd/rp/lom.htmhttp://www.ind.tno.nl/prototyping/rapid_prototyping/lom.htmlhttp://www.ind.tno.nl/prototyping/rapid_prototyping/lom.htmlhttp://www.milparts.net/lom.htmlhttp://home.att.net/~castleisland/lom_int.htm
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    Source Credit Cont.

    http://www.cs.hut.fi/~ado/rp/subsection3_6_1.html

    http://www.padtinc.com/rm/sla/default.htm

    http://www.webworqs.com/nomura/stereo.html http://www.howstuffworks.com/stereolith3.htm

    http://www.nsf.gov/od/lpa/news/02/3dprinttip_images.htm

    http://web.mit.edu/tdp/www/whatis3dp.html

    http://web.mit.edu/tdp/www/applications.html

    http://www.zcorp.com/content/product_info/keyadvantage

    s.html

    http://www.cs.hut.fi/~ado/rp/subsection3_6_1.htmlhttp://www.padtinc.com/rm/sla/default.htmhttp://www.webworqs.com/nomura/stereo.htmlhttp://www.howstuffworks.com/stereolith3.htmhttp://www.nsf.gov/od/lpa/news/02/3dprinttip_images.htmhttp://web.mit.edu/tdp/www/whatis3dp.htmlhttp://web.mit.edu/tdp/www/applications.htmlhttp://www.zcorp.com/content/product_info/keyadvantages.htmlhttp://www.zcorp.com/content/product_info/keyadvantages.htmlhttp://www.zcorp.com/content/product_info/keyadvantages.htmlhtt