Rapid Prototyping Presentation 3D Printers

7/28/2019 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.htmlhttp://www.zcorp.com/content/product_info/keyadvantages.htmlhttp://web.mit.edu/tdp/www/applications.htmlhttp://web.mit.edu/tdp/www/whatis3dp.htmlhttp://www.nsf.gov/od/lpa/news/02/3dprinttip_images.htmhttp://www.howstuffworks.com/stereolith3.htmhttp://www.webworqs.com/nomura/stereo.htmlhttp://www.padtinc.com/rm/sla/default.htmhttp://www.cs.hut.fi/~ado/rp/subsection3_6_1.html

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Rapid Prototyping Presentation 3D Printers