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Massachusetts Institute for Technology Boston, US A, !"#"$ % 3D Systems, Valencia USA & ( ) (time to market ( * )$+ , % -* . / 0 1 2333$ ) RP ThermoJet 3D Printer 3D Systems. , % CATIA IBM Tempus JEP-14340/99 $ 1 4 % RP/RT5

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Type: Declaration 3D Systems Export Control Document Document Number: ECD 1 Document Description: Customer Use Decleration

Ph.D. Milan Sljivic IS INVOLVED IN lecturing about RP technology and research about the abilities of the investment casting supported by rapid prototyping - Thermo Jet technology Milan Sljivic understands the sensitive nature of 3D Systems SLA Systems and the possibilities of its proliferation for nuclear end use. The purchased system shall not be used for designing, developing or fabricating nuclear weapons or nuclear explosive devices; or devising, carrying out, or evaluating nuclear tests or nuclear explosions. We hereby declare that we are not involved in developing nuclear reactors (including power plants), fuel reprocessing and enrichment facilities and heavy water production facilities and their collocating ammonia plants. Milan Sljivic shall deploy the SLA System intended to be purchased from 3D Systems for the following purpose: Giving an Education to undergraduate and postgraduate student about RP technology and CATIA software for design. We shall take care to avoid any chance of applying this technology for military purpose. Furthermore, we shall not re-export any 3D Systems products to the U.S. embargoed countries of Cuba, Iran, Iraq, Libya, The Sudan, Syria, and the Taliban controlled areas of Afghanistan nor transfer, export or re-export directly or indirectly to entities on the denied lists of these named U.S. government agencies: Debarred Parties - Office of Defense Trade Control (DTC). http://www.pmdtc.org/ Denied Persons List - Bureau of Export Administration. http://www.bxa.doc.gov/PL/Default.shtm Entity List - Bureau of Export Administration. http://www.bxa.doc.gov/Entities/Default.htm Specially Designated Nationals List - Office of Foreign Assets Control (OFAC). http://www.ustreas.gov/ofac/ Customer Name: Ph.D. Milan Sljivic Address: Stepe Stepanovica 75, Mechanical Engineering Faculty, University Banja Luka Name of Manager: Ph.D. Milan Sljivic Signature:

Date:10.03.2002,

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1.2.1. Stereolitography (SLA) /www.3dsystems.com/ The implementation shown in Fig. 1 is used by 3D Systems and some foreign manufacturers. A moveable table, or elevator (A), initially is placed at a position just below the surface of a vat (B) filled with liquid photopolymer resin (C). This material has the property that when light of the correct color strikes it, it turns from a liquid to a solid. The most common photopolymer materials used require an ultraviolet light, but resins that work with visible light are also utilized. The system is sealed to prevent the escape of fumes from the resin. A laser beam is moved over the surface of the liquid photopolymer to trace the geometry of the cross-section of the object.

This causes the liquid to harden in areas where the laser strikes. The laser beam is moved in the X-Y directions by a scanner system (D). These are

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fast and highly controllable motors which drive mirrors and are guided by information from the CAD data. Some geometry of objects have overhangs or undercuts. These must be supported during the fabrication process. The support structures are either manually or automatically designed. The exact pattern that the laser traces is a combination of the information contained in the CAD system that describes the geometry of the object, and information from the rapid prototyping application software that optimizes the faithfulness of the fabricated object. Of course, application software for every method of rapid prototyping modifies the CAD data in one way or another to provide for operation of the machinery and to compensate for shortcomings. After the layer is completely traced and for the most part hardened by the laser beam, the table is lowered into the vat a distance equal to the thickness of a layer. The resin is generally quite viscous, however. To speed this process of recoating, early stereolithography systems drew a knife edge (E) over the surface to smooth it. More recently pump-driven recoating systems have been utilized. The tracing and recoating steps are repeated until the object is completely fabricated and sits on the table within the vat. Upon completion of the fabrication process, the object is elevated from the vat and allowed to drain. Excess resin is swabbed manually from the surfaces. The object is often given a final cure by bathing it in intense light in a box resembling an oven called a Post-Curing Apparatus (PCA). Some resins and types of stereolithography equipment dont require this operation, however. After final cure, supports are cut off the object and surfaces are sanded or otherwise finished. Stereolithography generally is considered to provide the greatest accuracy and best surface finish of any rapid prototyping technology. Work continues to provide materials that have wider and more directly useable mechanical properties. Recently, inkjet technology has been extended to operation with photopolymers resulting in systems that have both fast operation and good accuracy. See the section on inkjets.

1.2.2. Selective laser sintering (SLS) The process is somewhat similar to stereolithography in principle as can be seen from Fig. 2. In this case, however, a laser beam is traced over the surface of a tightly compacted powder made of thermoplastic material (A).

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The powder is spread by a roller (B) over the surface of a build cylinder (C). A piston (D) moves down one object layer thickness to accommodate the layer of powder.

The powder supply system (E) is similar in function to the build cylinder. It also comprises a cylinder and piston. In this case the piston moves upward incrementally to supply powder for the process. Heat from the laser melts the powder where it strikes under guidance of the scanner system (F). The CO2 laser used provides a concentrated infrared heating beam. The entire fabrication chamber is sealed and maintained at a temperature just below the melting point of the plastic powder. Thus, heat from the laser need only elevate the temperature slightly to cause sintering, greatly speeding the process. A nitrogen atmosphere is also maintained in the fabrication chamber which prevents the possibility of explosion in the handling of large quantities of powder.

After the object is fully formed, the piston is raised to elevate the object. Excess powder is simply brushed away and final manual finishing may be carried out. Thats not the complete story, though. It may take a considerable time before the part cools down enough to be removed from

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the machine. Large parts with thin sections may require as much as two days of cooling time. No supports are required with this method since overhangs and undercuts are supported by the solid powder bed. This saves some finishing time compared to stereolithography. However, surface finishes are not as good and this may increase the time. No final curing is required as in stereolithography, but since the objects are sintered they are porous. Depending on the application, it may be necessary to infiltrate the object with another material to improve mechanical characteristics. Much progress has been made over the years in improving surface finish and porosity. The method has also been extended to provide direct fabrication of metal and ceramic objects and tools.

1.2.3. Laminated Object Manufacturing (LOM)

Profiles of object cross sections are cut from paper using a CO2 laser as shown in Fig. 3.

The paper is unwound from a feed roll (A) onto the stack and bonded to the previous layer using a heated roller (B). The roller melts a plastic coating on the bottom side of the paper to create the bond. The profiles are traced by an optics system that is mounted to an X-Y stage (C). The process generates considerable smoke. Either a chimney or a charcoal filtration

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system is required (E) and the build chamber must be sealed. The finish and accuracy are not as good as with some methods; however objects have the look and feel of wood and can be worked and finished in the same manner. Several companies provide variations of LOM technologies: For example, Kiras Paper Lamination Technology (PLT) uses a knife to cut each layer instead of a laser and applies adhesive to bond layers using the xerographic process. Sol dimension of Israel also uses a knife, but instead bonds layers of plastic film with a solvent. This technology is sold in the US by 3D Systems as the InVisionTM LD. Other variations include Thick Layer Lamination from Stratoconception of France, Precision Stratiform Machining from Ford Research, and Adaptive-Layer Lamination developed by Landfoam Topographics. These are hybrids of additive and subtractive CNC technologies which seek to increase speed and material versatility by cutting the edges of thick layers to avoid stair stepping. The principal US commercial provider of laser-based LOM systems, Helisys, ceased operation in 2000. However the companys products are still sold and serviced by a successor organization, Cubic Technologies.

1.2.4. Fused Deposition Modeling (FDM) FDM is the second most widely used rapid prototyping technology, after stereolithography, fig. 4.

Fig.4. Fused Deposition Modeling (FDM) A plastic filament is unwound from a coil and supplies material to an extrusion nozzle.

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The nozzle is heated to melt the plastic and has a mechanism which allows the flow of the melted plastic to be turned on and off. The nozzle is mounted to a mechanical stage which can be moved in both horizontal and vertical directions. As the nozzle is moved over the table in the required geometry, it deposits a thin bead of extruded plastic to form each layer. The plastic hardens immediately after being squirted from the nozzle and bonds to the layer below. The entire system is contained within a chamber which is held at a temperature just below the melting point of the plastic. Several materials are available for the process including ABS and investment casting wax. ABS offers good strength, and more recently polycarbonate and poly(phenyl)sulfite materials have been introduced which extend the capabilities of the method further in terms of strength and temperature range. Support structures are fabricated for overhanging geometries and are later removed by breaking them away from the object. A water-soluble support material which can simply be washed away is also available. The method is office-friendly and quiet. FDM is fairly fast for small parts on the order of a few cubic inches, or those that have tall, thin form-factors. It can be very slow for parts with wide cross sections, however. The finish of parts produced with the method have been greatly improved over the years, but arent quite on a par with stereolithography. The closest competitor to the FDM process is probably three dimensional printing. However, FDM offers greater strength and a wider range of materials than at least the implementations of 3DP from Z Corp. which are most closely comparable. 1.2.5. MultyJet Modeling (MJM)

Thermal Phase Change Inkjets - This technology has also in the past been called ballistic particle manufacturing (BPM). Fig. 6 shows Solidscape, Inc.s implementation. It uses a single jet each for build and support materials. All phase change inkjet technologies rely on squirting a build material in a liquid or melted state which cools or otherwise hardens to form a solid on impact. 3D Systems also produces an inkjet machine, called the ThermoJet ModelerTM which utilizes several hundred nozzles. 3Ds name for their inkjet technology is MultiJet ModelingTM.

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The Solidscape machine uses plastic object and wax and support materials which are held in a melted liquid state at elevated temperature in reservoirs (A). The liquids are fed to individual jetting heads (B) through thermally insulated tubing. The jetting heads squirt tiny droplets of the materials as they are moved side to side in the required geometry to form the layer of the object. The heads are controlled and only place droplets where they are required to. The materials harden by rapidly dropping in temperature as they are deposited. After an entire layer of the object is formed by jetting, a milling head (C) is passed over the layer to make it a uniform thickness. Particles are vacuumed away as the milling head cuts and are captured in a filter (D). The operation of the nozzles is checked after a layer has been fabricated by depositing a line of each material on a narrow strip of paper and reading the result optically (E). If all is well, the elevator table (F) is moved down a layer thickness and the next layer is begun. If a clog is detected, a jetting head cleaning cycle is carried out. If the clog is cleared, the problem layers are milled off and then repeated. After the object is completed, the wax support material is either melted or dissolved away. The Solidscape system is capable of producing fine finishes, but to do so results in slow operation. Thus, there is a tradeoff between fabrication time and the amount of hand finishing required.

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The 3D Systems ThermoJet is much faster since it simultaneously deposits materials from hundreds of jets, but its also somewhat less accurate.

Fig. 6 a) Jetted Photopolymer System

This machine uses fine, hair-like structures made of the modeling material itself to support overhangs and undercuts. To remove the supports, these structures are simply brushed away manually after the part is fabricated.

1.2.6. Electron Beam Melting (EBM) Electron Beam Melting (EBM), is a type of rapid prototyping for metal parts. It is often classified as a rapid manufacturing method. The technology manufactures parts by melting metal powder layer per layer with an electron beam in a high vacuum. Unlike some metal sintering techniques, the parts are fully solid, void-free and extremely strong.

This solid freeform fabrication method produces solid metal pieces directly from metal powder with characteristics of the target material. The EBM machine reads in data from a 3D CAD model and lays down successive layers of powdered material and in this way builds up the model. These layers are fused together utilizing a computer controlled electron beam. The melted material is from a pure alloy in powder form of the final

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material to be fabricated (No filler). For that reason the Electron beam Technology doesnt require additional thermal treatment to obtain full mechanical properties of the parts. That aspect allows classification of EBM with LSM where competing technologies like SLS and DMLS which required thermal treatment after fabrication. Comparatively to SLS and DMLS, EBM has a generally inferior build rate (Speed) because of its scanning method (1D). Minimum layer thickness: 0.05mm.

This technology was developed by Arcam AB in Sweden

1.2.7. 3D Printing (3DP)

Three-dimensional printing is a method of converting a virtual 3D model into a physical object. 3D printing is a category of rapid prototyping technology. 3D printers typically work by printing successive layers on top of the previous to build up a three dimensional object. 3D printers are generally faster, more affordable and easier to use than other additive fabrication technologies.

One variation of 3D printing consists of an inkjet printing system. Layers of a fine powder (plaster, corn starch, or resins) are selectively bonded by "printing" an adhesive from the inkjet print head in the shape of each cross-section as determined by a CAD file. This technology is the only one that allows for the printing of full color prototypes. It is also recognized as the fastest method.

Alternately, these machines feed liquids, such as photopolymer, through an inkjet-type print head to form each layer of the model. These Photopolymer Phase machines use an ultraviolet (UV) flood lamp mounted in the print head to cure each layer as it is deposited.

Fused deposition modeling (FDM), a technology also used in traditional rapid prototyping, uses a nozzle to deposit molten polymer onto a support structure, layer by layer.

Another approach is selective fusing of print media in a granular bed. In this variation, the infused media serves to support overhangs and thin walls in the part being produced, reducing the need for auxiliary temporary supports for the work piece.

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Each technology has its advantages and drawbacks. Generally, the main considerations are speed, cost of the printed prototype, cost of the 3D printer, choice of materials, color capabilities, etc. [2]

Unlike "traditional" additive systems such as stereolithography, 3D printing is optimized for speed, low cost, and ease-of-use, making it suitable for visualizing during the conceptual stages of engineering design when dimensional accuracy and mechanical strength of prototypes are less important. No toxic chemicals like those used in stereolithography are required, and minimal post printing finish work is needed. One need only brush off surrounding powder after the printing process. Bonded powder prints can be further strengthened by wax or thermoset polymer impregnation. FDM parts can be strengthened by wicking another metal into the part.

Resolution is given in layer thickness and X-Y resolution in dpi. Typical layer thickness is around 100 microns (0.1 mm), while X-Y resolution is comparable to that of laser printers. The particles (3D dots) are around 50 to 100 microns (0.05-0.1 mm) in diameter.

3D printing technology is currently being studied by biotechnology firms and academia for possible use in tissue engineering applications where organs and body parts are built using inkjet techniques. Layers of living cells are deposited onto a gel medium and slowly built up to form three dimensional structures. Several terms have been used to refer to this field of research: Organ printing, bio-printing, and computer-aided tissue engineering among others.

The system was developed at MIT and is shown schematically in Fig. 7. The method is very reminiscent of selective laser sintering, except that the laser is replaced by an inkjet head. The multi-channel jetting head (A) deposits a liquid adhesive compound onto the top layer of a bed of powder object material (B). The particles of the powder become bonded in the areas where the adhesive is deposited.

Once a layer is completed the piston (C) moves down by the thickness of a layer. As in selective laser sintering, the powder supply system (E) is similar in function to the build cylinder In this case the piston moves upward incrementally to supply powder for the process and the roller (D)

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spreads and compresses the powder on the top of the build cylinder. The process is repeated until the entire object is completed within the powder bed.

After completion the object is elevated and the extra powder brushed away leaving a "green" object. Parts must usually be infiltrated with a hardener before they can be handled without much risk of damage.

The three dimensional printing process has been licensed to several companies: Soligen is using it to make investment castings from ceramic powders; Theirs for manufacture of controlled-dosage pharmaceuticals and in tissue engineering applications; ProMetal for direct metal tooling, etc. Several additional companies have either optioned or licensed the technology for applications ranging from filtration to figurines. Z Corp. is the only licensee that addresses the RP market directly, however. They use the process to create conceptual models out of starch, plaster and other types of powders. The company introduced a color-capable system in 2000, and greatly improved that technology in 2004 with the introduction of a 24-bit color system.

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39

%H H 89 H +; G (DIN 8580),8 9 9 9BC RP RT+/+*F+

%+/+*F+

14&;# #3=17#-&I514&;# #3=17#-&I514&;# #3=17#-&I514&;# #3=17#-&I5 + /+*@+ % B 8 H +

40

Gl avna grupa 1PRI MARNO OBLI KOVAWE

1.1i z te~nog stawa

1.2i z pl asti ~nog

stawa

1.3i z ka{ astog

stawa

1.4i z zrnastog i l i

pra{ kastogstawa

1.5i z treskastogi l i f aznog

stawa

1.6i z gasnog i l ite~nog stawa

1.7i z

joni zi raju}egstawa

%+/+*@+$ [DIN

8580]

%+/+/6+

5J#41%&I54 DIN 8582+/+/*+

Gl avna grupa 2DEFORMI SAWE

2.1Def ormi sawe

pri t i skom: vaqawe,vu~ewe, kovawe,

ut i ski vawe, i st i ski vawe

DIN 8583

2.2Def ormi sawei zvl a~ewem i

t i skawem: dubokoi zvl a~ewe,

rotaci ono t i skaweDIN 8584

2.3Def ormi sawei stezawem:razvl a~ewe

DIN 8585

2.4

Savi jawe

DIN 8586

2.5

Tangenci jal nodef ormi sawe

DIN 8587 %+/+/*+ [DIN 8582]

:

41

+/+//+ + , G 8 + , G+ 9 + 8 9B +% G B H+,/66 B +> : &2-&)&I5 +/+/:+

%+/+//+

42

Gl avna grupa 3RAZDVAJAWE

3.1- Odsi jecawe- Prosi jecawe- Probi jawe- Fi norazdvajaweDIN 8588

3.2Obrada

rezawem sadef i ni sanomgeometr i jom

al ataDIN 8589

3.3Obrada

rezawem sanedef i ni san-

om geometr i jomal ata

DIN 8589

3.4Obrada odno{ ewem- Erodi rawe(termi ~ko, hemi j-sko, l asersko)

DIN 8590

3.5- Rastavqawe- Demont i rawe- Raskl apawe- Razl agawe

DIN 8591

3.6- i { }ewe- Pro~i { }avawe- Bi strewe

DIN 8592 %+/+/:+ [DIN 8580]

%+/+/?+ ; G +/+/?+,B G +> ? %&)&I5 DIN 8593+/+/.+

Gl avna grupa 4SPAJAWE

(DIN8593 od 1-9)

4.1- Spajawe- Sl agawe- Mont i r -

awe

4.2- Puwewe- Popuw-

avawe

4.3- Ut i ski -

vawe- Pr i t i s-

ki vawe

4.4Spajawe

krozpreobl i k-

ovawe

4.5Spajawepomo}udef orm-i sawa

4.6Spajawepomo}u

zavar i va-wa

4.7Spajawepomo}u

l etovawa

4.8Spajawepomo}ul i jepq-

ewa

4.9Tekst i l nospajawe

%+/+/.+ [DIN 8593]

:

43

+/+/L+ % ?+* ?+@ + /+/.! 98+

%+/+/L+

> . 2&E1& +/+/A+7 +! ! !+

Gl avna grupa 5ZA[ TI TA

5.1Za{ t i tai zjoni zi ra-ju}egstawa

5.2Za{ t i tai zpl ast i -~nogstawa

5.3Za{ t i tai zka{ astogstawa

5.4Za{ t i ta i zzrnastog

i l ipra{ kast-og stawa

5.5Za{ t i tapomo}uzavar i va

wa

5.6Za{ t i tapomo}u

l etovawa

5.7Za{ t i tai z gasnog

i l iparnogstawa

5.8Za{ t i ta

i zjoni zi ra-

ju}egstawa

%+/+/A+ [DIN 8580]

+/+/F+

%+/+/F+

44

1 L B C +/+/@+

Gl avna grupa 6I ZMJENA SVOJSTAVA

MATERI JE

6.1Oja~awepomo}udef ormi -sawa

6.2Topl otnipostupci

6.3Termome-hani ~kipostupci

6.4Si ntero-

vawe@arewe

6.5Magnet i -zi rawe

6.6Ozra~i va-

we

6.7Foto-

hemi jskipostupci

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:

45

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Kval i tet

Tro{ kovi

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- I ntegraci ja proi zvodwei kval i tet i spi t i vawa

- Pouzdan proi zvodniproces

Kupci :- Vi soki standardi kval i teta- I sporuka nul te gre{ ke

Budu}i

Do sada

Preduze}e:- Ni ski tro{ kovi- Opt i mal ni tro{ koviosvajawa

Kupci :- Ni ske ci jene

Preduze}e:- Ni ski tro{ kovi- Opt i mal ni tro{ koviosvajawa

Kupci :- Kratko vr i jeme i sporuke- Odr avawe termi na

%+/+:/+39C

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Produkti vnostTro{ kovi proi zvodwe

Tro{ kovi materi jal a

Zakonskeobaveze

Za{ ti ta okol i ne

Kval i tet

Fl eksi bi l nost

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Sada{ wost

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[3] www.ems-usa.com [4] www.3dsystems.com [5] www. Worldwide Guide to Rapid Prototyping\sw1_lks.htm [6] www.home.att.net/castleisland [7] . /

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[8] Feng, L., Wei, S.Yongnian, Y.: "Optimization with minimum pro-cess error for layered manufacturing fabrication", Rapid Proto-typing Journal, MCB University Press, Vol.7, Num.2, 2001

[9] B 4 Rapid Prototyping and Rapid Tooling Efficient way to reduce Time to Market, 5 th International conference on accomplishments of electrical and mechanical industries, Banja Luka, 2001.

[10] 0 ,$5 - 9 9; 0 9+69233?$

[11] %C 4+ E9C 4+G Identification of major factors influenced on the surface quality and accuracy of RP-Models processed by Multy-Jet Technology, 5th International conference on accomplishments of electrical and mechanical industries, Banja Luka, 2001.

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