new advances in rp

7/28/2019 New Advances in RP

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DISCLAIMER:ObjetGeometriesLtd.("Objet")doesnotguaranteethefinalreleaseandavailabilityofmaterials,productsand/or

featuresreferredtoherein.MaterialswillbereleasedsubjecttoObjetssolediscretion.Notallreleasedmaterialsarecurrently

availableforallplatforms/systems.Objetwillupdateitswebsitefurthertoreleasesbecomeavailableand/orcompatiblewith

specificplatforms/systems.

Apri l 2011Objet Geometries Ltd.

New Advances in Rapid Prototyping usingInkjet-based 3D Printing


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BringingPrototypingtotheModernEra

Rapidprototypingtechniqueshavefoundtheirplaceinarangeofindustriessuchas

consumergoodsandelectronics,automotive,defense,education,motorsports,

jewelry,dentistry,orthodontics,medicine,andmore.Todayitisenablingbothlarge

andsmallcompaniestosimulatecomplexpartsandfinishedassembliesstraight

fromtheprinter quicklyandmoreaccuratelythaneverbefore.

Workshoplathes,boringmachines,planningandslottingandshapingmachinesall

essentialcapitalequipmentformassproductionwereallinventedinthe1800s.

Sincethedaysoftheindustrialrevolution,manufacturershave,untilnow,never

succeededinreplicatingandtransferringthecostefficiencyofmassproductionto

theprototyping

process.

PrototypinghasremainedamajorAchillesheelfordesignersandmanufacturing

companiesduetoitsinabilitytoconformtotheeconomiesofscaleprinciple:

Architectspaystudentstopainstakinglybuildandgluecardboardmodelsoftheir

buildings;carmanufacturershireteamstobuildheavywoodandclaymodelsof

theirnextgenerationofvehicles;dentallabsusebiteimpressionstodesignveneers,

crownsandorthodonticappliances,andsoon.

Prototyping

has

therefore

traditionally

been

slow,

tedious,

expensive,

difficult

to

repeat,andinsomecases,inadequateforthetaskofsimulatingtheendproducts

theyarebuilttorepresent.

Whenonceitmighthavetakendays,weeksormonthstoproduceprototypes,using

3Dprintingtechnologies,thesameworkcannowbeachievedinhours.Businesses

whowanttostreamlinetheirefficiencyandbecomemoreproductivecannowuse

3Dprintingtechnologytodeliverfastturnaroundfrominitialdesigntofinal

productionofgoods.

Answeringthe

Requirements

of

Form,

Fit

and

Function

Alongwithspeed,accuracyandrepeatability,3Dprintingprovidesthemassive

advantageofproducingrealisticrepresentationsthatcanbeproperlytestedand

checkedfordesignfaultsearlyoninthedesigncycle.Onceadesignfaultisidentified

inthemodel,designersandengineerscansimplytweakthedesignontheCAD/CAM

programandprintandtestagain,asmanytimesastheylike,untilthedesignis

perfectedandmeetstheir precisevisualizationandverificationrequirements.


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3

ese

Whereasfulfillingthefitandformrequirementsofrapidprototypinghasalwaysbeendependentuponthetypeof3Dprintingtechnologyused,thefunctional

requirementsarenaturallymoredependentuponthepropertiesofthematerials

beinglaid

down

by

the

3D

printing

machine.

FitandFormTesting:AccuracyandResolution

Accordingtoindustryreports,companiestodayuse55%oftheiradditive

manufacturingprocessestodayforfitandformtesting.Fitandformrequiresan

accuratelookandfeel,sodesigners,marketersandfocusgroupscanaccurately

visualizetheirintendedproduct.Sowhatsortof3Dprintingtechnologiesisbest

suitedtosimulatingfitandform?

Inkjetbased3DPrinting

Technology

AcursoryGooglesearchforRapid

ManufacturingTechnologieswill

displaymanycompetingcompanies.

Themaindifferencesbetweenth

additivemanufacturingtechnologies

arefound

in

the

way

layers

are

built

to

createparts.Someinvolvemeltingorsofteningmaterials,othersbybinding

powderedmaterial,whileothersinvolvejettingorselectivelylaserhardeningliquid

materials.

ObjetGeometrieshasover110registeredpatentsandpendingapplicationsininkjet

based3Dprintingtechnologyandarangeofover60UVcurableliquid

photopolymeracrylicbasedmaterials.Thesematerialsareusedonspecialized3D

printingmachinesfittedwithinkjetheadsconceptuallysimilartoregularprinters.

Providinghigh

resolution,

detailed

parts,

and

the

ability

to

print

finished

model

assembliesstraightfromthemachine,inkjetbased3Dprintingpromisesdesigners

andengineerstheabilitytoaccuratelysimulatethefitandformoftheproductsthey

aimtoproduce,andwiththeprovisionofanewrangeofmaterialsthatclosely

simulateengineeringplastics;realisticfunctiontestingnowcomesintoplayaswell.

Smoothsurfaces Perhapsmorethananyothertechnology,inkjetbased3D

printinghastheabilitytoproducepreciselybuiltpartsbasedonalayer

thicknessof16microns.Acloserlookatthestructureofwallswillshowthat

layersare

highly

integrated,

with

no

log

building

effect

that

is

typical

of

manyofthemeltedmaterialdeposition(alsoknownasFusedDeposition

Molding)3Dprinting.


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Choiceofglossormattfinish

Inkjetprintingalsoproduces

partswithsmoothsurfaces,

withachoice

of

either

matt

or

glossfinishstraightfromthe

printer.Thisisnotcommonly

foundinother3Dprinting

technologies.

Minimalpostprocessing

Apartfromtheadvantageofusingonlywhatyouneed,jettingthematerial

ontoabuildtrayratherthanusingStereolithographytechniqueswhichcures

orhardens

aselected

area

within

afull

vat

of

liquid

resin,

means

you

can

jet

differentmaterialsfromthedifferentnozzlesoftheinkjethead.Thishastwo

majoradvantagesoverStereolithographywithregardtofitandformtesting:

1. ObjetinkjettechnologyhasmultimaterialcapabilityDuetotheuse

ofinkjetnozzlesthatcanspraydifferentmaterialspartscanbemade

ofmultiplematerialsorevenmixed,compositematerials,providing

designerstheuniqueabilitytosimulatecomplexpartsthatinclude

bothrigidandflexibleelementswithinthesamemodel.Anexample

would

be

a

remote

control

with

hard

surfaces

and

soft,

rubber

like

buttonsandovermoldinggrips,essentialforsimulatingtheprecise

lookandfeelofanendproduct.

2. InkjetcanuseawaterremovablesupportmaterialStereo

lithographyusesthesamematerialforbothmodelsandsupport.This

supporthardensalongwithmodelandmustthereforebebrokenoff

byhandoftenleavingflashingsandprotrusionsonthesurfacethat

needtobefettled,filedorsandeddowninpostprocess.

Thislast

point

will

have

adirect

bearing

on

the

ability

to

simulate

engineering

plasticsinthenextsection.

NewDevelopments:MoreDimensional

StabilityandVisualization

Withthereleaseofanewrangeofmaterials,ObjetGeometrieshasnowfurther

enhanceditsfitandformcapabilitiesbyprovidingenhanceddimensionalstability

andclear

transparent

properties.


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HigherDimensionalStability

ObjethasnowreleasedthenewObjet

VeroWhitePlus

amaterial

providing

high

dimensionalstability(theabilitytomaintainits

originaldimensionswhensubjectedtochanges

intemperatureandhumidity).Thisisan

essentialcharacteristicforfitandformtesting,

sinceifamodelsdimensionsaredistortedeven

slightly,thenfittingprecisepartstogether

becomesmoredifficultorevenimpossible.

Transparency&

High

Dimensional

Stability

ObjetsnewlyreleasedObjetVeroClearmaterialproducesprototypeswithsimilar

visualpropertiestoPMMA,acommonglass

substituteusedwhenlightweightand

resistancetoshatteringisimportantandwhere

theindexofrefractionandlighttransmission

qualitiesarerequiredtobecomparableto

regularglass.Commonapplicationsforthis

materialinclude

lighting

covers

and

cases

and

glasslikeelementsinconsumergoods,

consumerelectronicsandcosmeticspackaging.

AnsweringtheRequirementsforFunction:

EngineeringPlasticsSimulation

Functionaltestingisanessentialrequirementfortherapidprototypingprocessand

inmany

cases

requires

the

simulation

of

engineering

plastics.

A

major

player

within

thismarketisAcrylonitrileButadieneStyrene,orABSbyitscommonlyknown

acronym.

WhyABS? Intermsofpriceperformance,ABSrepresentsanimportantbenchmark

for3Dprintingduetoitsabilitytocombinethestrength,rigidityandsurfacequality

ofacrylonitrileandstyrenepolymers,thetoughnessofpolybutadienerubber,but

withthelowerpricepointassociatedwithstandardplastics.

ThelistofapplicationsforABSislongandstillgrowing.Itslightweightandabilityto

beinjection

molded

and

extruded

make

it

extremely

useful

in

awide

range

of

manufacturingproductsincludingautomotivetrimcomponents,enclosuresfor

electricalandelectronicassemblies,protectivesurfaces,homeappliancesandtoys.
http://en.wikipedia.org/wiki/Acrylonitrilehttp://en.wikipedia.org/wiki/Butadienehttp://en.wikipedia.org/wiki/Styrenehttp://en.wikipedia.org/wiki/Polymerhttp://en.wikipedia.org/wiki/Polymerhttp://en.wikipedia.org/wiki/Styrenehttp://en.wikipedia.org/wiki/Butadienehttp://en.wikipedia.org/wiki/Acrylonitrile


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with

roGraymaterial.

ABSLikeToughness

ObjetsnewABSlikeDigitalMaterial

(RGD5160DM)

has

atemperature

resistanceof65Coutofprinter,90C

postthermaltreatmentandahigh

toughnessof6580J/m.Thisiscomparable

tostandardABSandthreetimesthe

toughnessoftheObjetVe

Thisuniquelytoughandlightphotopolymer

materialisactuallyacompositedigital

material

created

by

jetting

two

different

materials

simultaneously

both

ahigh

temperaturematerialandhightoughnessmaterial.

Thisisacapabilityuniquetoinkjetbased3Dprinting,andtheObjetConnexMulti

Material3Dprinterinparticular,andcannotbereplicatedbyanyother3Dprinting

technologycurrentlyavailable.Usingthistechnique,manufacturerscanutilizethe

highaccuracyandresolutionofinkjetforfitandformtesting,andalsothe

engineeringplasticqualityforfunctionaltesting.TheObjetABSlikeDigitalMaterial

features:

Dimensionalstability

The

ABS

like

Digital

Material

has

great

dimension

stability,duelargelytoitscombinationofhardnessandheatdeflection

properties.Thesepropertiesallowmodelstoremainstableovertime,even

inharshenvironments.Modelshelflivescanbeextendedandshipmentsin

harshenvironmentsarerenderedpossiblethankstothis.

SnapfitabilityThankstoitshighimpactresistance,ObjetsABSlikeDigital

Materialallowsusestosimulatesnapfitassembliesincludingmodelswith

hingesdesignedtoallowforrepeatedbendingandflexing.Suchusagesare

extremelychallenging

in

the

3D

printing

industry;

yet

the

ABS

like

Digital

MaterialisabletosimulatetheseinsimilarwaystorealABS. Thermalresistance Thermalresistanceofupto95degreescentigrade(293

Fahrenheit)canbeattainedwiththeABSlikeDigitalMaterial.Thisallows

designersandengineerstoperformform,fitandfunctionaltestsinharsh

environments.Anotherbenefitiseasierpostprocessingusingdrypaintingin

hightemperatures(ovenpainting)andchromeplating.Waterandgastests

underhightemperatureflowsarealsopossible.

Static/dynamicloads ThehighimpactresistanceoftheABSlikeDigital

Materialallowsforpartstobeprintedenduringhighdynamicloads.Thisalso


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vebyany

en

ut

dDepositionModelingstyle3D

printing.

rapidly

protrusionsthatmaybetypicalofothermethodssuchasStereolithography.

enablesfurtherfunctionalteststobeundertakenwhenapplyingprototypes

totestingenvironmentsdesignedtosimulatethedesiredendproduct.

HighTemperature

Resistance

Toproducepartscombininghigh

surfacequality,finedetailsand80C

resistanceisnoteasytoachie

prototypingstandards.

ObjetsnewHighTemperaturematerial

(RGD525)combineshighsurfacequality

withaheatresistanceof65Coutof

theprinter

and

80

Cafter

ashort

ov

basedpostthermaltreatment.

Lighttesting Theprimaryapplicationsforthismaterialarethermaltesting

ofstaticparts.Thiscanincludelighttestingunderprolongedstronglighting

suchasisrequiredforvariousautomotiveandheavyindustrydesign

projects.

Hotwaterandhotairflowtesting Anotherapplicationinvolvesrunninghot

waterthrough

atap

at

65C

aprocess

that

typically

requires

hours

of

testing. Themainadvantageof

inkjetbased3Dprintingforhot

watertestingisclear.Whereas

before,customerswouldhave

toproduceanactualproduction

partverymuchattheendof

thedesignprocess,thisisno

longerthecase.Atapcanbe

testedstraight

out

the

printer

andstillmimicthepreciselook

andfunctionofatapwitho

anyofthelogbuildingeffecttypicalwithFuse

Metalizing,painting,gluing ObjetsHighTemperaturematerialisalsoideal

forpainting,gluingandmetalizing,whichallrequirehighlysmoothsurfaces.

PostprocessingofthissortwithObjetsHighTemperaturematerialis

andeasily

achieved,

without

the

filing

down

or

fettling

of

unwanted


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form

testing.

nd

epositionModelingandStereo

lithographyinthefitandformdepartments.

ing

als

used

in

both

Fused

Deposition

Modeling

and

Stereo

lithography3Dprinting.

g

ngtheway,providingthedemandedlevelsofprintqualityandmaterial

properties.

d

ndattheendofthe

day,abetterendproduct,morequicklydeliveredtomarket.

Trademarkedcompanyandproductnamesarethepropertyoftheirrespectiveowners.

Summary

Oneofthebiggestchallengesof3D

printingtodayishowtoachieveall

roundhighscoresforfit,formand

functionaltesting.

Asshown,onlyinkjetbased3D

printingtechnologycurrentlyhasthe

abilitytoproducethefinedetail

printing,ultrathinlayers,smooth

surfaces,highdimensionalstabilityandcleartransparencyrequiredforfitand

Inaddition,Objetsuniqueabilitytoprintmultiplematerials,conveysacleara

significantcompetitiveleadoverbothFusedD

WithanewrangeofhightemperatureandABSlikematerials,Objetsinkjetbased

3Dprintingtechnologynowfillsmuchoftheremainingfunctionalgapbyprovid

anABSlevelstandardofengineeringplasticssimulationforfunctionaltesting,

comparable

to

the

materi

The3Dworldinthecomingyearswillmovetoincreasinglyresemblethe2Dprintin

world.Thenextstepintheevolutionof3Dprintingwillseemoreandmorerapid

prototypingtasksforform,fitandfunctiontestingperformedatthedesignand

engineeringofficeanddesktoplevels.Thereagain,inkjetbased3Dprintingledby

Objetispavi

Withsuch

atechnology

at

their

fingertips,

product

designers

and

engineers

can

now

makelightworkofprototypingcyclesthatusedtotakeweeksorevenmonthsan

thatfaredpoorlyinrealworldrepresentation.Withinkjetbased3Dprintingthe

resultisamoreinstructiveandefficientprototypingprocessa

*


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new advances in rp

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