rapid prototyping
TRANSCRIPT
HAPPY ENGINEERS DAY
From
Department of Mechanical Engineering
Anuradha Engineering College Chikhli
1
RAPID PROTOTYPING
Creating Real Parts from Solid Models
BY
Mr A R Gosavi
Lecturer
Anuradha Engineering College Chikhli
2
INTRODUCTION
WHAT IS A PROTOTYPE
A prototype is a draft version or an approximation of a finalproduct
Prototypes are developed for several reasons to identify possible problems to confirm the suitability of a design prior to starting mass
production Provides a scale model to conduct tests and verify
performance for visualization purposes Some prototypes are used as market research and
promotional tools
Most importantly it is cheaper to manufacture test andmake changes to a prototype than it is to a final product
3
DEVELOPMENT OF RAPID PROTOTYPING
First Phase Manual (or Hard) Prototyping
Age-old practice for many centuries
Prototyping as a skilled craft is traditional and manual and based on
material of prototype
Natural prototyping technique
Second Phase Soft (or Virtual) Prototyping
Mid 1970rsquos
Increasing complexity
Can be stressed simulated and tested with exact mechanical and
other properties4
DEVELOPMENT OF RAPID PROTOTYPING Third Phase Rapid Prototyping
Mid 1980rsquos
Hard prototype made in a very short turnaround time (relies on CADmodelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the products
3 times complex as soft prototyping
5
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
RAPID PROTOTYPING
Creating Real Parts from Solid Models
BY
Mr A R Gosavi
Lecturer
Anuradha Engineering College Chikhli
2
INTRODUCTION
WHAT IS A PROTOTYPE
A prototype is a draft version or an approximation of a finalproduct
Prototypes are developed for several reasons to identify possible problems to confirm the suitability of a design prior to starting mass
production Provides a scale model to conduct tests and verify
performance for visualization purposes Some prototypes are used as market research and
promotional tools
Most importantly it is cheaper to manufacture test andmake changes to a prototype than it is to a final product
3
DEVELOPMENT OF RAPID PROTOTYPING
First Phase Manual (or Hard) Prototyping
Age-old practice for many centuries
Prototyping as a skilled craft is traditional and manual and based on
material of prototype
Natural prototyping technique
Second Phase Soft (or Virtual) Prototyping
Mid 1970rsquos
Increasing complexity
Can be stressed simulated and tested with exact mechanical and
other properties4
DEVELOPMENT OF RAPID PROTOTYPING Third Phase Rapid Prototyping
Mid 1980rsquos
Hard prototype made in a very short turnaround time (relies on CADmodelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the products
3 times complex as soft prototyping
5
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
INTRODUCTION
WHAT IS A PROTOTYPE
A prototype is a draft version or an approximation of a finalproduct
Prototypes are developed for several reasons to identify possible problems to confirm the suitability of a design prior to starting mass
production Provides a scale model to conduct tests and verify
performance for visualization purposes Some prototypes are used as market research and
promotional tools
Most importantly it is cheaper to manufacture test andmake changes to a prototype than it is to a final product
3
DEVELOPMENT OF RAPID PROTOTYPING
First Phase Manual (or Hard) Prototyping
Age-old practice for many centuries
Prototyping as a skilled craft is traditional and manual and based on
material of prototype
Natural prototyping technique
Second Phase Soft (or Virtual) Prototyping
Mid 1970rsquos
Increasing complexity
Can be stressed simulated and tested with exact mechanical and
other properties4
DEVELOPMENT OF RAPID PROTOTYPING Third Phase Rapid Prototyping
Mid 1980rsquos
Hard prototype made in a very short turnaround time (relies on CADmodelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the products
3 times complex as soft prototyping
5
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
DEVELOPMENT OF RAPID PROTOTYPING
First Phase Manual (or Hard) Prototyping
Age-old practice for many centuries
Prototyping as a skilled craft is traditional and manual and based on
material of prototype
Natural prototyping technique
Second Phase Soft (or Virtual) Prototyping
Mid 1970rsquos
Increasing complexity
Can be stressed simulated and tested with exact mechanical and
other properties4
DEVELOPMENT OF RAPID PROTOTYPING Third Phase Rapid Prototyping
Mid 1980rsquos
Hard prototype made in a very short turnaround time (relies on CADmodelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the products
3 times complex as soft prototyping
5
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
DEVELOPMENT OF RAPID PROTOTYPING Third Phase Rapid Prototyping
Mid 1980rsquos
Hard prototype made in a very short turnaround time (relies on CADmodelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the products
3 times complex as soft prototyping
5
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
RAPID PROTOTYPING
Rapid prototyping is a broad term that comprises many differenttechnologies used to quickly fabricate a physical model directly fromcomputer data
The first rapid prototyping method called stereo lithography wasdeveloped in the late 1980s but more sophisticated techniques areavailable today
6
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
RAPID PROTOTYPING
The term ldquorapidrdquo is relative Some prototypes may take hours or even days to build
Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together
Most common types of rapid prototyping systems
SLA (Stereo Lithography)
SLS (Selective Laser Sintering)
LOM (Laminate Object Manufacturing)
FDM (Fused Deposition Modeling)
Different technologies use different materials to produce the parts
7
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
RAPID PROTOTYPING
There are many different RP processes but the basic operating principles
are very similar
8
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
BASIC OPERATING PRINCIPLES OF RP
Building computer model
Model is build by CADCAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
Stereo Lithography (STL) file is a standard format to describe CAD geometry used in RP system
STL file approximates the surfaces of the model by polygons
9
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of liquidpowder
Removing support structure and cleaning
After building Drain out extra material
Cut out the prototype
Cut out unnecessary support material
Post processing
Includes surface finishing and other applications10
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
APPLICATIONS OF RP
Applications of rapid prototyping can be classified into three categories
1 Design
2 Engineering analysis and planning
3 Tooling and manufacturing
11
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
DESIGN APPLICATIONS
Designers are able to confirm their design by building a real physical model in minimum time using RP
Design benefits of RP
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
12
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
ENGINEERING ANALYSIS AND PLANNING
Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process planning and tool design
13
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
TOOLING APPLICATIONS
Called rapid tool making (RTM) when RP is used to fabricate production tooling
Two approaches for tool-making
1) Indirect RTM method
Pattern is created by RP and the pattern is used to fabricate the tool
Examples
Patterns for sand casting and investment casting
Electrodes for EDM
2 )Direct RTM method
RP is used to make the tool itself
Example
3DP to create a die of metal powders followed by sintering and infiltration to complete the die
14
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
ADVANTAGES OF RAPID PROTOTYPING
Process is Fast and accurate
Superior Quality surface finish is obtained
Separate material can be used for component and support
No need to design jigs and fixtures
No need of mould or other tools
Post processing include only finishing and cleaning
Harder materials can be easily used
Minimum material wastage
Reduces product development time considerably 15
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LIMITATIONS OF RP
Some times staircase effect is observed
Many times component get distorted
Limited range of materials
Cost of operating
16
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
STEREO LITHOGRAPHY FILES
The stereo lithography file format known as STL (Standard Tessellation Language) is the current industry standard data interface for rapid prototyping and manufacturing
Before a 3D model is sent to a rapid prototype machine it must be converted to this format
From a user standpoint the process typically requires only exporting or saving the model as an STL file Some software packages however allow the user to define some specific parameters
The STL file format defines the geometry of a model as a single mesh of triangles Information about color textures materials and other properties of the object are ignored in the STL file
When a solid model is converted into an STL file all features are consolidated into one geometric figure The resulting STL file does not allow individual features created with the parametric modeling application to be edited
17
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
INVENTOR STL SAVE PROCEDURE
Remember to
use ldquoSave Copy
Asrdquo not ldquoSaverdquo
Select stl as file type
18
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
STEREO LITHOGRAPHY FILES
The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation
When the tessellated STL file is sent to the rapid prototype machine the model is sliced into multiple horizontal layers that are later reproduced physically by the device
19
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
WHY STL FILE FORMAT The STL files translate the part geometry from a CAD system to the RP machine
Universal file format that every system needs to be able to produce so that an RP machine can process model
Slicing a part is easier compared to other methods such as B-rep (boundary representation) and CSG (constructive solid geometry)
20
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
RP ndash TWO BASIC CATEGORIES
1 Material removal RP ndash
Machining using a dedicated CNC machine that is available to the designdepartment on short notice
Starting material is often wax
Easy to machine
Can be melted and re-solidified
The CNC machines are often small - called desktop machining
2 Material addition RP ndash
Adds layers of material one at a time to build the solid part from bottom totop
21
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
CLASSIFICATION OF RP TECHNOLOGIES
There are various ways to classify the RP techniques that have currently beendeveloped
The RP classification used here is based on the form of the starting material
1 Liquid-based
2 Solid-based
3 Powder-based
22
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LIQUID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a liquid Mostly resins and polymers
About a dozen RP technologies are in this category
Includes the following processes
Stereo lithography
Solid ground curing
Droplet deposition manufacturing
23
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SOLID-BASED RAPID PROTOTYPING SYSTEMS
Starting material is a solid wood plastic metal sheets etc
Solid-based RP systems include the following processes
Laminated object manufacturing
Fused deposition modeling
24
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
POWDER-BASED RP SYSTEMS
Starting material is a powder of hard materials like
Powder-based RP systems include the following
Selective laser sintering
Three dimensional printing
Laser engineered and Net shaping
25
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
STEREO LITHOGRAPHY (SLA) Works based on the principle of
curing liquid photomer into specific shape
A vat which can be lowered and raised filled with photocurable liquid acrylate polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and produces a solid body
This process is repeated till the level b is reached as shown in the figure
Now the plat form is lowered by distance ab
Then another portion of the cylinder is shaped till the portion is reached
He-Cd Laser
UV beam
Rotating mirror
High-speed
stepper motors
Focusing system
Liquid resin
Part
Platform
Elevation control
Support structures
He
-Ne L
ase
r
Se
nso
r syste
m
for
resin
de
pth
26
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
STEREO LITHOGRAPHY (SLA)
Each layer is 0076 mm to 050 mm (0003 in to 0020 in) thick
Thinner layers provide better resolution and more intricate shapes but
processing time is longer
Starting materials are liquid monomers
Polymerization occurs on exposure to UV light produced by laser scanning
beam
Scanning speeds ~ 500 to 2500 mms
Accuracy(mm) - 001- 02(SLA)
27
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SLA companies and applications
Companies that develop and sell SLA machines
1 3D Systemstrade Inc (www3Dsystemscom)
2 Aaroflex Inc (wwwaaroflexcom)
Shower head
Automobile Manifold
(Rover)
28
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
STEREO LITHOGRAPHY (SLA) PARTS
29
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LAMINATED OBJECT MANUFACTURING (LOM)
30
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LAMINATED OBJECT MANUFACTURING
Laminated Object Manufacturing is a relatively low cost rapid prototyping technology
where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape
The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform
When new paper is in position it is flattened and added to the previously created
layers using a heated roller
The shape of the new layer is traced and cut by a blade or a laser When the layer
is complete the building platform descends and new paper is supplied
When the paper is in position the platform moves back up so the new layer can be
glued to the existing stack and the process repeats31
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LOM companies applications
Original technology developed by Helisys Inc Helisys acquired by Corum
1 Cubic Technologies Inc [wwwcubictechnologiescom]
2 KIRA Corp Japan [wwwkiracorpcojp]
[source Corum Inc] [source KIRA corporation]
32
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LAMINATED OBJECT MANUFACTURING (LOM)
33
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
LAMINATED OBJECT MANUFACTURING FACTS
Layer thickness(mm) - 01 - 1(LOM)
Starting sheet stock includes paper plastic cellulose metals or
fiber-reinforced materials
Accuracy(mm) - 01 - 02(LOM)
34
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
FUSED DEPOSITION MODELING
bull A gantry robot controlled extruder head moves in two principle directions over a table
bull Table can be raised or lowered as needed
bull Thermo plastic or wax filament is extruded through the small orifice of heated die
bull Initial layer placed on a foam foundation with a constant rate
bull Extruder head follows a predetermined path from the file
bull After first layer the table is lowered and subsequent layers are formed
Fig (a)Fused-deposition-modeling process
(b)The FDM 5000 a fused-decomposition-
modeling-machine
35
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
FDM companies and applications
FDMtrade is a patented technology of Stratasystrade Inc
Monkey Cinquefoil
Designed by Prof Carlo Sequin UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
Gear assembly
Toy design using FDM models of different colors
36
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
FUSED DEPOSITION MODELING (FDM)
37
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
FUSED DEPOSITION MODELING (FDM)
Materials
ABS
Polycarbonate (PC)
Polyphenylsulfonen (PPSF)
Metals
Layer thickness(mm) - ~005(FDM)
Accuracy(mm) - 0127 - 0254(FDM)
38
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SELECTIVE LASER SINTERING (SLS)
Uses a high power laser and powdered materials
A wide variety of materials can be used ranging from thermoplastic
polymers such as nylon and polystyrene to some metals
3D parts are produced by fusing a thin slice of the powdered material
onto the layers below it
The surfaces of SLS prototypes are not as smooth as those produced
by SLA processes
SLS parts are sufficiently strong and resistant for many functional
tests
39
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SELECTIVE LASER SINTERING (SLS)
40
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SELECTIVE LASER SINTERING (SLS)
The powdered material is kept on a delivery platform and supplied to the
building area by a roller
For each layer a laser traces the corresponding shape of the part on the
surface of the building area by heating the powder until it melts fusing it with
the layer below it
The platform containing the part lowers one layer thickness and the platform
supplying the material elevates providing more material to the system
The roller moves the new material to the building platform leveling the surface
and the process repeats
Some SLS prototype machines use two delivery platforms one on each side of
the building platform for efficiency so the roller can supply material to the
building platform in both directions 41
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
SLS companies and applicationsFirst commercialized by Prof Carl Deckard (UT Austin)Marketed by DTM CorpDTM acquired by 3Dsystems Inc
1 3D Systemstrade Inc (www3Dsystemscom)
2 EOS GmbH Munich Germany
[both examples source DTM inc]
Plastic parts using SLS Metal mold using SLS injection molded parts
42
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
3D printingTechnology invented at MIT in1994 Part constructed with starch
powder
1 Layer of powder spread on platform
2 Ink-jet printer head deposits drops of waterglue on part cross-
section
3 Table lowered by layer thickness
4 New layer of powder deposited above previous layer
5 Repeat steps 2-4 till part is built
6 Shake powder to get part
43
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
MATERIALS USEDSTARCH PLASTER-CERAMIC POWDER METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS (SAME AS INK-JET
PRINTING)
Applications of 3DP
CAD-Casting metal parts A ceramic shell with integral cores can be fabricated directly from the CAD model
Direct metal parts It is adaptable to a variety of material systems allowing the production of metallicceramic parts with novel composition
Prototypes with colours and elastic feature
44
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
3D Printing companies applications
1 Z-corporation [wwwzcorpcom]
2 Soligen [wwwsoligencom]
Engine manifold for GM racing car
Cast after Direct Shell Production Casting
[source wwwsoligencom]
45
46
46