Lecture 1 Additive Rapid Prototyping Technologies Prototyping Technologies Base Materials Selective laser sintering SLS Thermoplastics metal powders Fused deposition modeling FDM ID: 782324
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Slide1
EML 2023 – Rapid Prototyping
Lecture
1
– Additive Rapid Prototyping
Slide2Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
2
Slide3Selective laser sintering (SLS)
additive technique
layer of powder placed on base
high power laser used to fuseselected parts of the powderthe powder bed is lowered asmall amount and a new layer of powder is spreaddoes not require any support structures3
Slide4Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
4
Slide5Fused deposition modeling (FDM)
additive technique
material is laid down in layers
plastic material is melted ina nozzle that moves in XYdirectiontypically uses ABS plasticsupport material is required5stratasys
Slide6Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
6
Slide7Stereolithography (SLA)
additive process
uses a vat of liquid UV-curable
resin and a UV laserexposure to the laser causesthe material to hardenafter a pattern has been traced,the platform descends and aresin filled blade recoats the toprequires support structures7
Slide8Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
8
Slide9Laminated object manufacturing (LOM)
sheet is adhered to substrate
with a heated roller
laser traces out the outlineof the layernon-part areas are cross-hatched to facilitate removalof waste materialnext layer is pulled across and the process is repeated9
Slide10Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
10
Slide11Electron beam melting (EBM)
metal parts are made from a metal powder
a layer of powder is spread and the part region is melted together by a computer controlled electron beam
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Slide12Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
12
Slide133D printing (3DP)
“inkjet” type process
a fine powder of plaster or corn starch is bonded by “printing” an adhesive from the printhead
considered the fastest technique13zcorp
Slide14Technologies
Prototyping
Technologies
Base MaterialsSelective laser sintering (SLS)Thermoplastics, metal powdersFused deposition modeling (FDM)Thermoplastics, eutectic metalsStereolithography (SLA)PhotopolymerLaminated object manufacturing (LOM)PaperElectron beam melting (EBM)Titanium alloys3D printing (3DP)Various Materials
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Slide15UF machines - FDM
Dimension 1200es SST (Soluble Support Technology)
15
Building MAE-BRoom 313
Slide16UF Rapid Prototyping Machines
16
8
68”build volume
101012”
build volume
sodium hydroxide
& water tank
Slide17former UF machine - FDM
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Slide18Existing Equipment2 Dimension
sst
1200es Rapid Proto Machines
ABS plastic101012” build volume.010” z-axis, .005” xy-axis resolutionRoland MDX-540 Subtractive R.P. machineplastic, wood, aluminum4 axis ; 4 tool magazine4412” build volume.0008” repeat accuracy
Slide19Existing EquipmentNext Engine 3D Scanner5
4” macro field of view
13.510” wide field of view
.005” accuracy
Slide20Equipment to be deliveredFortus
360mc Rapid Proto Machine
ABS plastic, Nylon, polycarbonate
161416” build volume.005” accuracy1.5 speed compared to existing machines
Slide21Equipment to be deliveredMedium Machinery Plastic Injection Molding
2 oz. shot capacity
12 ton clamping force
13,500 psi pressure884” max mold size
Slide22MAE-B 313
Lab Renovation Plan
Slide23Steps to Create a Part
Model part (or assembly) in SolidWorks.
Save part (or assembly) file in .
stl format.Note: To save an assembly as one single .stl file, go to Options and check the box next to ‘ Save all components of an assembly in a single file’.Run the Catalyst software. Orient the part on the build tray and send to rapid proto machine.23
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