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LENS - Principle

A High Powered Nd:YAG Laser focused onto

a metal substrate created a molten puddle on

the substrate surfaces. Powder is then

injected into the molten puddle to increase thematerial volume.

A Printing motion system moves a platform

horizontally and laterally as laser beam traces

the cross-section of the part being produced.After formation of layer powder delivery nozzle

moves upward prior to building next layer.

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Specification and Model

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Laser Engineered Net Shaping

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Applications: LENS

Build mould and die inserts

Producing Titanium components for biological

implants

Produce functionally gradient structure

Metallic parts- hip implant- example

Advantages: Dense material parts, complex

parts, reduce post-processing requirements

Disadvantages: Larger size, high power

consumption, limited material

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DSPC : Principle

It is based on 3D printing principle. This

technology invented, developed by MIT, USA.

It is suitable for metal casting. Binder from the

nozzle selectively binds the ceramic particlestogether to crate each layer. Layer after layer

is built and bound to the previous layer until

the ceramic shell completed. The shell is

removed from the DSPC machine and fired to

verification temperatures to harden and

remove all moisture. All excess ceramic

particles are blown away.

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SOLIGENS DIRECT SHELL

PRODUCTION CASTING ( DSPC)

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SOLIGENS DIRECT SHELL PRODUCTION CASTING (

DSPC)

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DSPC : Mechanism

A powder holder contains manufacturing

material powder

A powder distributor distribute a thin layer of

powder

Rollers which are used to compress each layer

before binding

A printer head which sprays binder on eachlayer

A bin which is used to hold the mold

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DSPC: Advantages &

Disadvantages

Pattern less casting: direct tooling, Functional

parts : metal tooling i.e, die for die-casting, Net

shaped integral model: No parting line, core

prints or draft angles re required Limited Material only : ceramic mold for metal

casting.

Applications: Automotive, Aero space,computer industries and medical prostheses.

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MULTIPHASE JET SOLIDIFICATION (

MJS)

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MJS: Principles & Process

The basic concept applies the extrusion of low viscosity

materials through a jet layer by layer. It is some what

similar to FDM process. Only difference is raw material

used to build and feeding systems. In MJS material is

supplied in different phases using powder-bindermixture or liquefied alloys instead of using material in

the wire form. Feeding and nozzle system also different.

Material is wax 50% with metal powder ( liquefied alloys

or powder binder mixture), chamber pressure, machinespeed, jet specification, material flow and operating

temperature.

Process : Data preparation, model building

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EBM

Principle: the parts are built up when an

electron beam is fired at the metal powder.

The computer controlled electron beam in

vacuum melts the layer of powder precisely. Alayer is added once previous layer has melted.

Application : H13 Tool steel injection and

compression molding tools, functional

prototype components

Product: Electron beam gun, vacuum chamber

with fabrication tank powder holder, vacuum

pumps, monitor, high voltage device etc.,

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Therics TheriForm Technology

Principle: It is based on 3D printing Technology

developed by MIT. Binder droplets are

selectively dispensed to bond the powders in

the same layer together as well as next layer. Process: The product are fabricated by printing

micro drops of binders, drugs and other

material and even lining cells onto an ultra-

thin- layer of powder polymers and

biomaterials in computer directed sequence.

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TheriForm Process

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ProMetal Process

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Prometal : Application

Printing Tool steel tooling parts, Injection

molds, extrusion dies, direct metal

components blow molding and repairing worn

out metal toolsAdvantages : Fast, flexible and reliable and

largest steel mold parts. ( 1016mm X 508 mm

X 254mm)

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STL File- ERRORS Missing

Facets

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Shell Puncture

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Overlapping , Non Manifold

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Valid and Invalid Model

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Model tessellated surface

without gaps

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Error Detection

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RP Machining Process

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RP Applications

Applications of rapid prototyping can be

classified into three categories:

1. Design

2. Engineering analysis and planning3. Tooling and manufacturing

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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

E i i A l i d

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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

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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

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Manufacturing Applications

Small batches of plastic parts that could not be

economically molded by injection molding

because of the high mold cost

Parts with intricate internal geometries thatcould not be made using conventional

technologies without assembly

One-of-a-kind parts such as bonereplacements that must be made to correct

size for each user

P bl ith R id

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Problems with Rapid

Prototyping

Part accuracy:

Staircase appearance for a sloping part surface due

to layering

Shrinkage and distortion of RP parts Limited variety of materials in RP

Mechanical performance of the fabricated parts is

limited by the materials that must be used in the RP

process

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Rapid Tooling

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Core and Cavity

Process yields excellent tool finish

Captures intricate detail

Core in Universal Base

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Core in Universal Base

600,000 shots and still running

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Cavity

Ideal for geometrically complex shapes

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Benefits

Versatility

Die casting

Thermoplastic injection molding

MIM (metal injection molding)

Fast turnaround, low cost

2 weeks from CAD file to part

Mold hardness Extended tool life

Quick cavity duplication

Ideal for multi-cavity molds

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MIM Metal Injection Molding

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MIM- Metal Injection Molding

Nickel/ Steel Alloy

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Metal Arc Spray Systems

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