Layered Manufacturing Technologies u Powder Solidification l 3D Printing (3DP) l Selective Laser...
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Transcript of Layered Manufacturing Technologies u Powder Solidification l 3D Printing (3DP) l Selective Laser...
SFFSFF Layered Manufacturing Technologies Layered Manufacturing Technologies
Powder Solidification 3D Printing (3DP)
Selective Laser Sintering (SLS)
Additive With Sacrificial Supports Stereolithography (SLA) {= Liquid solidification}
Thermoplastic deposition
Fused Deposition Modeling (FDM)
Solid Object Printing w/ Multi-Jet Modeling (MJM)
Solidscape’s ModelMaker {previously: Sanders}
“Subtractive” Laminated Object Manufacturing (LOM)
SFFSFF Layered Solidification ProcessesLayered Solidification Processes
Liquid-Based Approaches
Stereolithography(latest process needs almost no “supports”)
Powder-Bed Based Approaches
3D Printing (Z-Corporation)
Selective Laser Sintering
SFFSFF Stereolithography (SLA)Stereolithography (SLA)
First commercial layered manufacturing technology (1988)
Photo-curable liquid resin
www.3dsystems.com
SFFSFF Stereolithography (SLA)Stereolithography (SLA)
UV laser beam solidifies the top layerof a photosensitive liquid.
Build Stage
UV Laser Beam
Photopolymer
SFFSFF Stereolithography: ApparatusStereolithography: Apparatus
SFFSFF StereolithographyStereolithography
Pre-process:
Orient part.
Choose slice thickness.
Slice parts and plan supports.
SFFSFF StereolithographyStereolithography
Process:
Position build platform (stage)just below liquid resin surface.
Smooth surface with re-coater blade.
Scan the outline of the current slice, loosely hatch part interior with laser.
Lower the build platform for next layer.
SFFSFF StereolithographyStereolithography
Post-process: Raise part and drain out liquid.
(except liquid trapped by loose hatch)
Break off supports.
Rinse in isopropanol and water.
Dry with air hose.
Post-cure (strengthen) in UV oven.
SFFSFF StereolithographyStereolithography
Characteristics: Slow process
Supports must be removed by hand
Lab environment necessary (gasses!)
Needs trained operator
Laser lasts 2000hrs, costs $20’000!
Little material choice, ($700 per gallon)
Parts can be brittle, fragile
SFFSFF StereolithographyStereolithography
Characteristics (cont.):
High accuracy Layer thickness 0.001 - 0.006”
Minimum feature size 0.003 - 0.012”
Large build volume Up to 20 x 20 x 23”
SFFSFF Powder-based ApproachesPowder-based Approaches
Key Properties:
Needs no supports that must be removed!
Uniform bed of powder acts as support.
This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.
SFFSFF 3D Printing -- Principle3D Printing -- Principle
Selectively deposit binder droplets onto a bed of powder to form locally solid parts.
Powder Spreading Printing
Build
Feeder
Powder
Head
SFFSFF 3D Printing: Some Key Players3D Printing: Some Key Players
Z Corporation: http://www.zcorp.com/Plaster and starch powders for visualization models.
Soligen: http://www.zcorp.com/Metal and ceramic powdersfor operational prototypes.
ProMetal: http://www.prometal-rt.com/Metal sintering processfor operational prototypes and art work.
Therics Inc.: http://www.therics.com/Biopharmaceutical products,tissue engineering.
SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation
The Z402 3D Printer Speed: 1-2 vertical inches per hour
Build Volume: 8" x 10" x 8"
Thickness: 3 to 10 mils, selectable
SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation
SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation
Digging out
SFFSFF Optional Curing: 30 min. @ 200ºF Optional Curing: 30 min. @ 200ºF
Keep some powder in place
<-- Tray for transport
SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation
Cleaning up in the de-powdering station
SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation
The finished part
Zcorp,
6" diam.,
6 hrs.
SFFSFF 120 Cell -- Close-up120 Cell -- Close-up
SFFSFF Parallel Projection of the 4D 120-CellParallel Projection of the 4D 120-Cell
Zcorp,
6" diam.,
6 hrs.
SFFSFF Morin SurfaceMorin Surface
This is the half-way point of a sphere eversion (without causing creases or tears).
3D-Print6" diam.5 hrs.
SFFSFF 3D 3D ColorColor Printing: Z Corporation Printing: Z Corporation
The Z402C 3D Color Printer
Differences compared to mono-color printer: Color print head with: Cyan, Yellow, Magenta,
Black, and Neutral.
Smaller build area.
Specs: Speed: 0.33 - 0.66 vertical inches per hour
Build Volume: 6" x 6" x 6"
Layer Thickness: 3 to 10 mils, selectable
Color depth: 80 mils below surface
SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation
SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation
Use compressed air to blow out central hollow space.
SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation
Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors.
SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation
“Lizard-Frame”: Final Infiltrated Part
SFFSFF Hypercube, Perspective ProjectionsHypercube, Perspective Projections
SFFSFF Two Ways to Make a HypercubeTwo Ways to Make a Hypercube
3D Color Print
Assembly of flat FDM parts ==>
SFFSFFWhat Can Go Wrong ? What Can Go Wrong ? -- -- Parts may brake before infiltrationParts may brake before infiltration
SFFSFF What Else Can Go Wrong ?What Else Can Go Wrong ?
Blocked glue lines
Crumbling parts
SFFSFF What Else Can Go Wrong ?What Else Can Go Wrong ? Some blocked glue lines
Uneven coloring Art ?
SFFSFF Post-Processing for 3D-PrintingPost-Processing for 3D-Printing
Surface is porous, dusty. Seal and strengthen the part:
Dip in wax: Nice smooth finish Needs separate waxing station
Infiltrate with “superglue”: Tedious, dirty manual labor
Spray-paint with a sealant: Polyurethane (yellowish, smelly) Krylon (invisible)
SFFSFF Post-Processing for 3D-PrintingPost-Processing for 3D-Printing
Spray-paint surface with Krylon
SFFSFF 3D Printing: Z Corporation3D Printing: Z Corporation
An Informal Evaluation
Fast !
Running expenses: moderate,(but overpriced powder)
Color print head and tubes need some care in maintenance.
Somewhat messy cleanup !
Lot’s of dust everywhere ...
SFFSFF
Key Points:
Powder gets solidified with a laser.
Powder is kept just below melting point, heat from laser will fuse powder grains.
Un-fused powder acts as support,can easily be removed later.
Many different materials can be used when mixed with a suitable binder:nylon, metal, ceramics …
Selective Laser Sintering (SLS)Selective Laser Sintering (SLS)
SFFSFF SLS: Conceptual ViewSLS: Conceptual View
SFFSFF SLS PlayersSLS Players
3D SYSTEMS Representing the fourth generation of SLS®
(selective laser sintering) technology, Vanguard™ and Vanguard™ HS (High Speed), are the first SLS® systems developed specifically for advanced manufacturing applications.
With the Vanguard system you can move directly from a CAD file to a durable, functional plastic or metal part or tool — in a fraction of the time required for traditional machining and tooling.
http://www.3dsystems.com/products/sls/vanguard/index.asp
SFFSFF SLS from 3D SYSTEMSSLS from 3D SYSTEMS
Use Vanguard or Vanguard HS system for:• Plastic or metal parts, patterns & prototypes• Complex metal tooling inserts• Highly Durable Parts• Parts with small features• Short runs of plastic & metal parts
Benefits:• High part accuracy • Fast build speed• Unattended operation• Uses plastic or metal materials• Respond to customer demands• Worldwide service and support
SFFSFF SLS: Laserform PartsSLS: Laserform Parts
SFFSFF The Most Challenging SFF PartThe Most Challenging SFF Part
3rd-order 3D Hilbert Curve: much weight
much length
no supports
only two tube-connectionsbetween the two halves.
SFFSFF Fabricated by ProMetalFabricated by ProMetal
SFFSFF ProMetal ProcessProMetal Process
A ‘green’ part is first formed, composed of stainless steel powder and a selectively applied binder.
This part is built bottom-up, layer-by-layer under direct computer control.
This green part is then sintered, the binder is drained out and replaced by liquid bronze.
ProMetal is a division of ‘The Ex One Company’, Irwin, PA.
SFFSFF The Objet PolyJet ProcessThe Objet PolyJet Process
SFFSFF The Objet PolyJet ProcessThe Objet PolyJet Process
Pointer to the company:
http://www.2objet.com/
See the movie ...
http://www.youtube.com/watch?v=oMQWGBgNCtg
SFFSFF Which Process Should You Pick?Which Process Should You Pick?
Do you need a prototype (not just a model)?
SLS, FDM (for robustness, strength).
Do you need a mold for a small batch?
SLA (for smooth, hard surface).
Does part need multiple colors?
3D Color-Printing.
Does part have convoluted internal spaces?
3D-Print, SLS, SLA (easy support removal).
SFFSFF Informal Process Ratings MatrixInformal Process Ratings Matrix
Hollow Sphere
Hollow Sphere with Drain/Vent
2 Nested, Perforated
Spheres
3D Hilbert
Pipe
Preassembled Gear
Mechanism
LOM (F) F F D F
SLA (F) A B B C
FDM (F) F C C D
3D-P (F) A A C B
SLS (F) A A B B