PROTOTYPING Principles and

Applications

CKCHUA KFLEONG CSUM Nanyang Technological University, Singapore

^Ц) World Scientific N E W JERSEY • L O N D O N • S I N G A P O R E • B E I J I N G • S H A N G H A I • HONG KONG • T A I P E I • C H E N N A I

CONTENTS

Foreword xi

Preface xiii

Acknowledgments xvii

About the Authors xxi

List of Abbreviations xxiii

1 7

10 13 17 18 21 22

Chapter 2. Rapid Prototyping Process Chain 25 2.1. Fundamental Automated Processes 25 2.2. Process Chain 26

References 33 Problems 33

Chapter 3. Liquid-Based Rapid Prototyping Systems 35

3.1. 3D Systems' Stereolithography Apparatus (SLA) 35 3.2. Objet Geometries Ltd.'s Polyjet 52 3.3. D-MEC's Solid Creation System (SCS) 63

Chapter 1.

1.1. 1.2. 1.3. 1.4. 1.5. 1.6.

Introduction

Prototype Fundamentals Historical Development Fundamentals of Rapid Prototyping Advantages of Rapid Prototyping Commonly Used Terms Classification of Rapid Prototyping Systems References Problems

VII

viii Rapid Prototyping

3.4. Envisiontec's Perfactory 68 3.5. Autostrade's E-Darts 76 3.6. CMET's Solid Object Ultraviolet-Laser Printer 80 3.7. EnvisionTec's Bioplotter 84 3.8. Rapid Freeze Prototyping (RFP) 89 3.9. Microfabrication 98

3.10. Microfabrica®'s EFAB® Technology 102 3.11. D-MEC's ACCULAS 106 3.12. Other Notable Liquid-Based RP Systems 110

References 131 Problems 135

Chapter 4. Solid-Based Rapid Prototyping Systems 137

4.1. Stratasys' Fused Deposition Modeling (FDM) 137 4.2. Solidscape's Benchtop System 148 4.3. Cubic Technologies' Laminated Object

Manufacturing (LOM™) 153 4.4. 3D Systems' Multi-Jet Modeling System (MJM) 165 4.5. Solidimension's Plastic Sheet Lamination (PSL)/

3D System's Invision LD Sheet Lamination 171 4.6. Kira's Paper Lamination Technology (PLT) 176 4.7. CAM-LEM'sCL 100 182 4.8. Other Notable Solid-Based RP Systems 186

References 194 Problems 196

Chapter 5. Powder-Based Rapid Prototyping Systems 199

5.1. 3D System's Selective Laser Sintering (SLS) 199 5.2. Z Corporation's Three-Dimensional Printing (3DP) 213 5.3. EOS'sEOSINT Systems 222 5.4. Optomec's Laser Engineered Net Shaping (LENS) 236 5.5. Arcam's Electron Beam Melting (EBM) 243 5.6. Concept Laser GmbH's LaserCUSING 248 5.7. MCP-HEK Tooling GmbH's Realizer II

(Selective Laser Melting) 257

Contents ix

5.8. Phenix Systems's PM Series (LS) 262 5.9. Sintermask Technologies AB's Selective Mask

5.10. 5.11. 5.12. 5.13. 5.14.

Chapter 6.

6.1. 6.2. 6.3.

6.4. 6.5. 6.6. 6.7.

Chapter 7.

7.1. 7.2. 7.3. 7.4.

7.5. 7.6. 7.7. 7.8. 7.9.

Sintering (SMS) 3D-Micromac AG's MicroSINTERING Therics Inc's Theriform Technology The Ex One Company's ProMetal Voxeljet Technology GmbH'S VX System Other Notable Powdered-Based RP Systems References Problems

Rapid Prototyping Data Formats

STL Format STL File Problems Consequences of Building Valid and Invalid Tessellated Models STL File Repair Other Translators Newly Proposed Formats Standard for Representing Layered Manufacturing Objects References Problems

Applications and Examples

Application-Material Relationship Finishing Processes Applications in Design Applications in Engineering, Analysis and Planning Applications in Manufacturing and Tooling Aerospace Industry Automotive Industry Jewelry Industry Coin Industry

267 273 276 278 283 286 293 298

301

301 302

306 308 336 338

350 352 354

357

357 359 360

361 365 379 383 387 388

x Rapid Prototyping

7.10. 7.11. 7.12.

Chapter 8.

8.1. 8.2. 8.3. 8.4. 8.5.

Chapter 9.

9.1. 9.2. 9.3. 9.4. 9.5.

Appendix

Tableware Industry Geographic Information System Applications Arts and Architecture References Problems

Medical and Bioengineering Applications

Planning and Simulation of Complex Surgery Customized Implants and Prosthesis Design and Production of Medical Devices Forensic Science and Anthropology Visualization of Biomolecules References Problems

Evaluation and Benchmarking

Using Bureau Services Setting Up a Service Bureau Technical Evaluation Through Benchmarking Industrial Growth Recent and Future Development Trends References Problems

List of RP Companies

CD-ROM Attachment

CD-ROM I Jser Guide

390 393 394 396 400

403

403 413 423 427 429 432 435

437

437 438 453 470 470 476 481

483

491

493

Index 501