– Rapid Prototyping EML 2023 – Additive Rapid Prototyping Lecture 1
EML 2023 – Rapid Prototyping Lecture 1 – Additive Rapid Prototyping Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 2 Selective laser sintering (SLS) • additive technique • layer of powder placed on base • high power laser used to fuse selected parts of the powder • the powder bed is lowered a small amount and a new layer of powder is spread • does not require any support structures EML 2023 Department of Mechanical and Aerospace Engineering 3 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 4 Fused deposition modeling (FDM) • additive technique • material is laid down in layers • plastic material is melted in a nozzle that moves in XY direction • typically uses ABS plastic • support material is required EML 2023 Department of Mechanical and Aerospace Engineering stratasys 5 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 6 Stereolithography (SLA) • additive process • uses a vat of liquid UV-curable resin and a UV laser • exposure to the laser causes the material to harden • after a pattern has been traced, the platform descends and a resin filled blade recoats the top • requires support structures EML 2023 Department of Mechanical and Aerospace Engineering 7 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 8 Laminated object manufacturing (LOM) • sheet is adhered to substrate with a heated roller • laser traces out the outline of the layer • non-part areas are crosshatched to facilitate removal of waste material • next layer is pulled across and the process is repeated EML 2023 Department of Mechanical and Aerospace Engineering 9 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 10 Electron 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 EML 2023 Department of Mechanical and Aerospace Engineering 11 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 12 3D 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 technique EML 2023 Department of Mechanical and Aerospace Engineering zcorp 13 Technologies Prototyping Technologies Base Materials Selective laser sintering (SLS) Thermoplastics, metal powders Fused deposition modeling (FDM) Thermoplastics, eutectic metals Stereolithography (SLA) Photopolymer Laminated object manufacturing (LOM) Paper Electron beam melting (EBM) Titanium alloys 3D printing (3DP) Various Materials EML 2023 Department of Mechanical and Aerospace Engineering 14 UF machines - FDM • Dimension 1200es SST (Soluble Support Technology) Building MAE-B Room 313 EML 2023 Department of Mechanical and Aerospace Engineering 15 UF Rapid Prototyping Machines 101012” build volume 868” build volume sodium hydroxide & water tank 16 former UF machine - FDM EML 2023 Department of Mechanical and Aerospace Engineering 17 Existing Equipment • 2 Dimension sst 1200es Rapid Proto Machines – ABS plastic – 101012” build volume – .010” z-axis, .005” xy-axis resolution • Roland MDX-540 Subtractive R.P. machine – – – – plastic, wood, aluminum 4 axis ; 4 tool magazine 4412” build volume .0008” repeat accuracy Existing Equipment • Next Engine 3D Scanner – 54” macro field of view – 13.510” wide field of view – .005” accuracy EML 2023 Department of Mechanical and Aerospace Engineering Equipment to be delivered • Fortus 360mc Rapid Proto Machine – – – – ABS plastic, Nylon, polycarbonate 161416” build volume .005” accuracy 1.5 speed compared to existing machines EML 2023 Department of Mechanical and Aerospace Engineering MAE-B 313 Lab Renovation Plan EML 2023 Department of Mechanical and Aerospace Engineering Steps to Create a Part 1. Model part (or assembly) in SolidWorks. 2. 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’. 3. Run the Catalyst software. Orient the part on the build tray and send to rapid proto machine. EML 2023 Department of Mechanical and Aerospace Engineering 23 24 25 26 27 28 29 30
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