AM-Concept Modelers - 2020
AM-Concept Modelers - 2020
Concept models are typically used early to evaluate a product’s design. Whereas a prototype
simulates how a product will function, a concept model is the equivalent of a three-dimensional
sketch. Concept modelers, produce relatively crude & fragile parts cheaply and quickly.
Prototypes fabricated from AM machines are often used to evaluate how a part will perform,
concept models typically are used to evaluate a product’s design. Just as there are multiple AM
technologies, there are also several processes for making concept models. The characteristics of
concept models vary widely. To get the most benefit from a concept model, one has to choose a
process that makes parts matching their requirements.
As with other AM systems, the input for concept modelers is a CAD file that has been
converted into the tessellated STL format. Software in the Concept modeler system slices the STL
model into a series of horizontal cross sections. Concept modelers build parts layer by layer using
ink jet printing technology.
Table: Comparison between Concept Modelers and AM machine
Concept Modelers AM machine
Models produced are less accurate and Parts are more accurate and have good
surface finish is poor. surface finish
Models are fragile in nature typically Whereas a AM product is strong and
used to evaluate a product’s design at simulates how a product will function.
each stage.
Concept modelers and materials used AM machine and materials used are
are cheap hence models are inexpensive. expensive and hence products are costly
Concept models are built very quickly. AM products are built comparatively
slower.
Reside in design office environments. Reside outside design office space as some
AM machines are not safe for humans.
Operate much like a standard printer, Training is essential to operate AM machine
require very little or no training to
operate.
platform is repositioned (Y-axis) to continue building in the X-direction until the entire layer
is completed.
After one layer is completed, the platform is lowered and the building of the next layer begins
in the same manner as described in Steps 2 and 3.
The process continues with the continual repetition of Steps 2 to 4 until the part is complete,
after which the part is ready for instant removal and review with no further need for post-
processing or post-curing and hence can be used as soon as they are built.
Factors
Part size – Small parts with fine detail can be built. It’s not easy to glue waxy Thermojet parts
together.
Build orientation -- Downward facing surfaces on MultiJet modeling parts are uneven after
supports have been removed. Though much of this roughness can be smoothed with solvent,
one should indicate which surfaces are most important so the operator can orient them facing
upwards.
Finishing -- For concept models, it may not be necessary to spend the extra time required to
get perfect finishes on all surfaces.
if small features or fine detail are required, 3D Systems Multi Jet modeling might do a better
job.
Advantages
Efficient and ease of use: The large number of jets from 352 heads allows fast and continuous
material deposition at a resolution of 300 dpi for maximum efficiency. CAD program and no
file preparation is required. This makes the concept modeler easy to use.
Cost-effective: MJM uses inexpensive thermopolymer material that provides for cost-effective
modeling.
Fast build time: As a natural consequence of MJM’s raster-based design, the geometry of the
model being built has little effect on the building time.
Office-friendly process: As the system is clean, simple and efficient, it does not require special
facilities, thereby enabling it to be used directly in an office environment. Due to its networking
capabilities, several design workstations can be connected to the machine just like any other
computer output peripheral.
Material is loaded into the machine in cartridges. There is no messy powder or liquid. Support
removal can be done over a wastebasket and requires no protective clothing.
Disadvantages
Small build volume: The machine has a comparatively small build volume as compared to most
other high-end AM systems (e.g., SLA-500), thus only small prototypes can be fabricated.
Limited materials: Materials selection is restricted to 3D systems’ ThermoJet® 2000 and
ThermoJet 88 thermopolymer. This limited range of material means that many functionally-
based concepts that are dependent on material characteristics cannot be effectively tested with
the prototypes.
Weak accuracy: The process lacks sufficient accuracy in building exact prototypes when
compared with the high-end AM systems.
Surfaces where supports have been removed are quite rough but can be improved by polishing
Applications:- MultiJet modeling is best for applications where part detail is more important
than durability. It is also ideal for building parts to be used as investment-casting patterns. Because
Thermo Jets run cleanly and quietly in an office environment, the technology is ideal for small
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company use in-house.. The main application for the ThermoJet® is to produce concept models for
visualization and proofing during the early design process. It is meant to function in an office
environment in the immediate vicinity of the CAD workstations.
To quickly produce a more robust model, parts can be dipped in wax. Once the powder is
removed from the part surfaces, the part is placed in a small oven and heated to a temperature
just above that of the infiltrant wax, to provide a wicking characteristic as opposed to coating.
The part temperature for paraffin infiltrant is approximately 200°F.
Immediately after the part is heated, it is dipped for a few seconds into a vat of molten wax,
then removed and placed on a sheet to dry. After drying the part is complete.
For a robust model that can be sanded, finished and painted, the part can also be infiltrated with
a resin or urethane.
A unique capability of three-dimensional printing is the ability to produce multicolored parts. A
part’s color is determined by dyes added to the liquid binder. Almost any color is possible.
Advantages
High speed. Fastest 3D printer to date. Each layer is printed in seconds, reducing the
prototyping time of a hand-held part to 1 to 2 hours.
Versatile. Parts are currently used for the automotive, packaging, education, footwear,
medical, aerospace, and telecommunications industries. Parts are used in every step of the
design process for communication, design review and limited functional testing. Parts can be
infiltrated if necessary, offering the opportunity to produce parts with a variety of material
properties to serve a range of modeling requirements.
Simple to operate. The office compatible Z-corp system is straightforward to operate and
does not require a designated technician to build a part. The system is based on the standard,
off the shelf components developed for the ink-jet printer industry, resulting in a reliable and
dependable 3D printer.
No wastage of materials. Powder that is not printed during the cycle can be reused.
Color. Enables complex color schemes in parts from a full 24-bit palette of colors.
Bulky parts can be produced.
Disadvantages
Limited functional parts. Relative to the SLS, parts built are much weaker, thereby limiting
the functional testing capabilities.
Limited materials. The materials available are only starch and plaster-based materials, with
the added option to infiltrate wax.
Poor surface finish. Parts built by 3D printing are porous and hence have a relatively poorer
surface finish and post-processing is frequently required.
Application: - Three-dimensional printing is best used when speed and price are more critical than
accuracy, surface finish, and material properties. 3DP parts are most often used as concept models
but, when infiltrated, also can be finished and used as patterns for duplication. Parts built with starch-
based material can be used directly as investment-casting patterns. 3DP parts a have relatively poor
surface finish. Small features and fine details are not replicated well. Thin walls can be problematic
because all materials are brittle.
A secondary use of three-dimensional printing is for making casting shells. Z Corporation is now
testing methods of building casting shells from its plaster material. Z Corporation suggests making
molds in pieces that are put together along with cores prior to casting, much like sand-casting molds
are assembled. That way, the casting surface of each mold piece can be sanded or filled to remove
stair steps. Z Corporation says shells built with 3DP deliver a surface finish and accuracy similar to
traditional sand casting in a fraction of the time.
Factors
Part size: - Large parts can be built in pieces and then glued together, but this takes extra time.
Moreover, the low accuracy of 3DP can prevent part sections from fitting together well.
Feature size: - 3DP systems can have problems producing very small features, and thin walls
are sometimes impossible to build.
Accuracy: - Three-D printed parts have low accuracy. Consequently, it is difficult to assemble
parts made with 3DP. Threads are not replicated.
Joining: - Because materials are brittle, 3DP parts are difficult to drill and tap for joining with
conventional fasteners.
Material: - Plaster powder is more expensive than starch but delivers better strength, detail, and
surface finish For investment-casting patterns or just to get parts as cheaply and quickly as
possible, starch dipped in wax is sufficient. Changing materials in a 3DP system is messy and
takes time. Not all service providers will offer both starch and plaster.
Finishing: - For concept models, it may not be necessary to spend the extra time required to get
pretty parts.
Disadvantage of the system would be its single- material capacity, which results in more difficult
support removal on complex parts.
The intended application of the Genisys system's product was mainly concept modeling and
verification. However, as with all AM devices, various users have progressed the use of Genisys
models into analysis, direct use, even low-impact wind-tunnel modeling. The material is said to be
suitable for painting, drilling, and bonding to create the necessary appearance for an application
JP SYSTEM 5
This is developed by Schroff Development Corporation. It is an inexpensive system requires
only a PC and cutting device, material used is paper sheets. The JP-5 software Silver Screen accepts
the standard .STL file, as well as Silver Screen CAD files. The build material supplied with the JP-5
is label paper which has adhesive on its underside. The JP-5 plotter has stainless steel cutting blades.
The plotter moves the paper back-and-forth in the -y direction, while the blade is controlled in the -x
direction. This result in the two axis motion used to cut the cross sections of the parts being built.
The assembly board is used to align the sheets of paper for final fabrication of the parts. It has many
threaded holes across its surface, into which the alignment pins can be placed.
Fabrication steps of JP system 5
A software package is used to slice the model into series of cross sections.
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These slices are the converted to HPGL plot file format and sent to a plotter.
Plotted sheets are layered by aligning specially cut orientation hole.
The sheets are positioned on a registration board.
An adhesive is sprayed on the first sheet.
Each subsequent sheet adheres to the exposed adhesive surfaces of the previous sheet.
Sections formed by the nesting operation are cut
The final model is assembled.
the third and all remaining slices are cut through the label side, and the sheets are placed on
the previous layer such that their adhesive side up for the next layer. The alignment pegs
allow the cross sections to be set properly and ensure part is built accurately.
Finishing a Part
Once the JP-5 part has been completely assembled, it should be sealed to prevent moisture
from being absorbed into the paper. Moisture can cause the parts to warp, sag, or deform.
Different sealers can be used, including sanding sealers and varnishes or polyurethane sprays,
but the simplest method is to use ordinary school glue brushed on with a small paintbrush.
The glue hardens, leaving a nice glossy seal around the part, which helps the appearance as
well.
Advantages
This process is quick, cheap and simple
Shape and size of the part can be checked easily.
Disadvantages
Parts are produced by paper hence life of the part is short
Parts are not as strong as other concept models.
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