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MEng8041 Rapid Prototyping and Tooling
MEng8041 Rapid Prototyping and Tooling
October 1, 2022
Fakada Dabalo (PhD Candidate) (JIT & UiS) MEng8041 Rapid Prototyping and Tooling October 1, 2022 1 / 50
Presentation Outlines
1 Metal printing
2 Rapid tooling
Fakada Dabalo (PhD Candidate) (JIT & UiS) MEng8041 Rapid Prototyping and Tooling October 1, 2022 2 / 50
1. Metal printing (MP)
MP is one of 3D printing or additive manufacturing (AM) process.
If 3D printing is using metal, the process is also known as 3D welding.
The Metal Printing Process (MPP) is a rapid manufacturing concept
aimed at developing the equivalent of a high-speed photocopier that
produces 3D objects.
The MPP is making a layer by manufacturing principles.
It all starts with making a virtual design and/or using a 3D scanner (to
copy an existing object) of the object desired to create.
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1. Metal Printing Contd
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a) Available Technologies of Metal Printing and
Processes
Not all 3D printers use the same technology.
Some methods use melting while other use powder or softening
material to produce the layers.
There are 10 technologies of Metal 3D Printing:
FDM/Extrusion fused deposition modeling with metal filament
(stainless steel (316L, 17-4 PH), copper, titanium, bronze, tungsten,
aluminum).
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SLM/PBF selective laser melting or powder bed fusion with laser
(aluminum, copper, nickel, stainless and tool steels, titanium, precious
metals),
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a) Available Technologies of Metal Printing and
Processes Contd
EBM/PBF electron beam melting or powder bed fusion with electron
beam (aluminum, copper, nickel, stainless and tool steels, titanium,
precious metals).
Metal Binder Jetting (maraging steel, stainless and tool steels, nickel,
cobalt, titanium, aluminum, copper, bronze), WAAM wire arc additive
manufacturing (stainless and tool steels, titanium, nickel-based alloys),
DED Laser directed energy deposition (laser)(steels, cast iron,
nickel alloys, titanium alloys, aluminum, copper), DED eBeam directed
energy deposition (electron beam)(stainless and tool steels, nickel alloys,
titanium alloys), Metal Lithography (stainless steels, titanium, copper,
nickel, brass), Cold Spray (titaniums, coppers, stainless and tool steels,
aluminum, nickels, niobium, tantalum), Micro 3D Printing (steel, copper,
precious metals)
Selective Laser Sintering,
Direct Metal Laser Sintering,
Three Dimensional Printing,
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Mechanical behavior characteristics of printed parts
"Good mechanical properties" is widely used in the 3D printing industry.
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2. Rapid Prototyping (RP) and Rapid Tooling (RT)
A much-anticipated application of rapid prototyping is rapid tooling,
the automatic fabrication of production quality machine tools.
Tools often have a complex geometry, yet must be dimensionally
accurate to within a hundredth of a millimeter.
Process can create metal tools directly from CAD files using RP
Technique.
Production of functional products:- Other special applications: Reverse
engineering, flow visualization, medical models, etc...
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2. Rapid Tooling (RT) Contd
RT is a term used to describe a process which either uses a rapid
prototyping model as a pattern to create a mould quickly or uses the
rapid prototyping process directly to fabricate a tool for a limited volume
of prototypes.
RT refers to mold cavities that are either directly or indirectly
fabricated using rapid prototyping (RP) techniques.
RT is generally categorized as soft or hard and direct or indirect
tooling as illustrated in Figure below.
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Rapid Tooling RT Contd
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Rapid Tooling Contd
In indirect tooling, a master part is first produced in almost all the cases
in RT in order to obtain the final molding tool and generally requires at
least one intermediate step.
On the other hand, direct tooling involves no intermediate steps during
the production of the tool.
RT process use CAD/CAM techniques to make tools and moulds for
product assessment short production run and full production.
The most common RT methods are:
keltool
Sprayed metal tooling
ACES
Investment casting
Selective laser sintering
Stereolithography
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Rapid Tooling Contd
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Advantages of RT
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Applications of RP
Historical Developments
Rapid Tooling
To Support Medical Applications
Surgical and Diagnostic Aids
Prosthetics Development
Manufacturing
Tissue Engineering and Organ Printing
Aerospace Applications
Automotive Applications
Reverse Engineering
Direct Tooling
Jewelry Design
Patterns for Casting
Molds for Casting
Patterns for Casting
Validation of Invention
Wind Tunnel Testing
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Indirect Rapid Tooling: Aluminum filled epoxy tooling
In the indirect method, master patterns were produced with the SLS and
SL process as shown in Fig. a.
These master patterns were vacuum cast such that a silicon rubber mold
with a cavity (the same of the master pattern) can be produced.
An aluminum epoxy mixture is then poured into the silicon rubber mold
cavity to create the aluminum epoxy tooling that follows the shape of the
cavity as shown Fig. b.
These aluminum epoxy parts undergo further curing to improve
mechanical properties. These parts exhibit similar properties to that of
aluminum.
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Indirect Rapid Tooling: Spray Metal Tooling
Currently, several industrial and government groups are working to
develop spray-metal tooling technologies.
Thermal metaldeposition technologies such as wire-arc spray and
vacuum plasmadeposition are being developed to essentially coat low
temperaturesubstrates with metallic materials.
The payoff results in a range oflow-cost tools that can provide varying
degrees of durability underinjection pressures.
The concept is to first deploy a high-temperature, highhardness shell
material to an RP positive, and then backfill the remainder of the tool
shell with inexpensive low-strength, lowtemperature materials and
cooling channels (if necessary).
Thisprovides a hard, durable face that will endure the forces and
temperatures of injection molding, and a soft backing that can beworked
for optimal thermal conductivity and heat transfer from themold.
The range of materials applied in MCP is limited to lowâĂŞmelting zinc
allows, aluminium and copper.
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Although some successes are being achieved, the currentstumbling block
is the capability to deposit the harder, hightemperature material directly
onto the RP pattern without affectingthe integrity of the component
geometry.
One alternative is to usethe RP pattern to create a silicone-rubber mold,
which is used to create a ceramic spray substrate.
This ceramic substrate can then endurethe high-temperature metal spray.
However, as it sounds, time andcost are multiplied by this approach.
In wire-arc spray, the metal to be deposited comes in filamentform.
Two filaments are fed into the device, one is positivelycharged and the
other negatively charged, until they meet and createan electrical arc.
This arc melts the metal filaments, while simultaneously a high-velocity
gas flows through the arc zone and propelsthe atomized metal particles
onto the RP pattern.
The spray patternis either controlled manually, analogous to spray
painting, or automatically by robotic control.
Metal can be applied, in successivethin coats, to very low-temperature
RP patterns without deformationof the geometry.
Current wire-arc spray technologies are limited tolower-temperature
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Direct Rapid Tooling: Direct AIM
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Direct Rapid Tooling: Direct DMLS
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Direct Rapid Tooling: Quick cast process
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2. Rapid Tooling (RT) Contd
RT is divided in to two different categories.
1 Direct route - uses the CAD file to produce the tool in the final material.
Direct Rapid Tooling - Direct AIM, Quick cast process, Copper
polyamide, Rapid Tool, DMILS, Pro Metal, Sand casting tooling,
Laminate tooling, soft tooling vs hard tooling.
2 Indirect route - uses a rapid prototyping model as a master pattern or case
to make the moulds by established, more traditional routes.
Silicone rubber tooling, Aluminum filled epoxy tooling, Spray metal
tooling, etc.
Capturing 3D data of an object in computerized (digitized) form
Shortens design-to-market - is an effective time-compression technology
As RP becomes more mature, material properties, accuracy, cost and
lead-time have improved to permit it to be employed for the production
of tools. Some
Two part negative tooling is easily created with LOMTM systems. Since
the material is solid and inexpensive, bulk complicated tools are cost
effective to produce. These wood-like molds can be used for injection of
wax, polyurethane, epoxy or other low pressure and low temperature
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Indirect Rapid Tooling
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Metal Printing
in general, do not need planning of process sequence manufactured in
one step
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Software for Rapid Prototyping
Fakada Dabalo (PhD Candidate) (JIT & UiS) MEng8041 Rapid Prototyping and Tooling October 1, 2022 25 / 50
3. Software for Rapid Prototyping
STL (Stereolithography) is a file format native to the stereolithography
CAD software created by 3D Systems. STL has several after-the-fact
backronyms such as "Standard Triangle Language" and "Standard
Tessellation Language".
The format was developed for 3D Systems’ first commercial 3D printers.
It is widely used for rapid prototyping, 3D printing and computer-aided
manufacturing.
STL files describe only the surface geometry of a three-dimensional
object without any representation of color, texture or other common
CAD model attributes.
The STL format specifies both ASCII and binary representations.
Binary files are more common, since they are more compact.
An STL file describes a raw unstructured triangulated surface by the unit
normal and vertices (ordered by the right-hand rule) of the triangles
using a three-dimensional Cartesian coordinate system. STL coordinates
must be positive numbers, there is no scale information, and the units are
arbitrary.
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Instead of having a machine that has to communicate with all of these
different systems, there is a single, universal file format that every system
needs to be able to produce so that an RP machine can process what a
part looks like for slicing. This is the STL file.
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Why is STL format used? The reason is because slicing a part is easier
compared to other methods such as B-rep (boundary representation) and
CSG (constructive solid geometry), which will need geometric reasoning
and data conversion.
To calculate the interaction between the geometry and a plane that
represents the slicing operation is not very efficient.
The slicing operation is computed by "intersecting" a ray of virtual lines
with the object of interest.
Fakada Dabalo (PhD Candidate) (JIT & UiS) MEng8041 Rapid Prototyping and Tooling October 1, 2022 28 / 50
ASCII STL
An ASCII STL file begins with the line
Solidname where name is an optional string (though if name is omitted
there must still be a space after solid). The file continues with any
number of triangles, each represented as follows
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3.2. Overview of solid view in rapid prototyping
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Overview of solid view in rapid prototyping Contd
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3.2.1 Magics in rapid prototyping
Materialise Mimics is image processing software for 3D design and
modeling, developed by Materialise NV, a Belgian company specialized
in additive manufacturing software and technology for medical, dental
and additive manufacturing industries.
Materialise Mimics is used to create 3D surface models from stacks of
2D image data. These 3D models can then be used for a variety of
engineering applications.
Mimics is an acronym for Materialise Interactive Medical Image Control
System.
It is developed in an ISOenvironment with CE and FDA 510k premarket
clearance.
Materialise Mimics is commercially available as part of the Materialise
Mimics Innovation Suite, which also contains 3-matic, a design and
meshing software for anatomical data.
The current version is 20.0, it supports Windows 10, Windows 7, Vista
and XP in x64.
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3.2.1 Magics in rapid prototyping Contd
Materialise Mimics calculates surface 3D models from stacked image
data such as Computed Tomography (CT), Micro CT, Magnetic
Resonance Imaging (MRI), Confocal
Microscopy, X-ray and Ultrasound, through image segmentation.
The ROI, selected in the segmentation process is converted to a 3D
surface model using an adapted marching.
The Materialise Magics software uses the 80-byte header at the top of the
file to represent the overall color of the entire part. If color is used, then
somewhere in the header should be the ASCII string "COLOR="
followed by four bytes representing red, green, blue and alpha channel
(transparency) in the range 0âĂŞ255. This is the color of the entire
object, unless overridden at each facet. Magics also recognizes a material
description; a more detailed surface characteristic. Just after
"COLOR=RGBA" specification should be another ASCII string
",MATERIAL=" followed by three colors (3ÃŮ4 bytes): first is a color
of diffuse reflection, second is a color of specular highlight, and third is
an ambient light. Material settings are preferred over color. The per-facet
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Software for Rapid Prototyping: Magics in RP
Materialise Mimics is image processing software for 3D design and
modeling, developed by Materialise NV, a Belgian company specialized
in additive manufacturing software and technology for medical, dental
and additive manufacturing industries.
Materialise Mimics is used to create 3D surface models from stacks of
2D image data.
These 3D models can then be used for a variety of engineering
applications.
Mimics is an acronym for Materialise Interactive Medical Image Control
System.
It is developed in an ISOenvironment with CE and FDA 510k premarket
clearance.
Materialise Mimics is commercially available as part of the Materialise
Mimics Innovation Suite, which also contains 3-matic, a design and
meshing software for anatomical data.
The current version is 20.0, it supports Windows 10, Windows, 7, Vista
and XP in x64.
Fakada Dabalo (PhD Candidate) (JIT & UiS) MEng8041 Rapid Prototyping and Tooling October 1, 2022 34 / 50
Software for in RP: Magics communicator
Materialise Magics is a versatile, industry-leading data preparation and
STL editor software for AM that allows you to convert files to STL,
Materialise Magics 3D Print Suite Modules.
Product Information Âů Sinter Module. Materialise Magics, the top
choice of data preparation software for any 3D Rapid Prototyping team
saved about 80 hours by utilizing Materialise Magics STL. Materialise
Magics, the top choice of data preparation software for any 3D . Rapid
Prototyping team saved about 80 hours by utilizing Materialise Magics
STL. âĂć Magics rapid prototyping software enables you to import a
wide variety of CAD formats and to export STL files ready for rapid
prototyping, tooling and. How to make support and make ready models
for Digitalwax printer - GLORIOUS JEWEL - Duration: Magics is rapid
prototyping software and is a key element of the Magics e-Solution
Suite, a full range of. Magics RP is leading software, from Materialise
BV, for preparing STL CAD models for rapid prototyping and additive
manufacturing applications. âĂć 3D printing trends in additive
manufacturing, 3D printing, and rapid product development.
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3.2.4 Internet based software
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3.2.4 Internet based software Contd
TMF allows users to easily submit jobs and have the system
automatically maintain a queue. It can also automatically check many
flaws in .STL (Stereolithography) files, and in many cases, fix them. A
laminated object manufacturing (LOM) machine was first connected
with network, and then the .STL file of a part to be built could be
submitted to this machine via a command-line.
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3.2.5 Rapid Manufacturing Process Optimization
(RPPO)
Process optimization
The parameters of RP can be classified as nuisance parameters, constant
and control parameters.
Nuisance parameters include age of the laser, beam position accuracy,
humidity and temperature, which are not controlled in the experimental
analysis but may have some effect on a part.
Constant parameters include beam diameter, laser focus and material
properties, etc. the constant parameters will affect the output of the
process and are controllable in a run.
These include layer thickness, hatch space, scan pattern, part orientation,
shrinkage of the material and beam width compensation, etc.
Layer thickness, hatch space, part orientation and depth of cure are the
most vital among the control parameters.
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3.2.5 RPPO Contd
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Factors influencing accuracy
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Data preparation errors
Errors due to tessellation: Most RP systems employ standard STL
input files. A STL file approximates the surface of the 3D CAD model
by triangles. Errors caused by tessellation are usually ignored because of
the belief that tessellation errors can be minimised by increasing the
number of triangles. However, in practice the number of triangles cannot
be increased indefinitely. The resolution of STL files can be controlled
during their generation in a 3D CAD system through tessellation
parameters.
Chord Height
Angle Control
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Part Building Errors
There are two main types of errors in the part building process,
namely curing errors and control errors.
Curing errors refer to those errors that are caused by over-curing and
scanned line shape.
Control errors are those errors caused by layer thickness and scan
position control.
Both types of errors affect part accuracy.
Over-curing: Laser over-curing is necessary to adhere layers to form
solid parts. However, it causes dimensional and positional errors to
features.
Scanned Line Shape: A scanned line is created when a laser beam
scans the resin surface. The cross section of the scanned line is referred
to as the scanned line shape.
The part building process is assumed to be a stacking up of rectangular
shaped blocks.
Control errors: theoretically, the layer thickness should be at the defined
value and the border line should be positioned at the specified positions.
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Errors of Parts infinishing
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Influence of part build orientation
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ALLIED PROCESSES
The following feature constraints should be considered in choosing
candidate build orientations for SL process. ïĆů User specified critical
surfaces: if these surfaces are planes, they have to be placed such that
their normal point in the build direction. In other words, they are
horizontal and upward facing. Cylinders, cones and surfaces of
revolution are oriented so that their axes are vertical. ïĆů Coordinate
system: since a coordinate system is usually created by the designer and
employed whilst modelling, the orientation of the coordinate axes may
represent the most logical build direction. It is placed so that the z-axis
points in the build direction. ïĆů Holes: in order to avoid hard- to
remove supports and stair-stepping inside holes, these are placed
orthogonally to horizontal planes. ïĆů Cuts: if these curve through the
part entirely or have a depth greater than a certain minimum, the planes
which they cut through placement planes are made horizontal.
Otherwise, they are ignored. ïĆů Protrusions: if these are created by
revolving a section, the axes are positioned so that they are vertical. ïĆů
Shells: these are orientated so that the concave part of the shell faces
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Vacuum Casting
Possibilities of use RP techniques could be significantly extended by
taking advantages of devices for Vacuum Casting. It enable to produce
models from different resins (with properties very similar to finished
plastic or rubber products) and wax models for lost-wax casting process.
VC System consist of: vacuum chamber and heat chambers. Vacuum
chamber herself gives possibilities for producing silicon rubber moulds
and resin free of air bubbles generated during mixing. Main use of
vacuum chamber is casting of resins, waxes and other plastics in silicon
moulds - prepared in the first step from the RP models. It is easy to reach
wide range of resins, which gives possibilities to achieve variety
properties of produced products. It is possible to produce objects which
are similar in hardness and elasticity to rubber, and also to significantly
harder and less elastic like ABS plastic. Additionally it is possible to
produce dye models. It is possible also to produce wax models. In this
case is necessary to install additional unit to melt wax through heating up
to proper temperature. Next, wax models can be used in die casting
process for producing ceramic moulds.
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Vacuum Casting Contd
Vacuum chamber is equipped in driver which manage all processes:
pumping out air from chamber, mixing resin components, and pouring
ready resin to mould. Characteristic technical data about our device for
vacuum casting are:
Working area which determine maximum dimensions of produced
moulds 450 x 425 x 530 mm;
Time for silicone rubber mould preparation: 12h;
Time for single resin casting: 40-50min.
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Surface digitization
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Surface generation from point cloud
A point cloud is a set of data points in some coordinate system.
In a three-dimensional coordinate system, these points are usually
defined by X, Y, and Z coordinates, and often are intended to represent
the external surface of an object.
Point clouds may be created by 3D scanners. These devices measure a
large number of points on an object’s surface, and often output a point
cloud as a data file. The point cloud represents the set of points that the
device has measured.
As the output of 3D scanning processes, point clouds are used for many
purposes, including to create 3D CAD models for manufactured parts,
metrology/quality inspection, and a multitude of visualization,
animation, rendering and mass customization applications.
While point clouds can be directly rendered and inspected, usually point
clouds themselves are generally not directly usable in most 3D
applications, and therefore are usually converted to polygon mesh or
triangle mesh models, NURBS surface models, or CAD models through
a process commonly referred to as surface reconstruction.
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3. Data formats for exchange of design data to AM
machines
The PDES Initiation Effort proposed that the new standard should be
based on a "three layer" architecture, significantly influenced by the
ANSI/SPARC three layer architecture for database systems.
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