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Rapid Prototyping: Department of Mechanical Engineering, The Ohio State University
Rapid Prototyping: Department of Mechanical Engineering, The Ohio State University
Rapid Prototyping
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Rapid Prototyping
What is Rapid Prototyping?
A CAD technique to allow Automatic creation of a physical model or prototype from a 3-D model. Create a 3-D Photocopy of a part. Computer Real life
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Pre-lim Design
Drawings
Iterate
Testing
Manufacturing
Department of Mechanical Engineering, The Ohio State University
Sl. #3
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Prototype Classifications
Conceptual
Team members are aware of what is to be designed.
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Process:
Starts with solid model from some CAD package (Solid Edge, Solid Works, I-DEAS or Pro-E for example) Next create the desired tool paths
Problems/Limitations:
Process not totally automatic. Operator must make many decisions: Appropriate tools How to fixture the stock Re-fixturing during machining
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NC - Brief History
Late 1950s - MIT developed a common language to describe cutting motions with a certain machine.
Code placed on a paper tape the machine could read
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NC - in Present Day
Machining Centers
In prototyping many tools required by the user to create the parts. Machining centers hold & manage a large number (up to 120) of tools Eliminates tool-change time by machine operator Much more complex parts with less operator interaction Ex: T500 (Cincinnati Milacron)
NC software
Early program languages for NC required the path to be explicitly defined (Exact path known - no modification allowed -program began with the user entering the tool paths, NOT the workpiece shapes as is desired) Programs now perform calculations for the user Very complicated geometries easily handled by computer Department of Mechanical Engineering, The Ohio State University
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NC machining requires a skilled operator to set up machine and to specify tools, speeds, and raw materials. For this reason, many do not consider NC machining to be a true Rapid Prototyping (RP) technique. True RP should create a part from some model without any assistance. NC Machining does have some benefits over true RP
NC Machining allows a wide range of materials for prototypes (true RP techniques often prohibit material for function prototype) NC Machining allows better accuracy than most true rapid prototyping techniques (may be needed for fit prototypes) True RP techniques can produce a prototype of a part that is impossible to manufacture. NC machining often reveals manufacturing limits in a given design. Department of Mechanical Engineering, The Ohio State University
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Overhang
Department of Mechanical Engineering, The Ohio State University
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Liquid
Bulk Liquid Polymerization Light
Two frequencies
Beam Interference solid
Gluing Sheets
Laminated Object Manufacturing
Heat
Thermal Polymerization
Polymerization
Foil Polymerization
One frequency
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SFM Technology
Solid Base Curing- photopolymer is cured by UV light Fused Deposition Modeling - molten plastic is extruded &
solidifies
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Stereolithography
Stereo Lithography (SLA) was the first commercially available Solid Freeform Manufacturing system. It is still the industry leader, setting many industry trends. 1) Laser traces current cross section onto surface of photocurable liquid acrylate resin 2) Polymer solidifies when struck by the lasers intense UV light 3) Elevator lowers hardened cross section below liquid surface 4) Laser prints the next cross section directly on top of previous 5) After entire 3-d part is formed it is post-cured (UV light) Note: care must be taken to support any overhangs The SLA modeler uses a photopolymer, which has very low viscosity until exposed to UV light. Unfortunately this photopolymer is toxic. Warpage occurs.
Department of Mechanical Engineering, The Ohio State University
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Stereolithography
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Stereolithography Overview
Laser is focused/shaped through optics. A computer controlled mirror directs laser to appropriate spot on photopolymer surface. Polymer solidifies wherever laser hits it.
When cross section is complete, elevator indexes to prepare for next layer.
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SLA Interface
Stereolithograpy was first commercial Solid Freeform Manufacturing process, released in 80s by 3-D Systems
3-D Systems developed interface between CAD systems and their machine
STL files (*.stl) allow CAD systems to interface with 3-D system machines Virtually all subsequent SFM processes can use this same format (SFM industry standard) Many CAD programs now can export the *.stl file for easy conversion from CAD to part
Department of Mechanical Engineering, The Ohio State University
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Much less warpage than SLA, but still uses photopolymers which are toxic.
Department of Mechanical Engineering, The Ohio State University
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Laser then shines through mask, solidifying the entire layer in one shot. More rapid layer formation, and thorough solidification.
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Remove excess polymer, and fill gaps with liquid wax. Chill to solidify wax.
Mill wax & workpiece Department of Mechanical Engineering, The Ohio State University
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FDM modelers typically use nylon or some wax. The material is non toxic and can be used anywhere, including offices. Machines can be equipped with second head to extrude a support structure (BASS breakaway support system).
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Notice that the FDM filament cannot cross itself, as this would cause a high spot in the given layer Department of Mechanical Engineering, The Ohio State University
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BPM Process
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1) 2) 3) 4)
5) 6) 7) 8)
Thin distribution of powder is spread over powder bed Inkjet printheads deposit small droplets of binder Upon contact, binder droplets join powder to form solid Piston supporting powder bed lowers so that the next layer can be spread and joined Process repeats until completion The shell that has been created is fired Shell is filled with molten metal Metal solidifies & shell is broken away from part
Process allows use of metal for parts. Uses alumina powder & silica binder for shell. 3-D printing can have other uses.
Department of Mechanical Engineering, The Ohio State University
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SLS Process
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LOM Process
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LOM Example
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1) Deposition- material is added by plasma or laser based welding techniques 2) Filler material is deposited around part 2) Material is shaped using conventional CNC 3) Solid is stress relieved 4) Components can be embedded 5) Filler is removed to leave only finished part
Department of Mechanical Engineering, The Ohio State University
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Material: Stainless Steel (308) Support Material: Copper Deposition Method: Microcasting Support Removal: Etching Size: 75 x 50 x 42 mm Average Tensile Strength: 670 MPa Number of Layers: 29 Layer Thickness: 1.0 - 1.7 mm
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Advances in SFM technology have greatly increased the number of allowable materials and reduced the cost However many limitations still exist-- can be combined with traditional processes 3-d Printing Direct Shell Production Casting SFM process creates a mold- casting is traditional process Similarly one can generate a part from SFM process and then use investment casting Molds can also be made from SFM part by encasing in RTV RTV mold can make urethane or epoxy parts Can also create SFM mold and then coat with metal (process called metal spraying) to get functional mold
Department of Mechanical Engineering, The Ohio State University
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Summary
Many different processes for Rapid Prototype Machining Stereo-lithography Phostosolidification Layer at a Time Solid Base Curing Fused Deposition Modeling Ballistic Particle Manufacturing 3D Printing Direct Shell Production Casting Selective Laser Sintering Laminated Object Manufacturing
Department of Mechanical Engineering, The Ohio State University
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Credits
This module is intended as a supplement to design classes in mechanical engineering. It was developed at The Ohio State University under the NSF sponsored Gateway Coalition (grant EEC9109794). Contributing members include: Gary Kinzel .. Project supervisor Chris Hubert and Alan Bonifas ..... Primary authors Phuong Pham and Matt Detrick ... Module revisions
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Disclaimer
This information is provided as is for general educational purposes; it can change over time and should be interpreted with regards to this particular circumstance. While much effort is made to provide complete information, Ohio State University and Gateway do not guarantee the accuracy and reliability of any information contained or displayed in the presentation. We disclaim any warranty, expressed or implied, including the warranties of fitness for a particular purpose. We do not assume any legal liability or responsibility for the accuracy, completeness, reliability, timeliness or usefulness of any information, or processes disclosed. Nor will Ohio State University or Gateway be held liable for any improper or incorrect use of the information described and/or contain herein and assumes no responsibility for anyones use of the information. Reference to any specific commercial product, process, or service by trade name, trademark, manufacture, or otherwise does not necessarily constitute or imply its endorsement.