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ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 1 Rapid Prototyping ver. 1ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 2 Process • Additive fabrication – material is added, not removed • Direct fabrication from a CAD file • Layered manufacturingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 3 Layered Manufacturing - Stereolithography Laser Mirror Layered Object Platform VatME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 4 Rapid Prototyping ExamplesME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 5 Process Examples • Stereolithography (SL) • Selective Laser Sintering (SLS) • Wax jet printing (Thermojet) • 3-D Printing • Light Engineered Net Shaping (LENS) • Fused Deposition Modeling (FDM) • Solid Base Curing • Laminated Object Modeling (LOM)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 6 StereolithographyME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 7 Stereo-lithography The computational steps in producing a stereolithography file. (a) Three-dimensional description of part. (b) The part is divided into slices (only one in 10 is shown). (c) Support material is planned. (d) A set of tool directions is determined to manufacture each slice. Shown is the extruder path at section A-A from (c), for a fused-deposition-modeling operation.ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 8 Stereolithography PartsME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 9 StereolithographyME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 10 Common Support Structures Overhangs need supportME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 11 Injection Mold Making Process CAD Models SLA Build SLA-250 CAD package Back Filled Inserts Epoxy Back Fill Plastic Part Injection MoldME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 12 Stereolithography MoldME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 13 Rapid Tooling - Quick CastME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 14 Rapid Tooling - Quick CastME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 15 Selective Laser SinteringME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 16 Selective Laser Sintering (3D Systems)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 17 SLS PartsDirect Metal Laser Sintering • http://www.youtube.com/watch?v=88BPmL8cGAo • http://www.youtube.com/watch?v=DW-2xaIDtMk&feature=related ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 18ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 19 Wax Jet Printing - ThermojetME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 20 ThermojetME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 21 Three-Dimensional PrintingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 22 Z Corp Machine http://www.youtube.com/watch?v=ZboxMsSz5Aw&feature=youtube_gdata_playerME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 23 3D Printing Head (Soligen)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 24 SoligenME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 25 Light Engineered Net Shaping (1) (Sandia National Lab)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 26 Light Engineered Net Shaping (2) (Sandia National Lab) Laser Powder delivery tubeME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 27 Light Engineered Net Shaping (3) (Sandia National Lab)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 28 Light Engineered Net Shaping Parts (Sandia National Lab)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 29 Fused Deposition Modeling (FDM)-(Stratasys)Direct Metal Writing • http://www.youtube.com/watch?v=gcIdSBxtO1Q&feature=related • http://www.youtube.com/watch?v=SYbw1oSzPVA&feature=related • http://www.youtube.com/watch?v=iLndYWw5_y8 ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 30ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 31 FDM PartsFDM Prototype Biosensor ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 32ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 33 Solid-Base Curing - Cubital SoliderME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 34 Solid Base CuringME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 35 Laminated Object Manufacturing (LOM) - (Helisys)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 36 Laminated Object ManufacturingME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011 37 Summary • Additive fabrication – material is added, not removed • Direct fabrication from a CAD file • Layered manufacturing • Stereolithography (SL) • Selective Laser Sintering (SLS) • Wax jet printing (Thermojet) • 3-D Printing • Light Engineered Net Shaping (LENS) • Fused Deposition Modeling (FDM) • Solid Base Curing • Laminated Object Modeling (LOM)ME 4210: Manufacturing Processes and Engineering Prof. J.S. Colton © GIT 2011


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