SINTERING Selective Laser Sintering (SLS, registered trademark by DTM of Austin, Texas, USA) is a process that was patented in 1989 by Carl Deckard, a University of Texas graduate student
The selective laser sintering stations (SLS) use a
plastic powder to create prototype parts. The powder is melted, layer by layer, by a computer- directed heat laser. Additional powder is deposited on top of each solidified layer and again sintered. PROCESS a laser beam is traced over the surface of a tightly compacted powder made of thermoplastic material . The powder is spread by a roller over the surface of a build cylinder . A piston moves down one object layer thickness to accommodate the layer of powder. The powder supply system is similar in function to the build cylinder. It also comprises a cylinder and piston. In this case the piston moves upward incrementally to supply powder for the process. PROCESS Heat from the laser melts the powder where it strikes under guidance of the scanner system . The CO2 laser used provides a concentrated infrared heating beam. The entire fabrication chamber is sealed and maintained at a temperature just below the melting point of the plastic powder. Thus, heat from the laser need only elevate the temperature slightly to cause sintering, greatly speeding the process. A nitrogen atmosphere is also maintained in the fabrication chamber which prevents the possibility of explosion in the handling of large quantities of powder. SINTERSTATION 2500 PLUS
Build chamber dimension 381 x 330 x 457 mm
Laser 50 or 100 Watt CO2 (beam dia= 0.420 mm)
Beam delivery system M3St Galvanometer 3 axis Scan speed =
5.000mm/s positional accuracy = 50mm
Software Windows NT DTM sinterstation system software
materialize NV, magics
Computer system Pentium based controller
SINTERSTATION 2500 PLUS
System dimensions Process station =2133 x 1346 x 1981 mm
Computer cabinet =609 x 609 x 1828mm Chiller = 533 x 838 x 914 mm Peripherals Breakout station/ air handler/ sifter, vacuum cleaner
Power requirements 240 VAC,12.5 KVA,50/60 Hz, 3-phase
Nitrogen requirements Purity = 99.9%
Minimum pressure = 1.7 bars Continuous flow rate= 191lpm Atmospheric Temperature range = 150 to 270 C requirements Relative humidity =<60% EOSIHT P350 Building volume 340 x 340 x 600 mm3
Laser type CO2,50W
Laser scan speed Up to 5m/s
Building speed 10-25 mm height
Layer thickness 0.1-0.2 mm
Process computer PC
Electrical supply 400 V, 32 A
EOSIHT P350 Compressed air supply Minimum 5.000 hPa, 6m3/h
Cooling water supply 1.500hPa-4.000HpA, 5 l/min
Dimensions mm Process cabinet 1.250 x 1.300 x 2.150
Control cabinet 610 x 820 x 1.785
Weight Approx. 800kg
Workstation Silicon graphics indigo
PC Windows 95, windows NT
Interface to CAD Standard : STL,CLI
Optional : VDA-FS,IGES,CATIA ADVANTAGES Parts and/or assemblies that move and work that have a good surface finish and feature detail Selective laser sintering (SLS) gives the capability of flexible snaps and living hinges as well as high stress and heat tolerance Wide variety of materials such as flexible and rigid plastics, electrometric materials, fully dense metals and casting patterns inexpensive materials safe materials supports not needed reduced distortion from stresses produce parts simultaneously DISADVANTAGES rough surface finish ("stair step effect") porosity of parts the first layers may require a base anchor to reduce thermal effects (e.g. curl) part density may vary material changes require cleaning of machine APPLICATIONS Parts for mechanical and thermal tests Series of small plastic parts Large and complex functional parts Master patterns for castings and secondary processes Functional models. Case Study 1:
One of the early products developed by ARAD was the Moonshine
and the Moonshine Magnum. These products were developed for a major aquatic product distributor and are currently sold to marine/reef aquarists worldwide. The design intent was to create a light source that provides artificial moonlight to the reef aquarium. The light emitted simulates natural moonlight and promotes photosynthesis, healthy feeding and reproductive behavior in the life cycle of invertebrates and other marine organisms. Responding to the client needs, ARAD was able to realize the design objectives in a compact, convenient and cost effective device using our design expertise and state of the art LED technology. The finished products were then produced by ARAD at its US based facility. Case Study 2: ARAD was asked if its LED moonlight technology could be retro-fitted to be housed in metal halide fixtures. The design requirement from the customer was to provide ARAD’s Moonlight technology in a structure that will withstand the extremely high temperature found inside metal halide assemblies. There was no comparable product in existence and attempts by other designers were unsuccessful. Drawing its expertise in metal design, ARAD designs a LED light encased in a sleek metal housing. The product becomes very popular as this is the industry’s first successful and production-ready combination of metal halide and LED lights. To date there is still not a product out there like it.
(AAP Research Notes On Chemical Engineering) Ali Pourhashemi - G E Zaikov - A K Haghi - Chemical and Biochemical Engineering - New Materials and Developed Components-Apple Academic Press (2015) PDF