By: Sarah Westerdale

Rapid prototyping is the fabrication of parts from CAD data sources. Several rapid prototyping methods have been created to produce objects of complex geometries in a relatively short amount of time. These systems are beneficial to engineers by allowing them to better understand the products that they are designing and by providing them with a way to create a visual aid to communicate with others. Rapid prototyping allows design challenges to be determined earlier in the design process, saving time and money. The technology of rapid prototyping is easy to access and simple to understand.

Types of Rapid Prototyping 3-Dimensional Printing Fused Deposition Modeling Inkjet Methods Laminated Object Manufacturing Stereo lithography Selective Laser Sintering

Rapid Prototyping Chart Additional Prototyping Websites References Plastics Home

3-Dimensional Printing

Process Abbreviation: 3DP

Process Description: To begin the process, the powder delivery system is moved up a set distance permitting a layer of material powder to be created in the fabrication chamber by the roller. The function of the roller is to distribute and compress the powder evenly in the fabrication chamber. The multi-channel jetting head then creates a layer of liquid adhesive in the geometry of the part in the bed of powder. A layer of the part geometry is created when the powder that containing liquid adhesive bonds and hardens. When a layer is completed, the fabrication piston will move down in increments. These increments are specified to determine the layer thickness. Additional layers are formed to create the entire part geometry. Once the part is completed, the fabrication piston is raised to expose the part. With the part exposed, the access powder can be brushed away.

Advantages: Fast Fabrication Low Material Cost Variety of Colors No external supports are required

Disadvantages: Resolution Surface Finish Part Fragility Materials Available

Suppliers ProMetal Z Corporation

Fact Three dimensional printing was developed at MIT.

Fused Deposition Modeling

Process Abbreviation: FDM

Process Description:

The fused disposition modeling process uses plastic filament that is 1/16 in diameter and stored on a coil. Material that is fed from a hopper in the form of pellets is an option in some low cost configurations. The entire system is enclosed in an oven chamber to control of the process temperature. The system operates best slightly under the melting point of the plastic. During the fabrication process, a strand of filament is unwound from the coil and fed into an extrusion nozzle. The plastic is melted and controlled by the nozzle. The nozzle is able to move in the X and Y directions and is mounted to a stage system. Layers are formed by very small beads of plastic being deposited from the nozzle in the shape of the part geometry. The plastic beads begin harden immediately after being extruded from the nozzle in addition to bonding with the layer beneath.

Advantages: Numerous Material Available ABS Casting waxes Nylon like polymers PC PPS Water soluble materials Good layer bonding with ABS materials Fast small part production Good for parts with thin walls Usage of water soluble materials allow support structures to be easily removable

Disadvantages: Slow production rates for thick sectioned parts Secondary operations are needed to remove support structures

Poor surface finishes

Suppliers Stratasys Pliant Plastics

Facts FDM is the #2 rapid prototyping process The closest competitor to the FDM process is 3-D printing FDM has a wider range of materials FDM prototypes have more strength than 3-D printing

Inkjet Methods

Types: Thermal Phase Change Inkjet Photopolymer Phase Change Inkjet

Thermal Phase Change Inkjet Process Description:

During this process, Solidscape machines hold the build and support materials at elevated temperatures in a reservoir until the fabrication of the part beings. Once the process has begun, the liquid material moves though thermally insulated tubing to individual jetting heads. The jetting heads then disperses the material in the form of tiny droplets to create part geometry. As the jetting heads continue to lay the material droplets, layers are formed. The droplets begin to cool and harden immediately after leaving the jetting head. When one layer is complete, a milling head passes over the previously created layer to produce a uniform thickness. The material particles created from this step must be removed by a vacuum as the milling process is taking place. Before the next layer is created, the nozzles are checked to assure that the flow path is clear. If the nozzles do not need to be cleaned, the table will move down a set distance for the next layer to begin. Once the part is complete, the support structures are melted or dissolved away.

Supplier - Trade name: 3D Systems: Machine - ThermoJet ModelerTM Technology - MultiJet ModelingTM Objet Geometries Ltd.: Technology - PolyJetTM

Advantages: Capable of producing fine finishes Fast production of parts when using multiple jet heads

Disadvantages: Long production times for parts with fine finishes Less accuracy when using multiple jet heads

Supports must be removed in secondary operations Additional operation needed to provide uniform layer thickness

Fact: This process was previously referred to as Ballistic Particle Manufacturing

Photopolymer Phase Change Inkjet Process Description: This process is based on photopolymers and utilizes an inkjet head with a wide area. The area of the head helps to deposit build and support photopolymer materials which. Once a layer is completed the head will aid in the curing process by exposing the material to UV light produced by the UV flood lamp mounted on the head of the printer. A secondary operation in conducted to wash away support materials.

Supplier - Trade name: 3D Systems: Machine - InVisionTM Technology - MultiJet ModelingTM Solidscape:

Advantages: Low initial system price Machine specifications are similar to those of costly stereolithography systems

Laminated Object Manufacturing

Process Abbreviation: LOM

Process Description The LOM process produces prototypes by utilizing layer building concepts. During the LOM process, a laser is used to cut individual layers of paper to form a prototype. The process beings with a precoated sheet paper being fed from a roll onto a platform. Another layer of this paper is then fed over the first sheet and the two sheets are then pressed together by a heat roller. This roller bonds the sheets together by melting the plastic coating located on the bottom of the paper as it is compressing the layers together. The top layer of paper is then cut with a laser in the shape of the part in production. During this process a substantial amount of smoke is generated, causing the need for a sealed chamber and a ventilation system to be installed. The excess paper left from the formation of the geometry must be removed, and is referred to as a web. The web is then wound onto the waste paper take-up roll. Parts that contain open geometry require special attentions during fabrication. These parts must have the inner areas of geometry removed as they are being produced. If the layers are not removed before the opening is closed the excess paper cannot be detached.

Advantages: Does not require support structures Post curing is not needed No internal stresses Warpage is not an issue

Disadvantages: Few Materials Restricted surface finishes Must remove excess material Poor mechanical properties Low accuracy

Suppliers: Select Manufacturing Services Inc. Cubic Technologies

Facts: In 2000, the main commercial supplier of LOM systems (Helisys) ceased operation and Cubic Technologies took Helisys place. Layers are typically .002 - .010

Stereolithography

Process Abbreviation: SLA or SA

Process Description: The process begins with the movable table being lowered below the surface of the vat, which is filled with liquid photopolymer. The system is air tight to avoid fumes from the resin from being released into the air. The laser beam produces the part geometry by drawing over the surface of the liquid photopolymer. As the laser contacts the liquid photopolymer, the material hardens creating the part geometry. Most photopolymer materials require ultraviolet light, although some resins are able to produce the same results with visible light. The laser beam moves in the X-Y directions and is controlled by the scanner system located on the top of the system. The scanner system runs based on CAD data that simulates a fast and highly controllable motor and mirrors. Once the laser draws a complete layer and the part is hardened, the movable table will move lower into the vat. After each layer is created, the movable table will continue to lower into the vat at the same increments. This will allow the layers to stack up and the part to be created. Typically, the viscosity of the photopolymer is rather viscous. The viscosity of the material causes the need for a knife to trace the rough edges of the created geometry. Parts that contain overhangs or undercuts will require support during the fabrication of the part. The necessary supports can be manually or automatically designed. Once the part has been completed, the movable table is elevated above the surface of the liquid photopolymer and the excess resin is able to drain. An additional curing process is performed by exposing the part to intense light. This box is similar to a Post-Curing Apparatus

(PCA). Not all resins require this additional curing step. Following the curing step, supports are removed and additional surface finishing steps are conducted if necessary.

Advantages: Good accuracy (approximately + 0.005 inches) Superior surface finish Able to use a wide range of materials Compatible with several color changing materials Widely available

Disadvantages: Liquid materials tend to be messy Parts produced may require a post-curing operation in a separate oven Few materials compatible Warpage and shrinkage issues Require supports

Suppliers: 3-D Systems Select Manufacturing Services Inc. Sony - Solid Creation System

Facts: 3-D Systems patented SLA in 1988

SLA is the #1 prototyping method

Selective Laser Sintering

Process Abbreviation: SLS

Process Description: The process of selective laser sintering is similar to the process of stereolithography. In the case of selective laser sintering, the laser beam contacts a surface of compacted powder. The powder covering the surface of the build cylinder is spread by a roller and consists of a thermoplastic material. The amount of powder moved by the roller onto the building cylinder is controlled by the powder delivery piston. As the powder delivery piston position increases, the fabrication piston is lowered to compensate for the movement of powder. During the fabrication process, the system temperature is kept slightly lower than the melting point of the thermoplastic powder by sealing the system. When the compacted thermoplastic powder is traced by the laser it melts due to the heat generated by the laser. The heat generated from the laser raises the temperature slightly to induce sintering and increase the speed of the process. The laser is controlled by the scanner system, and produces a concentrated infrared heating beam. Explosion is a possibility if a nitrogen atmosphere is not maintained when large quantities of powder are being handled. Once the part is produced, the fabrication piston is fully raised to lift the part out from the surrounding powder. The excess powder is then brushed away from the final part and additional cooling time is permitted before the part is moved from the build cylinder.

Advantages: No Supports Required No final curing process required Can Fabricate metal and ceramic parts Ex: Prototype molds Prototype molds are low in cost and capable of producing large quantities parts Allows processing characteristics to be determined (ex. fill pattern, part shrinkage)

Disadvantages: Rough Surface Finishing Need to infiltrate parts with another material to improve mechanical characteristics Is unable to replicate molded parts Material changeovers are difficult

Suppliers: 3-D Systems EOS GmbH

Facts: Used to produce cavity and core inserts for injection molds.