Rapid Prototyping and Freeform

Fabrication

Techniques-continued

Cueto, Dean Paul

Mercado, Jose Gabriel
Stereolithography
• Patented in 1986, stereolithography started the
rapid prototyping revolution and the most
widely used of all the rapid prototyping
processes, abbreviated as SLA.
• The technique builds 3D models from liquid
photosensitive polymers that solidify when
exposed to UV light.
• an additive manufacturing process using a vat of
liquid UV curable photopolymer ,resin, and a UV
laser to build parts a layer at a time. On each
layer, the laser beam traces a part cross-section
pattern on the surface of the liquid resin.
Exposure to the UV laser light  cures, or,
solidifies the pattern traced on the resin and
adheres it to the layer below.
Stereolithography
Process:
• the model is built upon a platform
situated just below the surface in a
vat of liquid epoxy or acrylate resin
• A low-power highly
focused UV laser traces out the
first layer, solidifying the model’s
cross section while leaving excess
areas liquid
• elevator incrementally lowers the
platform into the liquid polymer
• sweeper re-coats the solidified layer
with liquid, and the laser traces the
second layer atop the first
• process is repeated until
the prototype is complete
Schematic Diagram
Selective Laser Sintering
• Developed by Carl Deckard for his Master’s thesis
at the University of Texas and was patented in
1989, abbreviated as SLS.
• Uses a laser beam to selectively fuse powdered
materials, such as nylon, elastomer, and metal
into a solid object such as plastic, metal, ceramic,
or glass.
•  The laser selectively fuses powdered material by
scanning cross-sections generated from a 3-D
digital description of the part
 Selective Laser Sintering
Process:
• SLS process produces parts
directly from 3D CAD model
• Layer by layer similar to SLA but
rather than liquid; resin powder
is used
• Laser provides a concentrated
heating beam which is traced
over the tightly compacted
layer of fine heat-fusible
powder
• The temperature in the entire
chamber is maintained little
below the melting point of the
powder Schematic Diagram
 Selective Laser Sintering
Process:
• laser slightly raises the
temperature to cause sintering,
means welding without melting
• piston moves down along with
the formed object and powder
is spread with a roller for next
layer
• process repeats until full object
is formed
• suitable for functional products
with snap fits, living hinges,
thermally and mechanically
loaded parts
Schematic Diagram
 Shape Deposition Manufacturing
Process:
• Begins with the construction
of a support material cavity
shaped like the underside of
the bottom of the desired
object
• Part material is deposited into
this cavity that will serve as
the bottom layer of the object
• Additional support material is
deposited to surround the
bottom layer of the part
 Solid Ground Curing
• also known as the Solider Process, is a process
that was invented and developed by Cubital Inc. of
Israel, abbreviated as SGC.
• The SGC process uses photosensitive resin
hardened in layers as with the Stereolithography
process
• In contrast to SLA, the SGC process is considered a
high-throughput production process which can be
achieved by hardening each layer of
photosensitive resin at once.
 Process:
Solid Ground Curing 2. For each layer, a photomask is
Process: produced using Cubital's
1. CAD model is created then it is proprietary ionographic printing
sliced into layers. At the technique
beginning of a layer creation
step, the flat work surface is
sprayed with photosensitive resin

3. the photomask is positioned over

the work surface and a powerful
UV lamp hardens the exposed
photosensitive resin
Solid Ground Curing
Process:
4. after the layer is cured, all
uncured resin is vacuumed for
recycling, leaving the hardened
areas intact. The cured layer is
passed beneath a strong linear
UV lamp to fully cure it and to
solidify any remnant particles
Process:
5. wax replaces the cavities left by
vacuuming the liquid resin. The
wax is hardened by cooling to
provide continuous, solid support
for the model as it is fabricated.
Extra supports are not needed
Solid Ground Curing
Process:
6. in the final step before the next
layer, the wax/resin surface is
milled flat to an accurate, reliable
finish for the next layer
Process:
7. Once all layers are completed, the
wax is removed, and any finishing
operations such as sanding, etc.
can be performed. No post-cure is
necessary.
Three Dimensional Printing
• is a form of additive manufacturing technology
where a three dimensional object is created by
laying down successive layers of material. 3D
printers are generally faster, more affordable and
easier to use than other additive manufacturing
technologies.
Robocasting
• it relies on robotics for computer-controlled
deposition of ceramic slurries -- mixtures of
ceramic powder, water, and trace amounts of
chemical modifiers -- through a syringe. The
material, which flows like a milkshake even
though the water content is only about 15
percent, is deposited in thin sequential layers
onto a heated base
• "Layer by layer the part grows before your
eyes," says Joe Cesarano, the engineer who
originated the concept. "The robot squeezes
the slurry out of the syringe, almost like a
cake decorator, following a pattern
prescribed by computer software."
References:
• http://www.scribd.com/doc/7370593/Rapid-Prototyping-
of-die-Casting-Presentation
• http://en.wikipedia.org/wiki/Solid_freeform_fabrication
• http://knowledge.stereolithography.com/activekb/questio
ns/8/Stereolithography
• http://en.wikipedia.org/wiki/Selective_laser_sintering
• http://www.arptech.com.au/slshelp.htm
• http://www-rpl.stanford.edu/user/files/papers/thesis_jkie
tzman.pdf
• http://www.cs.cmu.edu/afs/cs/usr/lew/www/NRR/nrr_pa
per.html
• http://www.efunda.com/processes/rapid_prototyping/sg
c.cfm
• http://en.wikipedia.org/wiki/3D_printing
• http://www.youtube.com/
 
 QUIZ
1-2) Solid Free Form Fabrication is also
known as _________ or __________..
3.) EBM means ______.
4.) EBF³ means ______.
5.) FDM means ______.
6.) LOM means _______.
7.) What is the main Difference between
EBM and EBF³?
 QUIZ
8. This technique builds 3D models from liquid photosensitive
polymers that solidify when exposed to UV light.
9. Part of SLA machine wherein it re-coats the solidified layer with
liquid, and the laser traces the second layer atop the first.
10.Means welding without melting
11.A technique in which support material is removed through
milling when part material is completed.
12.Known as the Solider process that considers high-throughput
process .
13.Form of additive manufacturing technology where a three
dimensional object is created by laying down successive layers of
material through printing.
14.A process that relies on robotics for computer-controlled
deposition of ceramic slurries through a syringe.
15.BONUS