VACUUM CASTING-AN APPROACH TO RAPID PROTOTYPING

SEMINAR REPORT

Submitted by

RENJITH R P
Roll No : S7 ME 09418046

DEPARTMENT OF MECHANICAL ENGINEERING PRS COLLEGE OF ENGINEERING

THIRUVANANTHAPURAM

ABSTRACT
The term Rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data. It is a five step process dealing with the creation of CAD model, conversion of it into STL format, slicing the file into cross sectional layers, construction of the model one layer atop another and finally cleaning and finishing the model. Commonly available Rapid Prototyping techniques are Stereolithography, Laminated object manufacturing, Selective laser sintering, Fusion deposition modeling, Solid Ground curing, 3-D Ink jet printing and Vacuum Casting. Vacuum casting is a technique of plastic casting under vacuum and with a silicone mold was developed at the Technical Universities of Dresden and Cottbus, the former German Democratic Republic, in the Sixties. Vacuum casting using Room Temperature Vulcanizing is an additional feature of manufacturing upto 20 prototypes. The Prototype need not be made from any production material or follow any production process. An SLA model can be used as a pattern. The prototypes made are essentially of Poly Urethane Resins (P.U.R). By using Vacuum casting technology highly complex, accurate Wax Models can be manufactured in a fraction of time and at considerably less cost than other methods. Vacuum Casting is extensively applied in manufacturing Vacuum cleaners, Car bumpers, hand held scanners, housings of automotive air-conditioners, Inline skaters, Mobile phones of various colours, Automotive rear reflectors etc. Vacuum cast models have high strength, elasticity and temperature resistance. Upto 25 prototypes can be manufactured depending the complexity of the model. The prototypes are accurate having an accuracy of 0.2 %. It costs only upto 3% of the traditional tooling costs.

CONTENTS
Page No. 1. INTRODUCTION TO VACUUM CASTING 2. OVERVIEW OF RAPID PROTOTYPING 3. THE BASIC PROCES 4. RAPID PROTOTYPING TECHNIQUES 5. RAPID TOOLING 6. WORKING OF VACUUM CASTING 7. VACUUM CASTING- AUTOMOTIVE REAR REFLECTORS 8. VACUUM CASTING USING RTV 9. VACUUM CASTING OF WAX MODELS 10. APPLICATIONS OF VACUUM CASTING 11. ADVANTAGES OF VACUUM CASTING 12. LIMITATIONS OF VACUUM CASTING 13. CONCLUSION 14. REFERENCES 1 2 3 5 11 11 15 21 23 24 29 30 30 30

1. INTRODUCTION TO VACUUM CASTING

Vacuum casting is a process that allows the user to evaluate moulding designs without committing to the delays and expense of production tooling. The system is capable of reproducing intricate designs with complex internal detail and surface finish comparable to injection moulded components and is suitable for producing a limited quantity of working prototypes or production parts. It is a process used to create polyurethane parts that simulate production plastics such as ABS, Nylon and rubber. This technique is a modification of pressure casting used for producing metal matrix composites. This technique of plastic casting under vacuum and with a silicone mold was developed at the Technical Universities of Dresden and Cottbus, the former

German Democratic Republic, in the Sixties. This copying technique starts from a master part (often a stereolithography part ) to produce a soft-rubber like silicone mould that is used to cast duplicates. Casting is done under gravity in vacuum conditions in order to avoid as much as possible air inclusions in the castings and to ensure good mould filling. Materials that can be cast in this way are two-part resins with potlife of typically a few minutes (polyurethanes, epoxies). A specific feature of this copying technique is an overall zero dimensional change between copies and master part. So, the master part can firstly be investigated with respect to the design specifications and tolerances. If it fulfils the design needs, a silicone mould is poured around the master part and several copies can be realized. The PU casting cycle takes some 2 hours and can be repeated for about 25 times. Hereafter, ageing of the silicone mould results in a decreased product quality.

2. OVERVIEW OF RAPID PROTOTYPING

The term Rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data.It is a free form fabrication technique by which a total object of prescribed shape, dimension and finish can be directly generated from the CAD based geometrical model stored in a computer,with less human intervention. These "three dimensional printers" allow

designers to quickly create tangible prototypes of their designs, rather than just twodimensional pictures. Such models have numerous uses. They make excellent visual aids for communicating ideas with co-workers or customers. In addition, prototypes can be used for design testing. For example, an aerospace engineer might mount a model airfoil in a wind tunnel to measure lift and drag forces. Designers have always utilized prototypes; rapid prototyping allows them to be made faster and less expensively. In addition to prototypes, RP techniques can also be used to make tooling (referred to as rapid tooling) and even production-quality parts (rapid manufacturing). For small production runs and complicated objects, rapid prototyping is often the best manufacturing process available. Of course, "rapid" is a relative term. Most prototypes require three to seventy-two hours to build, depending on the size and complexity of the object. This may seem slow, but it is much faster than the weeks or months required to make a prototype by traditional means such as machining. These dramatic timesavings allow manufacturers to bring products to market faster and more cheaply.

3. THE BASIC PROCESS

Although several rapid prototyping techniques exist, all employ the same basic five-step process. The steps are: 3.1. Create a CAD model of the design First, the object to be built is modeled using a Computer-Aided Design (CAD) software package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately than wire-frame modelers such as AutoCAD, and will therefore yield better results. The designer can use a pre-existing CAD file or may wish to create one expressly for prototyping purposes. This process is identical for all of the RP build techniques. 3.2. Convert the CAD model to STL format The various CAD packages use a number of different algorithms to represent solid objects. To establish consistency, the STL (stereolithography, the first RP technique) format has been adopted as the standard of the rapid prototyping industry. The second step, therefore, is to convert the CAD file into STL format. This format represents a three-dimensional surface as an assembly of planar triangles, "like the facets of a cut jewel." The file contains the coordinates of the vertices and the direction of the outward normal of each triangle. Because STL files use planar elements, they cannot represent curved surfaces exactly. Increasing the number of triangles improves the approximation, but at the cost of bigger file size. Large, complicated files require more time to preprocess and build, so the designer must balance accuracy with manageablility to produce a useful STL file. Since the .stl format is universal, this process is identical for all of the RP build techniques.

3.3. Slice the STL file into thin cross-sectional layers In the third step, a pre-processing program prepares the STL file to be built. Several programs are available, and most allow the user to adjust the size, location and orientation of the model. Build orientation is important for several reasons. First, properties of rapid prototypes vary from one coordinate direction to another. For example, prototypes are usually weaker and less accurate in the z (vertical) direction than in the x-y plane. In addition, part orientation partially determines the amount of time required to build the model. Placing the shortest dimension in the z direction reduces the number of layers, thereby shortening build time. The pre-processing software slices the STL model into a number of layers from 0.01 mm to 0.7 mm thick, depending on the build technique. The program may also generate an auxiliary structure to support the model during the build. Supports are useful for delicate features such as overhangs, internal cavities, and thin-walled sections. Each PR machine manufacturer supplies their own proprietary pre-processing software. 3.4. Construct the model one layer atop another The fourth step is the actual construction of the part. Using one of several techniques of prototyping RP machines build one layer at a time from polymers, paper, or powdered metal. Most machines are fairly autonomous, needing little human intervention. 3.5. Clean and finish the model The final step is post-processing. This involves removing the prototype from the machine and detaching any supports. Some photosensitive materials need to be fully cured before

use. Prototypes may also require minor cleaning and surface treatment. Sanding, sealing, and/or painting the model will improve its appearance and durability.

4. RAPID PROTOTYPING TECHNIQUES

Most commercially available rapid prototyping machines use one of six techniques. 4.1. Stereolithography: Patented in 1986, stereolithography started the rapid prototyping revolution. The technique builds three-dimensional models from liquid photosensitive polymers that solidify when exposed to ultraviolet light. As shown in the figure below, 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 models cross section while leaving excess areas liquid.

Fig 1: Schematic diagram of stereolithography. Next, an elevator incrementally lowers the platform into the liquid polymer. A sweeper re-coats the solidified layer with liquid, and the laser traces the second layer atop the first. This process is repeated until the prototype is complete. Afterwards, the solid part is

removed from the vat and rinsed clean of excess liquid. Supports are broken off and the model is then placed in an ultraviolet oven for complete curing. Stereolithography Apparatus (SLA) machines have been made since 1988 by 3D Systems of Valencia, CA. To this day, 3D Systems is the industry leader, selling more RP machines than any other company. Because it was the first technique, stereolithography is regarded as a benchmark by which other technologies are judged. Early stereolithography prototypes were fairly brittle and prone to curing-induced warpage and distortion, but recent modifications have largely corrected these problems. 4.2. Laminated Object Manufacturing: In this technique, developed by Helisys of Torrance, CA, layers of adhesive-coated sheet material are bonded together to form a prototype. The original material consists of paper laminated with heat-activated glue and rolled up on spools. As shown in the figure below, a feeder/collector mechanism advances the sheet over the build platform, where a base has been constructed from paper and double-sided foam tape. Next, a heated roller applies pressure to bond the paper to the base. A focused laser cuts the outline of the first layer into the paper and then cross-hatches the excess area (the negative space in the prototype). Cross-hatching breaks up the extra material, making it easier to remove during post-processing. During the build, the excess material provides excellent support for overhangs and thin-walled sections. After the first layer is cut, the platform lowers out of the way and fresh material is advanced. The platform rises to slightly below the previous height, the roller bonds the second layer to the first, and the laser cuts the second layer. This process is repeated as needed to build the part, which will have a wood-like

texture. Because the models are made of paper, they must be sealed and finished with paint or varnish to prevent moisture damage

Fig 2: Schematic diagram of laminated object manufacturing. 4.3. Selective Laser Sintering: Developed by Carl Deckard for his masters thesis at the University of Texas, selective laser sintering was patented in 1989. The technique, shown in Fig 3, uses a laser beam to selectively fuse powdered materials, such as nylon, elastomer, and metal, into a solid object. Parts are built upon a platform which sits just below the surface in a bin of the heat-fusable powder. A laser traces the pattern of the first layer, sintering it together. The platform is lowered by the height of the next layer and powder is reapplied. This process continues until the part is complete. Excess powder in each layer helps to support the part during the build. SLS machines are produced by DTM of Austin, TX.

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Fig 3: Schematic diagram of selective laser sintering. 4.4. Fusion Deposition Modeling: In this technique, filaments of heated thermoplastic are extruded from a tip that moves in the x-y plane. Like a baker decorating a cake, the controlled extrusion head deposits very thin beads of material onto the build platform to form the first layer. The platform is maintained at a lower temperature, so that the thermoplastic quickly hardens. After the platform lowers, the extrusion head deposits a second layer upon the first. Supports are built along the way, fastened to the part either with a second, weaker material or with a perforated junction. Stratasys, of Eden Prairie, MN makes a variety of FDM machines ranging from fast concept modelers to slower, high-precision machines. Materials include ABS (standard and medical grade), elastomer (96 durometer), polycarbonate, polyphenolsulfone, and investment casting wax.

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Figure No 4: Schematic diagram of fused deposition modeling. 4.5. Solid Ground Curing: Developed by Cubital, solid ground curing (SGC) is somewhat similar to stereolithography (SLA) in that both use ultraviolet light to selectively harden photosensitive polymers. Unlike SLA, SGC cures an entire layer at a time. Fig 5 depicts solid ground curing, which is also known as the solider process. First, photosensitive resin is sprayed on the build platform. Next, the machine develops a photomask (like a stencil) of the layer to be built. This photomask is printed on a glass plate above the build platform using an electrostatic process similar to that found in photocopiers. The mask is then exposed to UV light, which only passes through the transparent portions of the mask to selectively harden the shape of the current layer.

Fig 5: Schematic diagram of solid ground curing. 12

After the layer is cured, the machine vacuums up the excess liquid resin and sprays wax in its place to support the model during the build. The top surface is milled flat, and then the process repeats to build the next layer. When the part is complete, it must be dewaxed by immersing it in a solvent bath. SGC machines are distributed in the U.S. by Cubital America Inc. of Troy, MI. The machines are quite big and can produce large models. 4.6. 3-D Inkjet Printing: Ink-Jet Printing refers to an entire class of machines that employ ink-jet technology. The first was 3D Printing (3DP), developed at MIT and licensed to Soligen Corporation, Extrude Hone, and others. The ZCorp 3D printer, produced by Z Corporation of Burlington, MA is an example of this technology. As shown in Fig 6, parts are built upon a platform situated in a bin full of powder material. An ink-jet printing head selectively deposits or "prints" a binder fluid to fuse the powder together in the desired areas. Unbound powder remains to support the part. The platform is lowered, more powder added and leveled, and the process repeated. When finished, the green part is then removed from the unbound powder, and excess unbound powder is blown off. Finished parts can be infiltrated with wax, CA glue, or other sealants to improve durability and surface finish. Typical layer thicknesses are on the order of 0.1 mm. This process is very fast, and produces parts with a slightly grainy surface. ZCorp uses two different materials, a starch based powder (not as strong, but can be burned out, for investment casting applications) and a ceramic powder. Machines with 4 color printing capability are available.

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Fig 6: Schematic diagram of 3-D Ink jet printing

5. RAPID TOOLING
A much-anticipated application of rapid prototyping is rapid tooling, the automatic fabrication of production quality machine tools. Tooling is one of the slowest and the most expensive steps in the manufacturing process, because of the extremely high quality required. Tools often have complex geometries, yet must be dimensionally accurate to within a hundredth of a millimeter. In addition, tools must be hard, wear-resistant, and have very low surface roughness (about 0.5 micrometers RMS). To meet these requirements, molds and dies are traditionally made by CNC-machining, electrodischarge machining, or by hand. All are expensive and time consuming, so manufacturers would like to incorporate rapid prototyping techniques to speed the process. There are two classifications of rapid tooling, direct and indirect.

6. WORKING OF VACUUM CASTING

Fig 7: Initial pattern Patterns can be made of any material such as metal, wood, plastics or plaster.

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Fig 8: Pattern suspended in Frame The pattern is fitted with the casting Gate and set up on the parting line, and then suspended in the mould-casting frame.

Fig 9: Pouring of Rubber De-aerated silicone rubber is poured into the mould-casting frame around the pattern.

Fig 10: Hardening of Mould The mould gets hardened inside the heating chamber.

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Fig 11: Removal of Pattern The pattern is removed from the silicone casting by cutting along the parting line.

Fig 12: Closing of the mould The resins are measured, the casting funnels are placed and the mould is closed and sealed. For coloured components dye is added.

Fig 13:Pouring of the resin The computer controlled equipment mixes and pours the resin inside the Vacuum chamber.

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Fig 14: Moving of resin mould After casting, the resin mould is moved to the heating chamber.

Fig 15: Removal of Casting After hardening, the casting is removed from the silicone mould. Gates and risers are cut off to make an exact copy of the pattern. The required components can be painted or plated.

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7. VACUUM CASTING- AUTOMOTIVE REAR REFLECTORS

The working of vacuum casting when applied to automotive rear reflectors is illustrated below.

Fig 16: Cleaning of Model Thoroughly clean the master model and if necessary, apply barrier coating.

Fig 17: Drawing of Parting line Establish the models eventual parting line using clear adhesive tape and colour the tape edge with a marker pen to later assist in removing the master model from the silicone tool.

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Fig 18: Construction of Casting Frame A casting frame is constructed from laminated chipboard. Casting gates are attached to the model and the model is suspended in the casting frame and venting rods are attached.

Fig 19: Pouring of Silicone Rubber Degassed Silicone Rubber is then poured into the casting frame.

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Fig 20: Movement of Tool to oven After further de-gassing in the vacuum casting chamber the tool is moved to the oven to cure.

Fig 21:Cutting of Silicone rubber When fully cured and removed from the frame, the silicone rubber is then cut following the visible parting line marked on the tape edge.

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Fig 22: Reproduction of Master Model Revealing the master model faithfully reproduced in the silicone. The master model is then removed.

Fig 23: Taping of the Tool The tool is taped together and prepared for casting.

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Fig 24: Measured Resins Vacuum casting resins A+B are precisely measured by weight into their respective containers.

Fig 25: Automatic Casting Cycle Cups A+B are placed in the top and the tool in the lower of the vacuum casting chambers. Once programmed, then the automatic casting cycle will mix and pour the casting resin.

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Fig 26: Removal of Resin Prototype The liquids get down through the flexible hose and into the tool and after curing in the oven the cast resin prototype is removed from the tool.

Fig 27: Cast Component The cast component is an exact reproduction of the master model. Casting gates and runners are trimmed off.

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(b) Fig 28: Final Component Model Finally, checked for dimensional accuracy to master model the component is now ready for final finishing.

(a)

8. VACUUM CASTING USING RTV

RTV stands for the process called Room Temperature Vulcanizing. Vacuum casting using RTV tools is a method to manufacture up to twenty prototypes where the prototype does not have to be made from the production material or follow the production process. An SLA model can be used as a pattern. RTV produces three-dimensional copies of the SLA model. The material of the copies is PUR (Poly urethane resin). De-aerated silicon rubber is poured around the SLA model to produce a flexible rubber tool. The de-aerated PUR material components are mixed and poured into the tool under vacuum.

The working of Vacuum casting with RTV is as follows: 24

Fig 29: Silicone rubber poured De-aerated silicone rubber (RTV) is poured around the pattern. The patterns are normally made by Rapid Prototyping.

Fig 30: PUR Components De aerated The material components (PUR) are de-aerated in a vacuum casting device.

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Fig 30: PUR Components poured into tool The PUR material components are mixed and poured into the tool under vacuum.

9. VACUUM CASTING OF WAX MODELS

By using the heated cup module highly complex, thin wall wax components can be produced. These wax components would usually only be possible to manufacture by using injection-moulding techniques into rigid tools. For prototype metal parts this can be a long and costly process. The pictures of certain wax models manufactured by Vacuum casting are shown below.

(a) Fig 31: Wax Models 26

(b)

By using existing Vacuum Casting technology highly complex, accurate wax components can be manufactured in a fraction of the time and at considerably less cost than other methods. The waxes can then be converted into metal via traditional investment casting methods or by using the metal part casting system.

10. APPLICATIONS OF VACUUM CASTING

10.1. Coupe convertibles rigid folding roof

Fig 32: Rigid Folding Roof For Valmet Automotive Ltds Coupe convertibles rigid folding roof, Vacuum castings contribution consisted of 3D modeling, production of prototype moulds for sheet metal part manufacturing, and delivery of the sheet metal and Magnesium cast components. 10.2. Independently Functioning Vacuum Cleaner

Fig 33: Vacuum Cleaner 27

Electrolux utilized Vacuum casting process in creating their new, independently functioning Trilobite Vacuum cleaner. 10.3. Cooling Fans

Fig 34:Cooling Fans Flkt combined its expertise in aerodynamics, drives and intelligent systems with Vacuum casting systems to develop a new revolutionary range of compact, intelligent and powerful cooling fans the Integral Fan (IF) Seri. 10.4. Sports Car

Fig 35: 9-3 Sports Sedan Saab was able to launch its 9-3 Sports Sedan just in time and very successfully. RPI Alphaform, a company utilizing Vacuum casting as its major Rapid prototyping

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technique, supported Saab by delivering the prototypes of bumpers, a front spoiler, a rear bumper skirt, rocker panels and a rear spoiler. 10.5. Hand Held Scanner

Fig 36: Hand Held Scanner Several stereolithography models were used as master patterns for vacuum casting of this component. In this case the resulting castings were used as production items, due to the customer's low annual production run. 10.6. In-Car Mobile Phone Speaker

Fig 37:Mobile Phone Speaker

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In this prototype, stereolithography models were once again created to provide master patterns for vacuum casting. The resulting castings were assembled together with the internal circuitry to provide fully functional working models for consumer testing.

10.7. Implantable Heart

Fig 38: Implantable Heart The battery pack for ABIOMEDs new implantable heart was vacuum cast in silicone rubber molds using Ren PIM SG 200 VG polyurethane. 10.8. Virtual Reality Viewer and Control unit

(a) 30

(b)

Fig 39: Virtual Reality viewer Helmet Unit The virtual reality viewer helmet and control unit were produced in series of 100 pieces using Vacuum Casting Technology. The helmet consists of many different types of Vacuum Plastic ranging from extremely soft types to materials comparable to ABS with high impact strength. 10.9. Housings of Automotive Air conditioners

Fig 40: Housings of Automotive air Conditioners Housings for automotive air conditioner made in high temperature Vacuum Plastic 2181 with a high heat deflection temperature of more than 100C.

Multi segment silicone mould making is one of the many specialities of Vacuum casting. 10.10. In-Line Skater

Fig 41: In-Line Skater In-Line skater is a polypropylene type of Vacuum Plastic 2160. Chrome plating is a possible option. The mechanical properties of Vacuum Plastics are comparable to most thermoplastics. 10.11. Mobile Phones 31

Fig 42: Mobile Phones Mobile phones are colour matched in an ABS type Vacuum Plastic SG 95

11. ADVANTAGES OF VACUUM CASTING

1. Strength, Elasticity and Temperature Resistance: With the vacuum casting method it is possible to produce small quantities of prototypes from thermoplast-like plastics. These prototypes can be elastic or high-strength (including glass-reinforced),coloured or transparent and even resistant to high temperature. 2. Typical quantities: Up to 25 copies (depending on complexity) can be manufactured at a given time ; more than 25 copies may necessitate additional mould. 3. Standard accuracy: The standard accuracy of this process is 0.2 % with repeatability of 0.1 % (max. 0.2mm). 4. Time Savings: Timesavings of 70 to 90% can be achieved using Vacuum casting. 5. Surface sensitivity: Silicone is very sensitive for surface roughness; so it allows the reproduction of textured like parts, looking identical to injection moulded parts. 6. Cost: An important point to be noticed is that Vacuum casting costs only 3% of the traditional tooling costs.

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7. Use any type of model : For example: CNC machined, handmade, or by using STL data (rapid prototyping models) SLA, SLS, FDM, LOM or solider, etc.

12. LIMITATIONS OF VACUUM CASTING

1. To ensure the mould is filled properly a wall thickness of at least 0.5mm is necessary. 2. The size of the mould is constrained by the measurement of the vacuum machine (800 x 690 x 660mm) and by the volume of the product (maximum volume: 4 litres). 3. Initial tool equipment cost is comparatively high. 4. The Maximum part weight is limited to 6 kg and the Minimum part weight is limited to 2g.

13. CONCLUSION
The Features of Vacuum Casting are:1. Communicate your design intentions to your clients, toolmakers and to other departments easily and highly effectively. 2. Reduced time to market. 3. Shorter development cycles. 4. Lower development costs. 5. Shorter lead times in comparison to using conventional methods. 6. Allows simple and effective design changes before expense of tooling

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14. REFERENCES
1. J.P. Kruth-Material incress manufacturing by rapid prototyping technique-2002 2. Lecture materials of summer programme organised by IIT, Kharagpur -2004 3. www.mcpgroup.com

4. www.me.psu.edu

5. www.alphaform.com

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