INTRODUCTORY MECHATRONICS

Friday 12th November 2010 Rapid Prototyping

Alberto Parmiggiani (alberto.parmiggiani@iit.it)

RAPID PROTOTYPING
Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology.
The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts.

SEMANTIC PROLEMS
The RP field is relatively new (1980s)
RP techniques are under constant development. There has not been so far the time to establish widely accepted terminology for given processes

GOOGLE RESULTS
Name Rapid Prototyping Solid Freeform Fabrication Results 9.170.000 92.400

Rapid Manufacturing Layered Manufacturing 3D Printing Layered Fabrication Additive Manufacturing

111.000 38.900 325.000 9.440 303.000

VERY COMPLEX GEOMETRIES

APPLICATIONS
RP is used for a wide range of applications:
Design studies Creation of lost moulds (investment casting) Manufacturing production-quality parts in relatively small numbers (depends on the technique) Assembly studies Surgery planning Fine arts / sculpture

APPLICATIONS EVOLUTION
1980s

Model verification

Fit & function testing

Casting patterns

Rapid Tooling
Rapid Manufacturing
2010(s)

PROCESS OVERVIEW
FABRICATION

PRE-PROCESSING
POST-PROCESSING

CAD
Computer Aided Design
Computer technology for the process of design Mathematical description of 2D/3D objects and shapes

PART SLICING

ADDITIVE PROCESS
STEP EFFECT!

THE STEP EFFECT

Because of the layered process, the model has a surface composed of stair steps Sanding can remove the stair steps for a cosmetic finish Model build orientation is important for stair stepping and build time In general, orienting the long axis of the model vertically takes longer but has minimal stair steps Orienting the long axis horizontally shortens build time but magnifies the stair steps For aesthetic purposes, the model can be primed and painted.

RESIDUAL STRESSES
Inherent phenomenon because of the layered nature of the process Mainly caused by thermal expansion/contraction effects Considerably lowers the resistance of parts Can be relieved with postcuring treatments

OVERHANGING FEATURES

UNDERCUT FEATURES

SUPPORTS

SUPPORTS AGAIN...

RP MACHINES PARAMETERS
Resolution
The higher the better Generally different in the x-y vs. z direction Generally in the order of 50m to 100m

Scan speed
How fast can the parts be built Generally in the order of 6e-9m3/s

Build volume
Sets a maximum size for part dimensions Generally in the order of 0.02m3

RP MACHINES PARAMETERS
Material
Fundamental parameter Determines the functionality of the final product Often polymers (easier to process)

Cost
Of the machine (fixed) Of the material (generally the most relevant cost in running a RP machine)

TECHNOLOGIES
Electron beam melting
Fully fused void-free solid metal parts from powder stock

Electron beam freeform fabrication

Fully fused void-free solid metal parts from wire feedstock

Fused deposition modeling

Fused deposition modeling extrudes hot plastic through a nozzle, building up a model.

Laminated object manufacturing

Sheets of paper or plastic film are attached to previous layers by either sprayed glue, heating, or embedded adhesive, and then the desired outline of the layer is cut by laser or knife. Finished product typically looks and acts like wood.

Laser engineered net shaping

A laser is used to melt metal powder and deposit it on the part directly. This has the advantage that the part is fully solid (unlike selective laser sintering) and the metal alloy composition can be dynamically changed over the volume of the part.

Polyjet matrix
PolyJet Matrix Technology (developed by Objet geometries) is the first technology that enables simultaneous jetting of multiple types of model materials

TECHNOLOGIES
Selective laser sintering
Selective laser sintering uses a laser to fuse powdered nylon, elastomer, or metal. Additional processing is necessary to produce fully dense metal part.

Shape deposition manufacturing

Part and support material are deposited by a print head and then machined to near-final shape.

Solid ground curing

Shines a UV light on an electrostatic mask to cure a layer of photopolymers, uses solid wax for support.

Stereolithography
Stereolithography uses a laser to cure liquid photopolymers.

Three-dimensional printing
This label encompasses many technologies of modern 3D Printers, all of which use inkjet-like printheads to deposit material in layers. Commonly, this includes thermal phase change inkjets and photopolymer phase change inkjets.

Robocasting
Robocasting refers to depositing material from a robotically controlled syringe or extrusion head.

SLA
Highlights of Stereolithography
The first Rapid Prototyping technique and still the most widely used Inexpensive compared to other techniques Uses a light-sensitive liquid polymer Requires post-curing since laser is not of high enough power to completely cure (but long-term curing can lead to warping) Parts are quite brittle and have a tacky surface Support structures are typically required Process is simple: There are no milling or masking steps required. Uncured material can be toxic: ventilation is a must.

THE SLA PROCESS

A vat of photosensitive resin contains a vertically-moving platform The part under construction is supported by the platform that moves downward by a layer thickness (typically about 0.1 mm) for each layer The laser beam traces out the shape of each layer and hardens the photosensitive resin.

THE SLA PROCESS

The laser beam traces out the shape of each layer and hardens the photosensitive resin.

THE SLA PROCESS

Uncured resin is removed and the model is postcured to fully cure the resin. During fabrication, if extremities of the part become too weak, it may be necessary to use supports to prop up the model The supports can be generated by the program that creates the slices, and the supports are only used for fabrication.

SLA

The first stereolitography rapid prototyping process, was developed by 3D Systems of Valencia, CA, USA, founded in 1986.

SLS
Selective Laser Sintering
Patented in 1989 Considerably stronger than SLA (sometimes structurally functional parts are possible) Laser beam selectively fuses powder materials: nylon, elastomer, and metal. Advantage over SLA: Variety of materials and ability to approximate common engineering plastic materials Process is simple: There are no milling or masking steps required Living hinges are possible with the thermoplastic-like materials. Powdery, porous surface unless sealant is used. Sealant also strengthens part Uncured material is easily removed after a build by brushing or blowing it off.

THE SLS PROCESS

An SLS machine consists of two powder magazines on either side of the work area. The levelling roller moves powder over from one magazine, crossing over the work area to the other magazine. The laser then traces out the layer The work platform moves down by the thickness of one layer and the roller then moves in the opposite direction The process repeats until the part is complete.

Selective Laser Sintering (SLS) is a registered trademark by DTM of Austin, TX, USA The process was patented in 1989 by Carl Deckard, a University of Texas graduate student.

OTHER SIMILAR TECHNOLOGIES

Direct Metal Laser Sintering (DMLS)
Developed by: 3D Systems EOS

Selective Laser Melting (SLM)

Developed by: ConceptLaser MTT

OTHER SIMILAR TECHNOLOGIES

Laser Engineered Net Shaping (LENS)
Developed by Sandia National Laboratories Commercialized by Optomec

Electron Beam Melting (EBM)

Developed by ARCAM

SLA vs. SLS

Material Properties
The SLA (stereolithography) process is limited to photosensitive resins which are typically brittle. The SLS process can utilize polymer powders that, when sintered, approximate thermoplastics quite well.

Surface Finish
The surface of an SLS part is powdery, like the base material whose particles are fused together without complete melting. The smoother surface of an SLA part typically wins over SLS when an appearance model is desired. If the temperature of uncured SLS powder gets too high, excess fused material can collect on the part surface. This can be difficult to control since there are many variables in the SLS process In general, SLA is a better process where fine, accurate detail is required However, a varnish-like coating can be applied to SLS parts to seal and strengthen them.

SLA vs. SLS

Dimensional Accuracy
SLA is more accurate immediately after completion of the model, but SLS is less prone to residual stresses that are caused by longterm curing and environmental stresses Both SLS and SLA suffer from inaccuracy in the z-direction (neither has a milling step), but SLS is less predictable because of the variety of materials and process parameters. The temperature dependence of the SLS process can sometimes result in excess material fusing to the surface of the model, and the thicker layers and variation of the process can result in more z inaccuracy SLA parts suffer from the "trapped volume" problem in which cups in the structure that hold fluid cause inaccuracies SLS parts do not have this problem.

Machining Properties
In general, SLA materials are brittle and difficult to machine SLS thermoplastic-like materials are easily machined.

SLA vs. SLS

Size
SLS and SLA parts can be made the same size, but if sectioning of a part is required, SLS parts are easier to bond.

Investment Casting
The investment casting industry has been conservative about moving to RP male models SLS models made from traditional waxes, etc. are preferred since SLA resins do not melt but burn to form ash

Support Structures
SLA parts typically need support structures during the build SLS parts, because of the supporting powder, sometimes do not need any support, but this depends upon part configuration. Marks left after removal of support structures for parts cause dimensional inaccuracies and cosmetic blemishes.

FDM
Fused Deposition Modelling
Standard engineering thermoplastics, such as ABS, can be used to produce structurally functional models Two build materials can be used, and latticework interiors are an option Parts up to 600 600 500 mm can be produced Filament of heated thermoplastic polymer is squeezed out like toothpaste from a tube Thermoplastic is cooled rapidly since the platform is maintained at a lower temperature Milling step not included and layer deposition is sometimes non-uniform so "plane" can become skewed Not as prevalent as SLA and SLS, but gaining ground because of the desirable material properties.

THE FDM PROCESS

The FDM process was developed by Scott Crump in 1988. The fundamental process involves heating a filament of thermoplastic polymer and squeezing it out like toothpaste from a tube to form the RP layers. The machines range from fast concept modellers to slower, high-precision machines. The materials include polyester, ABS, elastomers, and investment casting wax.

FDM MACHINE SUPPLIERS

The Fused Deposition Modelling technology was developed and commercialized by Stratasys of Eden Prairie, MN, USA.

Hewlett-Packard recently entered the FDM market with a cheaper but lower quality machine.

POLYJET
Simple technology, with easy support removal, and easy replacement of jetting heads The PolyJet Technology allows for high-speed raster build with no post-curing The selling company offers a wide variety materials with different mechanical properties, and colors The support material is the same for all models types (makes switching materials easy and fast) Elastomeric components can be printed The PolyJet technology was introduced and patented by Objet in early 2000

THE POLYJET PROCESS

Standard layered process Photopolymer is cured instantly with a UV light housed on the printing head

MULTI-MATERIAL
3D printing system that jets multiple model materials simultaneously Unique ability to print parts and assemblies made of multiple model materials, with different mechanical or physical properties, all in a single build

PROBLEMS

Parts printed with the polyjet technology: Degrade rapidly under the effect of UV light Exhibit significant creep over time Generally have poor mechanical properties

LOM
Laminated Object Manufacturing
Layers of glue-backed paper form the model Low cost: (Raw material is readily available) Large parts: Because there is no chemical reaction involved, parts can be made quite large Accuracy in z is less than that for SLA and SLS Outside of model, cross-hatching removes material Models should be sealed in order to prohibit moisture Before sealing, models have a wood-like texture Not as prevalent as SLA and SLS

THE LOM PROCESS

Material is usually a paper sheet laminated with adhesive on one side, but plastic and metal laminates are appearing. Layer fabrication starts with sheet being adhered to substrate with the heated roller. The laser then traces out the outline of the layer. Non-part areas are crosshatched to facilitate removal of waste material.

THE LOM PROCESS

Once the laser cutting is complete, the platform moves down and out of the way so that fresh sheet material can be rolled into position. Once new material is in position, the platform moves back up to one layer below its previous position. The process can now be repeated. The excess material supports overhangs and other weak areas of the part during fabrication. The cross-hatching facilitates removal of the excess material.

THE LOM PROCESS

Once completed, the part has a woodlike texture composed of the paper layers. Moisture can be absorbed by the paper, which tends to expand and compromise the dimensional stability. Therefore, most models are sealed with a paint or lacquer to block moisture ingress. The LOM developer continues to improve the process with sheets of stronger materials such as plastic and metal. Now available are sheets of powder metal (bound with adhesive) that can produce a "green" part. The part is then heat treated to sinter the material to its final state.

LOM is a registered trademark by Helisys of Torrance, CA, USA.

3D PRINTING
Allows to obtain realistic-looking models Allows to obtain multiple-coloured parts Resulting parts have poor structural properties First company on the market: Z-Corp, Boston, MA, USA Layers of powder glued together.

3D PRINTING

MATERIALS/TECHNOLOGIES COMPARISON

Material

Tensile strength Modulus of [MPa] Elasticity [MPa] 65 3100

Elongation at break [-%] 7

HDT [C]

SLA photopolymer

130

PolyJet photopolymer
FDM polycarbonate FDM ABS

60
68 36

2870
2280 2413

20
4.8 4

40-50
130 90