i af uta ae ana roumng 8/ SOLID Bas; 2 ee * Insolid-basea nae RAPID PROTOTYPING SYSTEMS , «The solid state includes ons Systems, the initial form of the material used is in solid state. form. ‘Wires, roils, laminates and pallets. However, it docs not include powder d Modelling (FDM), Laminated Object Manufacturing (LOM) Fused Deposition Modelling (FDM): * Fused deposition modelli ; ; " n , after stereolithography. ing (FDM) is the second most widely used rapid prototyping technology Itis a solid-based rapid i 4 . a.20) Prototyping system. In is Process, the material used is solid thermoplastic (eg. ABS plastic, polycarbonate, | Polysulphone, etc.) in the form of wire-like filaments, - TO @ Components of Fused Deposition Modelling (FDM) System : The fused deposition modelling (FDM) system, shown in Fig. 8.8.1, consists of following components : @ _ Pre-processing computer Gi) | FDM system computer ii) Control unit (iv) FDM head with duel tip nozzle (¥) Platform heating systems (vi) Build platform Filament (Solid) Drive Wheels Liquifler (FOM Head) Filament Heating Elements (Semi-Liquid) Solidified Layers of Part Build Platform Maveront of Platform ) Fig. 88.1 : Fused Deposition Modelling (EDM) Process a, Working of Fused Deposition Modeling (FDM) Process: ; s is creation of 3D-model. , ing which includes : (i) Part orientation, (iv) Checking of STL files, ‘The first step in the process } The next step is pre-processi i) STL file generation, (ji) Support generation, ° Scanned with CamScanner(v) Transmission of STL files, and (vi) Slicing of STL model. ; © The real part-building starts with transfer of slice file format data to rapid prototyping machine by system computer. . . In a part building process, the thermoplastic material (ABS plastic, P potysulphone etc.) in a filament form, is heated slightly above (approxi above) its melting temperature in a FDM head using heating system. | . The semi-liquid material extruds through the movable nozzle that travels in XY plane fo create a two dimensional layer of material on the build platform. This process is like bi decorating a cake. A controlled extrusion helps to deposit a thin layer of material, + The build platform is maintained at a lower temperature so that the thermoplastic quickly hardens. © ‘The material solidifies within a very short time (approximately 0.1 s) after extrusion and cold welds to the earlier layer. © The movable nozzle is of duel tip, one nozzle tip for producing the part geometry and another nozzle tip for producing the support structure. © Once a layer is built, the platform lowers and the extrusion nozzle deposits another layer of material. The material solidifies within a very short time after extrusion (approximately 0.1 s) and cold welds to the earlier layer. The process is repeated until the part is completely built. © The material used for building the support structure is weaker than the material used for the building the part. Many a times, a solvent soluble or water-soluble material is used for building the support structure. . ‘The part is then removed for post processing. The support structure can be removed manually or dissolved by putting into solution. 3. Advantages of Fused Deposition Modelling (FDM) Process : Some of the advantages of fused deposition modelling (FDM) system are discussed below : (@ High strength of part : With ABS plastic as a material, FDM process can fabricate fully functional parts that have the strength equal to 90% of the actual injection moulded part. (i) Temperature stability : The FDM process produces the parts which are stable over the wide temperature range. (iii) Easy support removal : In FDM process, the supports can be easily broken or dissolved during post-processing. (iv) Minimum material wastage : In FDM process, the parts are built by extrusion process. Hence, only that much material is used during extrusion which is required to built a part. ‘Therefore, the wastage of material is at minimum level. (v) Safe operation : In FDM process, there is no use of laser. Hence, it is a safe operation. (vi) Building of large parts : FDM process can build larger parts easily as compared to other rapid prototyping processes. 4. Limitations of Fused Deposition Modelling (FDM) Process : Some of the limitations of fused deposition modelling are discussed below : () Limited accuracy of parts : The material used in FDM process is in the form of filament (diameter in range of 1.25 mm). Hence, the parts produced by FDM process have limited accuracy. polycarbonate, ately 0.5°C Scanned with CamScannerGi) Gi) (iv) 845 Rapid Prototyping and TooWng Slow buildings process : The speed of FDM process is restricted by the rate of on the Of material from nozzle, As the materials used are plastics which have high viscosities, Tate of extrusion can not be inereaeey casily. Hence, the part building process is slow. ion Poor shear strength of parts + The Parts built by FDM process are weak in directs Perpendicular to built axis i.e, shear ‘Strength. idly on JeastIlly Of shrinkage and distortion + The extruded merial cools rapidly deposition. Hence there is danger of shrinkage and distortion of the part. Applications of Fused Deposition Modelling (FDM) Process : S @ Gi) ii) ome of the applications of fused dey Position modelling process are as follows : sp process can Concept models : The models made by fused deposition modelling FM DF al be finished to look like the actual Product. Therefore, such models are u: models for presentation of product. on modelling Prototypes for design, analysis and functional testing : ‘The fused ee aiten ath of (FDM) process can produce prototype of ABS plastic which has 85 Pa checkin the actual part. Therefore, prototypes made by FDM process can be u functionality of the actual product. ; be used for Medical applications : The fused deposition modelling (FDM) rosea oe vo making the models of human organs like bones from ABS plastic for Irpose patient goes for surgery. Scanned with CamScanner882 Laminate: @ ovve aun oungery, id Object Manufacturing (Lom) Laminated object manufacturing (LOM) is the solid-based Tapid prototyping system. In this process, a thin sheet or laminate (plastic, metal or ceramic) coated with adhesive on one Side is used as a material. Components of Laminated Object Manufacturing (LOM) System : (Cross Hatch) Layer Contour Block Build Platform ‘Supply Roll Take-up Roll Scanned with CamScannerThe laminated object-manufacturing (LOM) system consists of following components Heated Roller (b) Fig. 8.8.2 : Laminated Object Manufacturing (LOM) System Pre-processing computer (i) LOM system computer Control unit Optical scanning system CO, laser Supply roll Take-up roll Heated press roller Build platform Working of Laminated Object Manufacturing (LOM) Process : The first step in the process is creation of 3D-model. The second step is pre-processing which includes : () STL file generation, (i) Part orientation, (iii) Checking of STL files, (iv) Transmission of STL files, and (v) — Slicing of STL model. The real part building process starts with transfer of slice file format data to rapid prototyping machine by system computer. ALOM process typically consists of three steps : @ Placing the thin sheet or laminate di Bonding the sheet or laminate to previous layer (iii) Cutting the laminate as per slice layer data In LOM process, the material consists of continuous and Jong thin sheet or laminate, made of plastic, metal or ceramic, which is coated with heat activated adhesive form lower side. ‘The material is rolled up on supply roll. It passes over the build platform and finally goes to the take up roll. The sheet is unwound from a supply rol orto the build platform. The heating press roller passes across the sheet after placing it on the build platform. Due to heat activated adhesive, the layer is bonded to previous layer: ¥ Scanned with CamScannera The CO, laser beam in creat fasr Cuts the cross-sectional outline of te layer as per the slice data orem controls thoy & depth of exactly one layer thickness. The optical se By Shawls the X-¥ motion of aser beam. 8 perimeter ene demarkets the outer perimeter. The unused material between the ae Fate wey the Part boundary is hatched by laser beam using a cTOSS- hatch Plat bullaumall rectangular pieces called tiles. This cross hatched part acts a8 suppor wl ing of the part and it can be easily removed later once the build process is complete. ier cutting of the one layer is complete, the build platform is lowered by a depth cae 10 one layer thickness. The remaining portion of sheet in wound on & take up roll an ne for next layer is supplied by the supply roll. . Process is repeated until the part is completely built. ‘The last step is post-processing which includes separating the part from its Support material and finishing it. Advantages of Laminated Object Manufacturing (LOM) Process : some of the advantages ‘of laminated object manufacturing process (LOM) are discussed low : @ @ Gib) (iv) @) (vi) Low material cost : The material used in LOM process is relatively of low cost. Vide variety of materials : Any material in sheet form can be used in LOM process. Some of the materials that can be used in LOM process are : paper, plastics, metals, composites, ceramics, etc. Faster process : In LOM process, the laser beam dose not scan the entire surface area of each layer, but it only cuts the outline, Therefore, the process is fast. High accuracy : In LOM process, there is no possibility of distortion or shrinkage, and hence, the accuracy of parts produced is high. No additional part supports : In LOM process, the part is supported by its own material which is outside the periphery to built part. Hence, additional supports are not required. No post curing : The parts produced by LOM process does not require post curing. Limitations of Laminated Object Manufacturing (LOM) Process : Some of the limitations of laminated object manufacturing (LOM) process are discussed below : @ i) ii) (iv) Requirement of precise laser control : In LOM process, the laser beam has to be precisely controlled so that it cuts only current layer of laminate and dose not of penetrate the pervious layer. - Inability to built hollow and thin walled parts : The LOM process is not suitable for building hollow parts like bottles as well as thin walled parts. This is due to the fact that such walls are not rigid enough to withstand the forces applied to remove the hatched portion, during the post processing. Limited strength of parts : The strength of parts made by LOM process is limited by bonding strength of the glued layers. Therefore, such parts cannot with stand high tensile or shear stresses. Tedious process of removal of supports : The process of removal of hatched portion is tedious, time-consuming, and hence, labour intensive, Scanned with CamScanner5. Applications of Laminated Object Manufacturing (LOM) Process : Some of the applications of laminated object manufacturing (LOM) process are discussed below : @ @ ii) (iv) Prototype for marketing purpose : The prototype produced by LOM process are highly accurate. Therefore, such prototypes can be painted and finished to exactly look like actual product and can be used by marketing department for visual demonstration of product. Functional models in low stress environment : The LOM process is used for making parts that can be successfully used for functional testing under low stress condition. Patterns for casting and moulding : The LOM process can be used for making prercise patterns for sand casting, investment casting and rubber moulding. Medical applications : The LOM process can be used for making the models of human organs like bones, skull, etc. for study purpose before patient goes for surgery. ee eee mem BHATATVDING CVSTEMS Scanned with CamScannerThe stereolithography is the ee Rapid Prototyping and Tooling rapid prototyping system, Most widely Used rapia rototypil fee 1, _ Principle of Operation ; Prototyping technology. It is the liquid-based The stereolithography (S14) - A Process j @ in ats process, ne Bie On the following two principles : : ae resin het ‘ t from Photo-curable liquid resin. The layer of photo- tured and solidfy. nosetting plastic) is exposed to a laser beam due to which it gets Gi) The partis buitt layer by 2, Components of Stereolithog The stereolithography (SLay y layer by repeat ‘Peating the proce raphy (SLA) System: = System, shown in Fig. 8.7.1, “Processing compute ( Control unit : (ii) SLA system computer () Helium Cadmi i Gv) Optical scanning system (vii) Build ae or Argon ion taser (vi) Vat filled with liquid resin (iil) Sweeping wiper blade 3. Working of Stereolithography (SLA) Process : . The first step in the Process is creation of 3D-model. * The next step is pre-processing which includes : @ STL file generation, ii) Part orientation, ii) Support generation, (iv) Checking of STL files, (v) Transmission of STL files, and (vi) Slicing of STL model. * The real part building process starts with transfer of slice file format data to rapid prototyping machine by system computer. * _ ASLA system consists of an elevator build platform which is mounted in a vat of liquid resin. ¢ The computer controlled optical scanning system redirects the laser beam. The laser beam scans and solidifies the first layer of liquid resin corresponding to the slice data of 2D cross-section to a depth greater than one layer thickness. ‘After scanning and solidifying one layer, the build platform is then lowered by a depth equal to one layer thickness and left for short time so that liquid resin settles on the cured solid layer. © A-sweeping wiper blade moves across the surface to coat a new layer of resin on the solid layer. The thickness of new layer of resin is equal to one layer thickness, The laser beam idifies the new tayer of liquid resin. scans and soli 2 ce bail «The process is repeated until the partis completely built. Serre platform is then raised out of the vat and put is removed for the post ea post-processing, the part is placed in an ultraviolet oven to harden any . uncured resin. . 4. Advantages of Streaithography (SLA) process areas follows : eolithoy Some of the advantages of st "The stereolthography (SLA) process is fully automatic (@ Unattended building Pre ged until the process is completed. and machine can work unattendi Scanned with CamScannerOptical Scanning ‘System Sweeping Wiper Blade Prototype Vat of Rasin Build Platform Fig. 8.7.1 : Stereolithography Apparatus (SLA) Scanned with CamScanner5. i) Gi) ww) (SLA) process has good ii . Lith hy Good dimensional accuracy : The stereolithograp! of $0.1 mm. dimensional accuracy and can built a parts within a tolerance Good surface finish : The stereolithography (SLA) process can ie ques glass like finish on the top surface of the part. It gives one crite ee amongst rapid prototyping technologies. However, the stairs are found on HE 0 NE Capable of building complex parts : The stereolithography (SLA) proces building parts with any complex geometry. Limitations of Stereolithography (SLA) Process : ‘Some of the limitations of stereolithography process are as follows : @ cc) (iii) dy) w) wi) Curling and warping : The resin absorbs water during the use of part. This results in curling and warping of part, especially in areas with thin sections. High initial cost : The cost of stereolithography (SLA) system is high, Narrow range of materials : The stereolithography (SLA) process is suitable only for making the parts from photosensitive resin, Such parts are not durable and also not suitable at high temperatures. : Requires post-processing : The stereolithography (SLA) process requires post- processing which includes removal of supports and cleaning. This post-processing is time consuming and sometimes can damage the part. Requires post-curing : In stereolithography (SLA) process, many a times the parts are not fully cured by the laser inside the vat. Hence, post-curing in ultraviolet oven is normally required. High running and maintenance cost : The running and maintenance cost of stereolithographys (SLA) system is high. Applications of Stereolithography (SLA) Process : Some of the applications of stereolithography (SLA) process are as follows : @ Concept models : The stereolithography (SLA) process is used for making prototypes for concept models. (i) Prototypes for design, analysis and functional testing : The stereolithography (SLA) process is used for making prototypes for design, analysis, verification and functional testing. (ili) Patterns for casting : The stereolithography (SLA) process is used for making patterns for investment casting, sand casting and moulding. (iv) Tooling : The stereolithography (SLA) process is used for making prototype for tooling and low volume production tools. Photo-Polymerization : Polymerization is the process of linking small molecules, known as monomers. The chain polymers are further cross-linked to one another to form cross-linked polymer. In photo-polymerization, the liquid polymers are solidified (cured) by exposure to electromagnetic radiation (X-rays, y-rays, ultra-violet rays etc.). Many a times, in order to carryout photo-polymerization at room temperature, catalyst is required. Scanned with CamScannergot Selective Laser Sintering (SLS) : The basic principle of selective laser sintering (SLS) process is similar to stereolithography (SLA) process. The difference is, in selective laser sintering (SLS) process, the material used is powdered polymer or powdered metal composite instead of liquid resin. Hence, in selective laser sintering (SLS) process, the powdered polymer or metal composite layer is sintered by selective scanning of surface of powder bed, using laser. 1. Principle of Operation : The selective laser sintering (SLS) process is based on the principle that powder of thermoplastic material, metals, composites or ceramics is sintered layer by layer, under the heat produced by CO, laser to build the part. 2. Components of Selective Laser Sintering (SLS) System : ‘The selective laser sintering (SLS) system, shown in Fig. 8.9.1 and Fig. 8.9.2 consist of following components : Pre-processing computer —‘(ii)_+—~« SLS system computer Control unit Optical scanning system CO, laser Powder feed bed Powder feed platform and cylinder Part build power bed Part-build platform and cylinder Roller mechanism Process chamber Scanned with CamScannerRapid Prototyping and Tooling Process Chamber Powder Feed Bed Powder Feed Platform Excess Powder Feed Bed Part Build Platform ie Di Selective Laser Sintering (SLS) System . : Schematic Diagram © . Fig. 8.9.2 Scanned with CamScanner1) GAUILAMIUAC Working of Selective Laser Sintering (SLS) System ‘The first step in the process is creation of 3D-model. ‘The next step is pre-processing which includes : @ STL file generation, Gi) Part orientation, (ii) Checking of STL files, (iv) Transmission of STL files, and (vy) Slicing of STL model. ‘The real part building process starts prototyping machine by system computer. ‘A SLS system consists of powder feed bed containing powdered polymer, (nylon, polyamide, polycarbonate, etc.) metals, composite or ceramics. The powdered polymers (nylon, polyamides, polycarbonate used in this process are thermoplastic materials. ‘The computer controlled optical scanning system redirects the laser beam. The laser beam scans a layer of powder corresponding to slice data of 2D cross-section to a depth greater than one layer thickness and carries out sintering of the powder layer. ‘The heat generated by CO, laser increases the temperature of powder to a melting point, fusing the powder particles to form a solid layer. The intensity of laser beam is controlled such that it melts and fuses the powder only in the area defined by the slicing data. ‘After scanning and sintering one layer, the part build platform is lowered by a depth equal to one layer thickness. ‘A roller mechanism convey a new layer of material from powder feed bed on top of the previously sintered layer for the next scanning and sintering process. ‘The process is repeated until the part is completely built. AAs sintering operation is performed by high power CO, laser, the build platform and the powder bed has to be preheated to certain temperature to avoid part deformation. Therefore, entire setup is kept in sealed and heated process chamber filled with nitrogen gas. Nitrogen gas prevents oxidation during sintering process. Selective laser sintering process does not require supports. This is due to the fact that not ‘melted and not fused excess powder in each layer during process acts as a support. ‘After SLS process, the part is removed from process chamber and loose powder simply falls away. The part or prototype is finished by post processing operation such as sanding, painting, with transfer of slice file format data to rapid Advantages of Selective Laser Sintering (SLS) Process : ‘Some of the advantages of selective laser sintering (SLS) process are as follows : @ Gi) Wide range of materials for parts : The powders of wide range of materials like: nylon, polyamides, polycarbonates, metals, composites and ceramics can be used for making parts in selective laser sintering (SLS) process. This provides flexibility in using materials for parts in different applications. Capable of producing strong parts : Due to process and type of material used, selective laser sintering (SLS) process can produce strong and tough . Therefc i parts can be built directly, aa ore, finetonal Scanned with CamScanner(Y)_ VAUILAMIGAE (MU) wre Gi) (iv) ) (vi) an e part is No additional part supports : In selective laser sintering (SLS) nana ine ne not supported by not melted and not fused excess powder. Hence, additional supp’ Tequired. This saves time and material required for support building. High rate of production : In selective laser sintering process, the parts can in short time, ; Minimum post processing required : The parts produced by laser sintering process Tequire only minimal post-processing such as sanding. No post curing : The sintered parts produced by selective laser sintering are fully cured, and hence, does not required further curing. be produced Limitations of Selective Laser Sintering (SLS) Process = Some of the limitations of selective laser sintering (SLS) process are as follows : @ Gi) (ii) (iv) Large physical size of unit : The size of selective laser sintering unit is large. High running cost ; In selective laser sintering process, high power is required for sintering the powder. In addition, process chamber requires continuous supply of nitrogen. This increases the running cost. Poor surface finish : There is limitations on the surface finish of the parts produced by selective laser sintering process due to size of the powder particles. Generation of toxic gases : Toxic gases are generated during selective laser sintering process. This leads to pollution. Applications of Selective Laser Sintering (SLS) Process : Some of the applications of selective laser sintering (SLS) process are as follows : @ wi Gi) Gv) Concept models : The selective laser sintering (SLS) process is used for making prototypes for concept models. Functional models and working prototypes : The selective laser sintering (SLS) process is used for making parts that can withstand limited functional testing. Polycarbonate patterns : The selective laser sintering (SLS) process is used for making polycarbonate patterns for using in investment casting. The polycarbonate patterns are suitable for designs with thin walls and fine features. These patterns are durable and heat resistant. ; Metal tools (rapid toots) : The selective laser sintering (SLS) process is used for making tools for low volume production. Scanned with CamScanner