UNIT 3

LIQUID BASED AND SOLID

BASED ADDITIVE
MANUFACTURING SYSTEMS
 UNIT III
LIQUID BASED AND SOLID BASED ADDITIVE
MANUFACTURING SYSTEMS
Classification – Stereo lithography Apparatus
(SLA)- Principle, process, advantages –Fused
Deposition Modeling – Principle, process, advantages.
 LIQUID-BASED RP SYSTEMS
 Liquid-based RP systems have the initial form of its material in
liquid state. Through a process commonly known as curing, the
liquid is converted into the solid state.
 The following RP systems fall into this category:
1. 3D Systems’ Stereolithography Apparatus (SLA)

2. Cubital’s Solid Ground Curing (SGC)

3. Sony’s Solid Creation System (SCS)

4. CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)

5. Autostrade’s E-Darts

6. Teijin Seiki’s Soliform System

 LIQUID-BASED RP SYSTEMS
 Most liquid-based rapid prototyping systems build parts in a
vat of photo-curable liquid resin, an organic resin that cures
or solidifies under the effect of exposure to laser radiation,
usually in the UV range.
 The laser cures the resin near the surface, forming a hardened
layer. When a layer of the part is formed, it is lowered by an
elevation control system to allow the next layer of resin to be
similarly formed over it. This continues until the entire part is
completed.
 LIQUID-BASED RP SYSTEMS
 The vat can then be drained and the part removed for further
processing, if necessary.
 There are variations to this technique by the various vendors and
they are dependent on the type of light or laser, method of
scanning or exposure, type of liquid resin, type of elevation and
optical system used.
 1. STEREOLITHOGRAPHY
(SLA)
 Stereolithography (SLA) builds three-dimensional prototypes
layer by layer through selective Photo-polymerization of a
liquid polymer held in vat.
 “Stereo” signifies 3D object realization
 “Litho” indicates solidification and
 “Graphy” suggest printing

 Photonic energy is supplied by scanning CNC controlled laser

beam across the liquid polymer surface.
STEREOLITHOGRAPHY
(SLA)
Stereo lithography is 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
(SLA)
 Stereolithography (SLA) was founded in 1986 by Charles and
Raymond S Freed and 1987 first commercial AM process was
developed.
 SLA is a additive manufacturing technology for producing
models, prototypes, and patterns.
 The first developed AM technique is SLA. There are several
models/Products available in SLA
 SLA 250/30A
 SLA 250/50
 SLA 250/50 HR
 Highlights of Stereo lithography
 The first RP technique and is still most widely used.

 Inexpensive compared to other techniques.

 Uses light-sensitive liquid polymer.

 Requires post-curing since laser is not of high enough power to

complete.
 Long-term curing.

 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.

 STEREOLITHOGRAPHY
PROCESS

Process parameter:
 The starting materials are liquid monomers

 Each layer is 0.076 mm to 0.50 mm (0.003 in to

0.020 in.) thick
 Thinner layers provide better resolution and more
intricate shapes; but processing time is longer
 Laser scan speeds typically 500 to 2500 mm/s
 STEREOLITHOGRAPHY
PROCESS
 Stereolithography is one of the more commonly used rapid
manufacturing and rapid prototyping technologies.
 It is considered to provide high accuracy and good surface finish.

 It involves building plastic parts a layer at a time by tracing a laser

beam on the surface of a vat of liquid photopolymer.
 The photopolymer is solidified by the laser light.

 Once one layer is completely traced, it is lowered a small distance

into the liquid and a subsequent layer is traced, adhering to the
previous layer.
STEREOLITHOGRAPHY PROCESS
 After many such layers are traced, a complete 3D model is
formed.
 Some specific technologies require further curing of the
polymer in an oven.
Some objects have overhangs or undercuts which must be
supported during the fabrication process by support structures.
 These are either manually or automatically designed and
fabricated right along with the object.
Upon completion of the fabrication process, the object is
elevated from the vat and the supports are cut off.
 STEREOLITHOGRAPHY
PROCESS
 A moveable table, or elevator, initially is placed at a position just
below the surface of a vat filled with liquid photopolymer resin.
 This material has the property that when light of the correct color
strikes it, it turns from a liquid to a solid.
 The most common photopolymer materials used require an
ultraviolet light, but resins that work with visible light are also
utilized.
 The system is sealed to prevent the escape of fumes from the
resin.
 STEREOLITHOGRAPHY
PROCESS
 A laser beam is moved over the surface of the liquid
photopolymer to trace the geometry of the cross-section of the
object.
 This causes the liquid to harden in areas where the laser strikes.

 The laser beam is moved in the X-Y directions by a scanner

system (D).
 These are fast and highly controllable motors which drive
mirrors and are guided by information from the CAD data.
 STEREOLITHOGRAPHY
PROCESS
 The exact pattern that the laser traces is a combination of the
information contained in the CAD system that describes the
geometry of the object, and information from the rapid
prototyping application software that optimizes the
faithfulness of the fabricated object.
 Of course, application software for every method of rapid
prototyping modifies the CAD data in one way or another to
provide for operation of the machinery and to compensate for
shortcomings.
 STEREOLITHOGRAPHY
PROCESS
 More recently pump-driven recoating systems have been utilized.

 The tracing and recoating steps are repeated until the object is
completely fabricated and sits on the table within the vat.
 Some geometries of objects have overhangs or undercuts. These
must be supported during the fabrication process. The support
structures are either manually or automatically designed.
 Upon completion of the fabrication process, the object is elevated
from the vat and allowed to drain.
 STEREOLITHOGRAPHY PROCESS
Excess resin is swabbed manually from the surfaces.
The object is often given a final cure by bathing it in intense
light in a box resembling an oven called a Post-Curing
Apparatus (PCA).
Some resins and types of stereolithography equipment don't
require this operation, however. After final cure, supports are
cut off the object and surfaces are sanded or otherwise
finished.
Stereo lithography generally is considered to provide the
greatest accuracy and best surface finish of any rapid
prototyping technology.
Work continues to provide materials that have wider and more
directly useable mechanical properties.
 STEREOLITHOGRAPHY
PROCESS PRINCIPLE

 Parts are built from a photo-curable liquid resin that cures

when exposed to a laser beam (basically, undergoing the photo
polymerization process) which scans across the surface of the
resin.
 The building is done layer by layer, each layer being scanned
by the optical scanning system and controlled by an elevation
mechanism which lowers at the completion of each layer.
 This first principle deals mostly with photo-curable liquid
resins, which are essentially photopolymers and the photo
polymerization process.
 The second principle deals mainly with CAD data, the laser,
and the control of the optical scanning system as well as the
elevation mechanism.
 STEREOLITHOGRAPHY
PROCESS PRINCIPLE

1. Photopolymers:
 There are many types of liquid photopolymers that can be
solidified by exposure to electro-magnetic radiation, including
wavelengths in the gamma rays, X-rays, Ultraviolet light and
visible range, or electron-beam.
 The vast majority of photopolymers used in the commercial RP
systems, including 3D Systems are curable in the UV range.
 The process through which photopolymers are cured is referred to
as the photopolymerization process.
Composition :
1)Binders:
A binder is an ingredient used to bind together two or more other
materials in mixtures. Its two principal properties are adhesion and
cohesion.
This material consists of long, chain-like, chemically-reactive
molecules that give the final solid its mechanical and other
properties.
Examples include acrylates, epoxies and urethanes.
Most of a photopolymer consists of these binders which might
typically be in the range of 50 to 80% of the total weight.
 2) Monomers:
 A monomer (from Greek mono "one" and meros "part") is an
atom or a small molecule that may bind chemically to other
monomers to form a polymer.
 Some examples include vinyls and shorter acrylate molecules.
Monomers may typically constitute 10 to 40% of the
photopolymer.
3) Photo initiators:
 Photo initiators are molecules that can be split into two or more
parts by exposure to light.
 At least one of these parts is capable of reacting with both the
monomers and binders to link them together.
 Photo initiators are only sensitive to specific wavelengths of
light.
The free-radical photo polymerization process
 Photo initiator molecules, Pi, which are mixed with the
monomers, M, are exposed to a UV source of actinic photons,
with energy of hν . The photo initiators absorb some of the
photons and are in an excited state.
 Some of these are converted into reactive initiator molecules,
P•, after undergoing several complex chemical energy
transformation steps.
 These molecules then react with a monomer molecule to form
a polymerization initiating molecule, PM•.
 This is the chain initiation step.

 Once activated, additional monomer molecules go on to react

in the chain propagation step, forming longer molecules,
PMMM• until a chain inhibition process terminates the
polymerization reaction.
 The free-radical photopolymerization process is schematically
presented in Figure.
2. Layering Technology, Laser and Laser Scanning:
 The basic principle is the availability of computer software to
slice a CAD model into layers and reproduce it in an “output”
device like a laser scanning system.
 The layer thickness is controlled by a precision elevation
mechanism. It will correspond directly to the slice thickness of
the computer model and the cured thickness of the resin.
 The limiting aspect of the RP system tends to be the curing
thickness rather than the resolution of the elevation
mechanism.
 The important component of the building process is the laser and its
optical scanning system.
 The key to the strength of the SLA is its ability to rapidly direct
focused radiation of appropriate power and wavelength onto the
surface of the liquid photopolymer resin, forming patterns of
solidified photopolymer according to the cross-sectional data
generated by the computer.
 In the SLA, a laser beam with a specified power and wavelength is
sent through a beam expanding telescope to fill the optical aperture
of a pair of cross axis, galvanometer driven, beam scanning
mirrors. These form the optical scanning system of the SLA.
 The beam comes to a focus on the surface of a liquid
photopolymer, curing a predetermined depth of the resin after a
controlled time of exposure (inversely proportional to the laser
scanning speed).
 The solidification of the liquid resin depends on the energy per
unit area (or “exposure”) deposited during the motion of the
focused spot on the surface of the photopolymer.
 To maintain accuracy and consistency during part building
using the SLA, the cure depth and the cured line width must be
controlled.
 Parameters which influence performance and
functionality of the parts are:
• The physical and chemical properties of the resin,

• The speed and resolution of the optical scanning system,

• The power, wavelength and type of the laser used, the spot

size of the laser,

• The recoating system,

• And the post-curing process.

 TRAPPED VOLUME
 All new SL machines now employ a method to apply the resin
that is superior to the deep-dip process.
 Because of the high resin viscosity, after the deep dip and
recoating, either too little or too much resin is left by the
recoating blade, which affects part accuracy.
 The new method involves spreading resin on the part as the
blade traverses the vat. Because the blade applies only the
required amount of resin, good accuracy is achieved.
 TRAPPED VOLUME
 This method also provides a smoother surface finish and reduces
non-productive recoating time. Another important advantage is
the elimination of 'trapped volumes'.
 A trapped volume is a volume of resin that cannot drain through
the base of the part.
 The presence of a trapped volume in the deep-dip process affects
part accuracy and may lead to delamination or collision of the
blade and part because of a build up of unwanted polymerised
resin at the surface of the trapped volume.
 TRAPPED VOLUME
 Once the part is completed, it is removed from the vat and the
excess resin drained. Due to the resin viscosity, this stage may
take several hours. Part is then placed in an UV oven to be
postcured.
 SOFTWARE MODULES
Maestro includes the following software modules;
• 3D verifyTM Module

• ViewTM Module

• MERGE Module

• VistaTM Module

• Part ManagerTM Module

• SliceTM Module

• ConvergeTM Module
 SOFTWARE MODULES
3D verifyTM Module
 This module can be accessed to confirm the integrity and/or
provide limited repair to stereolithography (STL) files before
part building without having to return to the original CAD
software.
 Gaps between triangles, overlapping or redundant triangles and
incorrect normal directions are some examples of the flaws that
can be identified and corrected.
ViewTM Module
 This module can display the STL files and slice file (SLI) in
graphical form.
 The viewing function is used for visual inspection and for the
orientation of these files so as to achieve optimal building.
MERGE Module
 By using MERGE, several STI files can be merged into a
group which can be used together in future process.
VistaTM Module
 Support structures are an integral part to successful part
building. This module is a powerful software tool that
automatically generates support structures for the part files.

Part ManagerTM Module

 This software module is the first stage of preparing a part for
building.
 It utilizes a spreadsheet format into which the STL file is
loaded and set-up with the appropriate build and recoat style
parameters.
SliceTM Module
 This is the second stage of preparing a part for building. It
converts the spreadsheet information from the Part
ManagerTM module to a model of three-dimensional cross
sections or layers.

ConvergeTM Module
 This is the third and last stage of preparing a part for building.
This is the module which creates the final build files used by
the SLA.
 ADVANTAGES OF SLA
Round the clock operation
• The SLA can be used continuously and unattended round the

clock.

Good user support

• The computerized process serves as a good user support.

Build volumes
• The different SLA machines have build volumes ranging from

small to large to suit the needs of different users.

Good accuracy

• The SLA has good accuracy and can thus be used for many

application areas.

Surface finish

• The SLA can obtain one of the best surface finishes amongst

RP technologies.

Wide range of materials

• There is a wide range of materials, from general-purpose

materials to specialty materials for specific applications.

 DISADVANTAGES OF SLA
Requires support structures
• Structures that have overhangs and undercuts must have supports
that are designed and fabricated together with the main structure.
Requires post-processing
Post-processing includes removal of supports and other unwanted

materials, which is tedious, time consuming and can damage the

model.
 DISADVANTAGES OF SLA
Requires post-curing.
Post-curing may be needed to cure the object completely and

ensure the integrity of the structure.

 APPLICATIONS OF SLA
 Models for conceptualization, packaging and presentation.

 Prototypes for design, analysis, verification and functional testing.

 Parts for prototype tooling and low volume production tooling.

 Patterns for investment casting, sand casting and molding.

 Tools for fixture and tooling design, and production tooling.

 2. SOLID GROUND CURING
(SGC)

 The Solid Ground Curing (SGC) System is produced by

Cubital Ltd. So it is also called as Cubital’s Solid Ground
Curing (CSGC).
 Cubital’s system uses several kinds of resins,

• including liquid resin and cured resin as materials to create

parts,
• water soluble wax as support material and

• ionographic solid toner for creating an erasable image of the

cross-section on a glass mask.

 SOLID GROUND CURING (SGC)

 Solid Ground Curing process includes three main steps:

• Data preparation

• Mask generation

• Model making
 SOLID GROUND CURING (SGC)

Data Preparation:
 In this first step, the CAD model of the job to be prototyped is
prepared.
 The software used, Cubital’s Solider DFE (Data Front End)
software.

Mask generation:
 After data are received, the mask plate is charged through an
“imagewise” ionographic process. The charged image is then
developed with electrostatic toner.(See image 1)
 SOLID GROUND CURING (SGC)

Model Making:
 In this step, a thin layer of photopolymer resin is spread on the
work surface (see image 2 to 7). The photo mask from the mask
generator is placed in close proximity above the workpiece, and
aligned.
 In the SGC 5600, an additional step (item 8) is provided for final
curing of the layer whereby the workpiece travels under a
powerful longitudinal UV lamp.
 The cycle repeats itself until the final layer is completed.
 SOLID CREATION SYSTEM
(SCS)

 The Solid Creation System (SCS) has been jointly developed

by Sony Corporation.
 Solid Creator creates the three-dimensional model by laser
curing polymer layer by layer.
 The software and hardware have been created by Sony
Corporation, the UV curable resin by JSR (Japan Synthetic
Rubber) Corporation and the forming and applied technology
by D-MEC Corporation.
 STEPS IN SOLID CREATION
SYSTEM (SCS)

Its process comprises five steps:

i. generating the CAD model,

ii. Slicing the CAD model and transferring data,

iii. Scanning the resin surface,

iv. Lowering the elevator,

v. Completion of the prototype and post-processing.

 STEPS IN SOLID CREATION
SYSTEM (SCS)

 First, a CAD model, usually a solid model, is created in a

commercial CAD system, like CADDS5, CATIA or
Pro/Engineer.
 Three dimensional CAD data of the part from the CAD system
are converted to the sliced cross-sectional data which the SCS
will use in creating the solid. This is the slicing process.
 Editing may be necessary if the slicing is not carried out
properly. Both the slicing and editing processes can be done
 STEPS IN SOLID CREATION
SYSTEM (SCS)

 Consequently, the section-data are passed to the laser controller

for the UV curing process.
 The ultraviolet laser then scans the resin surface in the tank to
draw the cross-sectional shape based on these data.
 The area of the resin surface which is hit by the laser beam is
cured, changing from liquid to solid on the elevator.
 STEPS IN SOLID CREATION
SYSTEM (SCS)

 The elevator descends to allow the next solid layer to be

created by the same process.
 This is repeated continuously to laminate the necessary number
of thin cross-sectional layers to shape the three dimensional
part.
 Finally, when the model is completed, the elevator is raised and
the model is lifted out and post-curing treatment is applied.
 MAIN HARDWARE OF THE
SOLID CREATOR

The main hardware of the Solid Creator includes:

1. The Sony NEWS UNIX workstation.

2. The main machine controller (VME based, MTOS — Multitasking

3. Operating System).

4. The galvano mirror and its controller.

5. The optical system including the laser, the lens and the Acoustic

6. Optical Modulator (AOM).

7. The photopolymer tank.

8. The elevator mechanism.

 APPLICATION

The general application areas are given as follows:

i. Mock-up in product design.

ii. Design study and sales sample of new products.

iii. Use as parts without need of modification in small lot

production.
iv. Simplified mold tool and master for investment casting
and other similar kinds of processes.
 ADVANTAGES

Solid Creator has the following strengths:

 Large build volume. The tank size is large and large
prototypes(especially large full-scale prototypes) can be
produced.
 Accurate. High accuracy (0.04 mm repeatability) model may
be produced.
 SOLID OBJECT ULTRAVIOLET-LASER
PRINTER (SOUP)

 CMET (Computer Modeling and Engineering Technology) Inc.

was established in November 1990 with the Mitsubishi
Corporation as the major share holder and two other substantial
shareholders.
 SOUP PROCESS

The SOUP process contains the following three main steps:

1. Creating a 3D model with a CAD system:
 The three-dimensional model, usually a solid model, of the

part is created with a commercial CAD system. Three-

dimensional data of the part are then generated.

2. Processing the data with the SOUPware:

Often data from a CAD system are not faultless enough to besed

by the RP system directly.

 SOUP’s software, SOUPware, can edit CAD data, repair its
defects, like gaps, overlaps, etc., slice the model into cross-
sections and finally, SOUPware generates the corresponding
SOUP machine data.

3. Making the model with the SOUP units:

 The laser scans the resin, solidifying it according to the cross-
sectional data from SOUPware.
 The elevator lowers and the liquid covers the top layer of the part
which is recoated and prepared for the next layer. This is repeated
until the whole part is created.
 PRINCIPLE

The SOUP system is based on the laser lithography technology

(Figure 3.13) which is similar to that described in Section 3.1.4. The

one major difference is in the optical scanning system. The SOUP
system has the option for XY plotter, which is easier to control and
has less optic problems than the galvanometer mirror system. The
main trade-off is in scanning speed and consequently, the building
speed. Parameters which influence performance and functionality
are galvanometer mirror precision for the galvanometer mirror
machine, laser spot diameter, slicing thickness and resin properties.