Rapid Prototyping ISE 240 Manufacturing Processes for Engineering

Rapid Prototyping ISE 240 Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Processing of RP Parts FIGURE 10. 46 The computational steps involved in producing a stereolithography file. (a) Three-dimensional description of the part. (b) The part is divided into slices. (Only 1 in 10 is shown. ) (c) Support material is planned. (d) A set of tool directions is determined for manufacturing each slice. Shown is the extruder path at section A-A from (c), for a fused-deposition modeling operation. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Rapid Prototyping Processes TABLE 10. 7 Characteristics of rapid-prototyping processes. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

RP Materials TABLE 10. 8 Mechanical properties of selected materials for rapid prototyping. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Stereolithography and FDM FIGURE 10. 47 Schematic illustration of the stereolithography process. Source: Courtesy of 3 D Systems. FIGURE 10. 48 (a) Schematic illustration of the fused-deposition modeling process. (b) The FDM Vantage X rapid prototyping machine. Source: Courtesy of Stratasys, Inc. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Support Structures FIGURE 10. 49 (a) A part with a protruding section that requires support material. (b) Common support structures used in rapid-prototyping machines. Source: After P. F. Jacobs. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Selective Laser Sintering FIGURE 10. 50 Schematic illustration of the selective-laser-sintering process. Source: After C. Deckard and P. F. Mc. Clu Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Three-Dimensional Printing FIGURE 10. 51 Schematic illustration of the threedimensional-printing process. Source: After E. Sachs and M. Cima. FIGURE 10. 52 (a) Examples of parts produced through three-dimensional printing. Full color parts also are possible, and the colors can be blended throughout the volume. Source: Courtesy ZCorp, Inc. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

3 D Printing of Metal Parts FIGURE 10. 53 The three-dimensional printing process: (a) part build; (b) sintering, and (c) infiltration steps to produce metal parts. Source: Courtesy of the Pro. Metal Division of Ex One Corporation. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Sprayed Metal Tooling Process FIGURE 10. 55 Production of tooling for injection molding by the sprayed-metal tooling process. (a) A pattern and base plate are prepared through a rapid-prototyping operation; (b) a zinc-aluminum alloy is sprayed onto the pattern (See Section 4. 5. 1); (c) the coated base plate and pattern assembly is placed in a flask and back-filled with aluminumimpregnated epoxy; (d) after curing, the base plate is removed from the finished mold; and (e) a second mold half suitable for injection molding is prepared. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7

Example: RP Injection Manifold FIGURE 10. 56 Rapid prototyped model of an injection-manifold design, produced through stereolithography. Source: 3 D Systems. Manufacturing Processes for Engineering Materials, 5 th ed. Kalpakjian • Schmid © 2008, Pearson Education ISBN No. 0 -13 -227271 -7