Solid based rapid prototyping systems

The solid is utilized as the primary medium to create prototyping Cubic Technologies Laminated object Manufacturing (LOM) Cubic technologies is exclusive manufacture of LOM rapid prototyping machine Product : LOM 1015 PlusTM and LOM 2030HTM Co2 Laser are used Process consist of 3 phases: Pre-Processing, Building and
Post-processing
Software Used : LOMSliceTM - which a provides menu driven interface to perform transformations

Phase
Pre-processing
phase comprise several operations generation of from CAD-derived STL file of the part to be generated. Sorting input data and creating secondary data structure.
LomSlice software create a cross section of 3d model measuring exact height of the model and slices the horizontal plane accordingly

Building:
The computer generate precise calculations, which guide the focused laser beam to cut the cross-sectional outline, the crosshatches and models perimeter. The laser beam power is designed to cut exactly the thickness of one layer of material at a time. After perimeter is burned , everything within the models boundary is freed from the remaining sheet. The platform with the stack of previously formed layers descended and new section of material advances. The platform ascends and the heated roller laminates the material to the stack with single reciprocal motion, thereby bonding it to the previous layer. The vertical encoder measures the height of the stack and relays the new height to LOMSlice, which calculate the cross section of the next layer.

 Post-processing:

Separating the part from its support materials and finishing. The separating sequence as shown Fork lift or hammer are used to remove the part

RPT-LOM - Specifications

Separation of Object

Basic Steps
Step 1. Each sheet is attached to the block, using heat and pressure to form a new layer. Sheet material is supplied from a continuous roll on one side of the machine and taken up on the opposite side. The heated roller provides the pressure and heat needed for lamination. Step 2. After a layer (sheet) is deposited, a laser is traced along the contours corresponding to the current cross section. Usually a 25 or 50 watt laser is used. As in the other processes, this step starts with the bottom cross section. Note that only the contours are scanned in this process more efficient than the RP&M processes that require a full raster scan. Step 3. Areas of the layer outside the contours are cross-hatched by the laser (i.e., cut into small pieces called tiles, for removal after fabrication). Step 4. Steps 1-3 are repeated until the top layer of the part is laminated and cut. Step 5. After all the layers have been laminated and cut. The results is a imbedded within a block of supporting material. This material is then broken into chunks along the cross-hatching lines. Step 6. The resulting part may then be coated with a sealant to keep out moisture.

Laminated-Object Manufacturing

Advantages
Wide variety of materials can be used Fast build time High precision Support structure- no need additional support structure as the part is supported by its own material that is out side the periphery of the part built. Post curing: no need

Disadvantages
Precise power adjustment is required Fabrication of thin walls Integrity of prototypes Removal of supports Applications:
Visualization Form fit and function Manufacturing Rapid tooling

Applications of Rapid Prototyping

Prototype for design evaluation Prototype for function verification Rapid tooling processes

Laminated Object Manufacturing (LOM)

1) Sheet of material is laminated onto existing stack-up 2) Laser perforates the outline of cross section into top sheet (cross section is NOT completely cut out- full sheet remains) 3) Edges of top sheet are trimmed to match rest of stack-up 4) Next layer is bonded and process repeats 5) When finished- have solid block with perforations separating the actual workpiece from extra material. Extra material must be removed & part is sanded. LOM modelers use paper w/ polyester adhesive. They pose no health hazards and can be set up in offices. Further they are comparatively inexpensive, and require no supports for any overhangs. Unfortunately, LOM modelers also require more post-processing work (removing part from block).

LOM Process

LOM Example

Fused-Deposition Modeling

Rapid Tooling Process

Direct tooling method Single-reverse methods Double reverse method Triple reverse method

As the number of reversals increases, the durability of a product can be improved but the product cost increases and the precision decreases.

Direct Tooling Method

Single Reverse Tooling Process

Double Reverse Tooling

Triple Reverse Tooling

Details of Lithography Process

Geometry input
STL format is the standard format for Rapid Prototyping

STL format

Advantages of STL
Easy to conversion Wide range of input Simple-slicing algorithm Splitting STL models

Disadvantage of STL
Verbosity and data redundancy Error due to approximation Truncation error Lack of information

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Support Structure

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Selective Laser Sintering

Basic Steps
Step 1. A part cylinder is located at the height necessary for a layer of powdered material to be deposited on the cylinder to the desired thickness. The powdered material being used for the prototype is applied from the feed cylinder by the leveling roller. Step 2. The layer of powder is selectively raster-scanned and heated with a laser, causing particles to adhere to each other. The laser scan forms the powder into the required cross section shape. Note that this step starts with the bottom cross section. Step 3. The part cylinder is lowered by the layer thickness to permit a n, layer of powder to be deposited. Step 4. The new layer is scanned, conforming it to the shape of the next upper cross section and adhering it to the previous layer. Step 5. Steps 3 and 4 are repeated until the topmost layer of the part is generated Step 6. Post-curing may be required for some materials.

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3D Printing