Logistics and Announcements

September 21, 2011 21

Volunteers for CS2 8 groups needed 161 enrolled students and 28 groups in total. Anyone left outside a group? Very last call! Labs start THIS WEEK (week of September 19, 2011) Lab attendance is mandatory and records will be kept. Meccano kits will be distributed during lab time. A borrowing contract has to be signed by the team leader. An updated version of the tentative course outline is available on WebCT.

Slide 1

ENGR 2310U Concurrent Engineering and Design

Lecture #3

Desktop Design, Manufacturing f and Rapid Prototyping

Prof. Remon Pop-Iliev, Ph.D, P.Eng. Wednesday, September 21, 2011, 2:10-3:30 PM, UA1350 Faculty of Engineering and Applied Science y g g pp University of Ontario Institute of Technology

Short Story: Lions or Gazelles? y

Slide 3

Quickly From Art to Part y

Desktop

Design & Manufacturing

Desktop D kt manufacturing enables engineers to catch and f t i bl i t t h d remedy problems early on the manufacturing process because they can inexpensively test out new p y p y product and manufacturing ideas. Desktop Manufacturing is also known as Rapid Prototyping.
Rapid

prototyping. Why?

To reduce time-to-market. To create accurate realistic physical objects directly from the CAD model without ever having to use a machining tool. To reduce cost and time for the process from 30 to 95 % %.
Slide 4

Rapid Prototyping Facts

Rapid prototyping is the most common name given to technologies that are used to fabricate physical objects directly from CAD data sources sources. These methods are unique in that they add and bond materials in layers to form objects. Such systems are also known by the general names freeform fabrication (FFF), solid freeform fabrication (S ) a d aye ed a u actu g (SFF) and layered manufacturing. Objects can be formed with any geometric complexity or intricacy without the need for elaborate machine setup or final assembly assembly. Rapid prototyping systems reduce the construction of complex objects to a manageable, straightforward, and relatively fast process.

Slide 5

Rapid Prototyping Facts Contd.

Rapid prototyping is the best way to reduce time to market in manufacturing, to better understand and communicate product designs, and to make rapid designs tooling to manufacture those products. Remember: Rapid prototyping isn't a solution to every part fabrication problem. t f b i ti bl

CNC technology is economical, widely understood and available, offers wide material selection and excellent accuracy. While the accuracy of rapid prototyping isn't generally as good as CNC, it's adequate today for a wide range of applications. The materials used in rapid prototyping are limited and dependent on the method chosen. Numerous secondary processes are usually needed to convert patterns made in a rapid prototyping process to final materials tt d i id t t i t fi l t i l or tools.

Slide 6

The Essence of Rapid Prototyping

Rapid prototyping is a family of printing technologies. All of them work by translating a CAD file into a number of fine layers then "printing" those layers in plastic layers, plastic, paper, or metal and stacking them one on top of the other. Often, the layers aren't made separately and then stacked, but are b i printed directly on th i t k d b t being i t d di tl their predecessors. In the first rapid p ototyp g de ces (ste eo t og ap c t e st ap d prototyping devices (stereolithographic machines), a laser created a layer by tracing a pattern in a photosensitive liquid polymer. The polymer turns solid where the laser hits, and remains fluid elsewhere. More recently, 3D inkjet printers have appeared, which create models by spraying binding fluid on a layer of powder, powder lowering the finished layer spreading more layer, powder, and repeating the process.

Slide 7

Rapid Prototyping Principles and Methods

Liquid polymerization methods

Point by point single frequency laser beam (Stereolitography) Light sculpturing (Photosolidification systems) Holographic interference solidification method Laser beam interference Solid Ground Curing (also known as the Solider Process, is a process that was invented and developed by Cubital Inc. of Israel) Selective Laser Sintering Laser Engineered Net Shaping 3D printing Melting and solidification (Fused Deposition Modeling) Gluing sheets ( G (Laminated O Object Manufacturing) f )
Slide 8

Powder based methods

Application of solid materials

Uses of Prototypes
Evaluating

design principles Visualization purposes Functional tests For further manufacturing processes for parts that otherwise would be impossible to produce out of one solid piece
Investment casting Vacuum casting Metal spraying Electronic Discharge Machining (EDM) Metal cutting

Slide 9

Stereolitography (SLA) g p y( )

Stereolithography is the most widely used rapid prototyping technology. Stereolithography builds 3-D objects a g p y j layer at a time by tracing a laser beam on the surface of a vat of liquid photopolymer that quickly solidifies wherever the laser beam strikes its surface. Once one layer is completely traced, it is lowered a small distance into the vat and y a second layer is traced on top of the first. The self-adhesive property of the material causes the layers to bond to one another and eventually form a 3-D object. Stereolithography provides the greatest accuracy and best surface finish of any rapid prototyping technology. However, parts often require a postcuring operation in a separate oven-like apparatus.

Stereolitography Video

10

Solid Ground Curing (SGC) g( )

Slide 11

Solid Ground Curing Steps

Slide 12

Thermal Phase Change Inkjets g j

Solidscape, Inc.'s inkjet method is illustrated, but others are also available. This machine uses a single jet each for a plastic build material and a wax-like support material, which are held in a melted liquid state in reservoirs. The liquids are fed to individual jetting heads which squirt tiny droplets of the materials as they are moved f in X-Y fashion in the required pattern to form a layer of the object. The materials The most outstanding harden by rapidly dropping in temperature characteristic of the as they are d h deposited. i d Solidscape system is the After an entire layer of the object is formed ability to produce extremely by jetting, a milling head is passed over the fine resolution and surface y layer to make it a uniform thickness. finishes, finishes essentially equivalent Particles are vacuumed away as the milling to CNC machines. head cuts and are captured in a filter. The process is repeated to form the entire However, the technique is very j j p , object. After the object is completed, the slow for large objects. wax support material is either melted or Materials selection is very limited. dissolved away.
13

Other Thermal Phase Change Inkjets

Other manufacturers use considerably different inkjet techniques, but all rely on squirting a build material in a liquid or melted state which cools or otherwise hardens to form a solid on impact. 3D Systems produces an inkjet machine called the ThermoJet Modeler which utilizes several hundred nozzles in a wide head configuration. It uses a hair-like matrix of build material to provide support for overhangs which can be easily brushed off once the object is complete. This machine is much faster than the Solidscape approach but doesn't offer as good a surface finish or approach, doesn t resolution. Objet Geometries Ltd., an Israeli company, introduced its first machine based on PolyJet technology in early 2000. It's a potentially promising replacement for t f stereolithography. Th process i b d on photopolymers, b t uses a wide lith h The is based h t l but id area inkjet head to deposit both build and support materials. It subsequently completely cures each layer after it is deposited with a UV flood lamp mounted on the print head. The support material, which is also a photopolymer, is removed b washing it away i a secondary operation. d by hi in d ti In July, 2002, 3D Systems announced a similar photopolymer-based system called the InVision. It uses the technology originally developed for the y ThermoJet Modeler and was introduced commercially in late 2003. The company has aggressively priced the system at about $40K to compete with concept modelers from Stratasys and Z Corp.
Slide 14

Fused Deposition Modeling (FDM)

FDM is the second most widely used rapid prototyping technology, after stereolithography. A plastic filament is unwound from a coil and supplies material to an extrusion nozzle. The nozzle is heated to melt the plastic and can turn on and off the flow of the melted plastic It is mounted on a mechanical stage which can be moved in 3-D. As the nozzle is moved over the table in the required geometry, it deposits a thin bead of extruded plastic to form each layer The plastic layer. hardens immediately after being squirted from the nozzle and bonds to the layer below. The entire system is contained within a chamber which is held at a temperature just below the melting point of the plastic. ABS (Acrylonitrile-Butadiene-Styrene) and investment casting wax are used. The closest competitor to the FDM process is 3D printing. But, FDM offers greater strength and the use of a wider range of materials.

Fused Deposition Modeling Video

15

Three Dimensional Printing (3DP) g( )

Developed at MIT. Used as a direct manufacturing process as well as for rapid prototyping. The process starts by depositing a layer of powder object material at the top of a fabrication chamber. To accomplish this, a measured quantity of powder is first dispensed from a similar supply chamber by moving a piston upward incrementally. The roller then distributes and compresses the powder at the top of the fabrication chamber The multi-channel jetting chamber. head subsequently deposits a liquid adhesive in a two dimensional pattern onto the layer of the powder which becomes bonded in the areas where the adhesive is deposited, to form a layer deposited of the object. Once a layer is completed, the fabrication piston moves down by the thickness of a layer, and the process is repeated until the entire object is ntil formed within the powder bed.

3D Printing Bycycle Video 3D Printing Video

16

Selective Laser Sintering (SLS) SLS)

Thermoplastic powder is spread by a roller over the surface of a build cylinder. The piston in the cylinder moves down one object layer thickness to accommodate the new layer of powder powder. A laser beam is then traced over the surface of this tightly compacted powder to selectively melt and bond it to form a layer of the object. The fabrication chamber is maintained at a temperature just below the melting point of the powder so that heat from the laser need only elevate the temperature slightly to cause sintering. The process is repeated until the entire object is fabricated fabricated. This method is commonly used for making functional parts in essentially final materials the method has also been extended to provide direct fabrication of metal and ceramic objects and tools tools. Surface finishes and accuracy are not quite as good as with stereolithography. Since the objects are sintered, they are porous. It may be necessary to infiltrate the part especially part, metals, with another material to improve mechanical characteristics.

Dyson SLS Video SLS Process Video

17

Laminated Object Manufacturing (LOM)

Profiles of object cross sections are cut from paper or other web material using a laser. The paper is unwound from a feed roll onto the stack and first bonded to the previous layer using a heated roller which melts a plastic coating on the bottom side of the paper. The profiles are then traced by an optics system that is mounted to an X-Y stage stage. After cutting of the layer is complete, excess paper is cut away to separate the layer from the web. Waste paper is wound on a take-up roll. Variations on this method have been developed by many companies and research groups. In general, the finish, accuracy and stability of paper objects are not as good as for materials used with other RP methods. However, material costs are very low, and objects have the look and feel of wood and can be worked and finished in the same manner This has fostered manner. applications such as patterns for sand castings.
18

Laser Engineered Net Shaping (LENS)

Laser Engineered Net Shaping and similar laser powder forming technologies are gaining in importance and are in advanced stages of commercialization. commercialization A high power laser is used to melt metal powder supplied coaxially to the focus of the laser beam through a deposition head. The laser beam typically travels through the center of the head and is focused to a small spot by one or more lenses. The X-Y table is moved in raster fashion to Fabricates fully-dense metal fabricate each layer of the object. The head is p parts with good g moved up vertically as each layer is completed completed. metallurgical properties Metal powders are delivered and distributed at reasonable speeds. around the circumference of the head either by gravity, or by using a pressurized carrier gas. An Fabricated objects are near net shape, but ma shape b t may inert h d i t shroud gas i often used t shield th melt is ft d to hi ld the lt require finish machining. pool from atmospheric oxygen for better control of properties, and to promote layer to layer SLS is at present the only adhesion by providing better surface wetting. other commercialized RP Stainless steel, Inconel, copper, aluminum, process that can produce titanium etc. can be used. metal parts directly.
19

Recap of Fundamental Rapid Prototyping Technologies

Slide 20

Recent Applications of Rapid Prototyping

Rapid prototyping systems can't yet produce parts in a wide enough range of materials, at a fast enough rate, to match the p q entire spectrum of requirements. An increasing number of applications are taking advantage of parts that are directly made by RP processes. In addition, RP is also often used as the starting point for making conventional fabrication f b i ti processes f t cheaper and better. faster, h d b tt Direct Processes

Specialized rapid prototyping processes have been developed to meet specific application and material requirements for molding and casting. These may be forms casting of basic RP processes, such as stereolithography or selective laser sintering, or may be unique RP methods developed for a specific application. Direct manufacturing has become a fast growing area in RP. Typically, Typically these requirements are for low volume items with complex geometries low-volume used in high value added applications such as medicine or aerospace. A part made by the RP system is used as a pattern or model for fabricating molds p y y p g through so-called indirect or secondary processes. Rapid Manufacturing Video Molds may be directly fabricated by an RP system
Slide 21

Indirect or Secondary Processes

Statement: This part has been produced by injection molding.

True? or False? Explain your answer.

CAD model Physical prototype

Slide 22

Rolls-Royce How Its Made Video

Rolls-Royce Craftsmanship Video

Slide 23