06_ASM_F24_Rapid Prototyping English Version.pptx

Rapid Prototyping English Version

1. Rapid Prototyping Federico Guedea Elizalde Feb-Jun 2024

2. What is rapid prototyping ? Rapid prototype design is the ability to quickly produce exactly tangible models of products designed under CAD systems. This new technology is based on the manufacturing process by material contribution (MIM - "Material Incress Manufacturing"), or Additive Manufacturing. The fundamental idea is to build an object by adding material instead of removing it as in the case of machining. Rapid Prototyping

3. It is a technique used to manufacture a sample of a new design quickly. These systems electronically divide the one-piece CAD model in thin cross sections and then transform the design, layer by layer, into a model physical or prototype . Rapid Prototyping Technologies

4. Technology that allows the creation of physical models of a product, prior to its industrialization The objectives of the Technology are: Aesthetics Dimensional Functional Experimental Benefits: Decrease costs Time reduction Existence of a physical model CAE on evaluation stage

5. Rapid Prototyping process 3D CAD modeling 3D CAD Model Surfaces completely closed or solid STL Model File STL generated in a workstation Geometry preparation and spliting Setup of RP machine parameters Built of the piece layer by layer On RP machine PIECE

6. Aditive Manufacturing Techniques BUILD CLASSIFICATION MATERIAL SOLIDIFICATION 2D 3D Liquids Solids Powder Photopolymers FDM Electro Fusion Deposit Fusion-solid Glue-solid Glue sheets Plastics layers semi-polymer

7. Stereolithography (SL) Denomination : Stereolithography Maker : 3D-Systems, (USA). Materials : Resines ( Ciba-Geigy ). Process Description : The piece is built on a horizontal platform submerged in a liquid resin. The solidification occurs point by point, by photopolymerization resulting from the incidence of a laser beam on the surface, which runs through "drawing" a series of cells that make up the 2D section corresponding to the cut made in the 3D CAD model at this height . In order to reduce the construction time, the sections of the piece are only partially solidified, except for the lower and upper face that must be totally so as to contain the non-polymerized liquid. The solidification of this liquid is carried out after all the layers are formed, in a post-curing operation in an oven.

8. Advantages of Stereolitography Stereolithography (SL) gives the power to touch, manipulate and evaluate a precise physical model of ideas in a few hours. Engineers can test and identify design errors early. SL models can be used to study the shape, assembly and function of the designed part, as well as serve as models for the creation of molds and to create a replica in Polyurethane or foundry. They allow design teams to visualize, verify, integrate and optimize design concepts. Stereolithography dramatically reduces the duration of a product's development cycle by 50% to 80%.

9. Stereolithography process This process uses a pool with a photosensitive resin with a vertically controlled table, has a servomotor with a laser focused on the resin. The laser traces the area of ​​each layer on the resin, the laser causes the resin to harden. The table goes up layer by layer to form the complete piece. The thickness of the layers varies between 0.0015 and 0.005 ”. https://www.youtube.com/watch?v=iceiNb_1E0I 52 seconds

10. Stereolithography Station

11. SLA Rapid Prototyping

12. SLA prototypes IRON PROTOTYPE JOYSTICK

13. Stereolithography (SLA)

14. Selective Laser Sintering (SLS) Denomination : Selective Laser Sintering (SLS). Maker : DTM, (USA). Materials : Casting wax , policarbonato, poliamida, poliamida fina, PVC, ABS. Process Description : The general principle of operation consists of a laser beam that travels a surface of powder-shaped material, solidifying successively different layers of material. The powder material is preheated to a temperature slightly lower than that of melting. Solidification is produced by the occasional incidence of a laser beam, which causes a warming above the sintering temperature. Dust grains that are not superheated remain unadhered , so that they act as support for successive layers and possible hanging parts of the piece. The remaining powder, not solidified, is subsequently removed at the end of the manufacturing process.

15. Advantages of Selective laser Sintering (SLS) While other systems are limited to a single material, Laser Selective Sintering not. With this system you have the parts in one day and, unlike other systems, the part does not have to receive any other subsequent treatment and can be used as it leaves the machine. Another advantage of the system is the possibility of making several pieces at the same time due to the possibility of stacking the pieces on top of each other.

16. Selective Laser Sintering Process Trace the figure of each cross section by fusing a thin layer of powder. A mechanical roller spreads more dust on the surface and the laser redraw another layer. Materials such as wax and polycarbonates are used. https://www.youtube.com/watch?v=9E5MfBAV_tA 2:30

17. Piece built using SLS

18. Laminated Object Manufacturing (LOM) Denomination : Laminated Object Manufacturing (LOM). Maker : Helisys , (USA). Materials : Paper and special polyesters for LOM. Process Description : The process is based on the adhesion of sheets of paper on top of each other, which are cut individually and at the precise depth by means of a laser beam. The cropping is done following the paths formed by the successive sections obtained, as in all the previous cases, of a 3D CAD model. The paper, more usual case, is self-adhesive, being its feeding by roll. The paper layer is glued to the previous one with the help of a roller heated to a predetermined temperature. Then a laser that travels in X, Y, cuts the paper according to the corresponding section. The excess paper is cut into grids so that it can be removed later. This sequence is repeated until construction is finished. .

19. Advantages of manufacturing with LOM The material used in the LOM can be paper, plastic or polyester. In the manufacture of the piece, each sheet is glued with an adhesive to the constructed part, then it is cut with the laser. LOM is 5 to 10 times faster than other rapid prototype processes, because the laser beam follows only the profile of each layer, and not of the total area. On the other hand, in the production of parts it is possible to have an accuracy of ± 0.03mm.

20. Process Manufacturing with LOM The parts are constructed of sections that are cut from thin sheets of materials such as plastics, paper or composite polyester, are glued with an adhesive and cut with a laser. https://www.youtube.com/watch?v=m0b3WIS2nqw&t=30s 3:27