Rapid Prototyping

ver. 1

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Prof. J.S. Colton © GIT 2011
 Process

• Additive fabrication
– material is added, not removed
• Direct fabrication from a CAD file
• Layered manufacturing

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Prof. J.S. Colton © GIT 2011
 Layered Manufacturing -
Stereolithography
Laser
Mirror

Layered
Object
Vat

Platform

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Prof. J.S. Colton © GIT 2011
Rapid Prototyping Examples

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Prof. J.S. Colton © GIT 2011
 Process Examples
• Stereolithography (SL)
• Selective Laser Sintering (SLS)
• Wax jet printing (Thermojet)
• 3-D Printing
• Light Engineered Net Shaping (LENS)
• Fused Deposition Modeling (FDM)
• Solid Base Curing
• Laminated Object Modeling (LOM)

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Prof. J.S. Colton © GIT 2011
Stereolithography

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Prof. J.S. Colton © GIT 2011
 The
computational
steps in
producing a
stereolithography
file. (a) Three-
dimensional
description of
part. (b) The part
is divided into
slices (only one
in 10 is shown).
Stereo- (c) Support
material is
planned. (d) A
lithography set of tool
directions is
determined to
manufacture each
slice. Shown is
the extruder path
at section A-A
from (c), for a
fused-deposition-
modeling
operation.

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Prof. J.S. Colton © GIT 2011
Stereolithography Parts

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Prof. J.S. Colton © GIT 2011
Stereolithography

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Prof. J.S. Colton © GIT 2011
 Common Support Structures

Overhangs need support

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Prof. J.S. Colton © GIT 2011
Injection Mold Making Process
CAD
SLA-250
package

CAD Models SLA Build

Epoxy Injection
Back Fill Mold

Back Filled Inserts Plastic Part

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Prof. J.S. Colton © GIT 2011
Stereolithography Mold

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Prof. J.S. Colton © GIT 2011
Rapid Tooling - Quick Cast

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Prof. J.S. Colton © GIT 2011
Rapid Tooling - Quick Cast

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Prof. J.S. Colton © GIT 2011
Selective Laser Sintering

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Prof. J.S. Colton © GIT 2011
Selective Laser Sintering
(3D Systems)

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Prof. J.S. Colton © GIT 2011
 SLS Parts

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Prof. J.S. Colton © GIT 2011
 Direct Metal Laser Sintering

• http://www.youtube.com/watch?v=88BP
mL8cGAo
• http://www.youtube.com/watch?v=DW-
2xaIDtMk&feature=related

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Prof. J.S. Colton © GIT 2011
Wax Jet Printing - Thermojet

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Prof. J.S. Colton © GIT 2011
 Thermojet

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Prof. J.S. Colton © GIT 2011
Three-Dimensional Printing

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Prof. J.S. Colton © GIT 2011
 Z Corp Machine

http://www.youtube.com/watch?v=ZboxMsSz5Aw&feature=youtu
be_gdata_player

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Prof. J.S. Colton © GIT 2011
3D Printing Head (Soligen)

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Prof. J.S. Colton © GIT 2011
 Soligen

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Prof. J.S. Colton © GIT 2011
Light Engineered Net Shaping (1)
(Sandia National Lab)

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Prof. J.S. Colton © GIT 2011
Light Engineered Net Shaping (2)
(Sandia National Lab)

Laser

Powder
delivery
tube

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Prof. J.S. Colton © GIT 2011
Light Engineered Net Shaping (3)
(Sandia National Lab)

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Prof. J.S. Colton © GIT 2011
Light Engineered Net Shaping Parts
(Sandia National Lab)

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Prof. J.S. Colton © GIT 2011
Fused Deposition Modeling (FDM)-
(Stratasys)

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Prof. J.S. Colton © GIT 2011
 Direct Metal Writing

• http://www.youtube.com/watch?v=gcIdS
BxtO1Q&feature=related
• http://www.youtube.com/watch?v=SYbw
1oSzPVA&feature=related
• http://www.youtube.com/watch?v=iLndY
Ww5_y8

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Prof. J.S. Colton © GIT 2011
 FDM Parts

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Prof. J.S. Colton © GIT 2011
FDM Prototype Biosensor

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Prof. J.S. Colton © GIT 2011
Solid-Base Curing - Cubital Solider

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Prof. J.S. Colton © GIT 2011
Solid Base Curing

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Prof. J.S. Colton © GIT 2011
Laminated Object Manufacturing
(LOM) - (Helisys)

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Prof. J.S. Colton © GIT 2011
Laminated Object Manufacturing

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Prof. J.S. Colton © GIT 2011
 Summary
• Additive fabrication • Stereolithography (SL)
– material is added, • Selective Laser Sintering
(SLS)
not removed
• Wax jet printing (Thermojet)
• Direct fabrication • 3-D Printing
from a CAD file • Light Engineered Net Shaping
(LENS)
• Layered • Fused Deposition Modeling
manufacturing (FDM)
• Solid Base Curing
• Laminated Object Modeling
(LOM)

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Prof. J.S. Colton © GIT 2011
ME 4210: Manufacturing Processes and Engineering 38
Prof. J.S. Colton © GIT 2011