VACUUM CASTING

AN APPROACH TO RAPID PROTOTYPING

Collected & Arranged by . . .

What is Rapid Prototyping ?

The term Rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from ComputerAided Design (CAD) data. It is a free form fabrication technique by which a total object of prescribed shape, dimension and finish can be directly generated from the CAD based geometrical model stored in a computer,with little human intervention.

The Basic Process

Although several rapid prototyping techniques exist, all employ the same basic five-step process. The steps are: Create a CAD model of the design Convert the CAD model to STL format Slice the STL file into thin cross-sectional layers Construct the model one layer atop another Clean and finish the model

1. 2. 3. 4. 5.

Rapid prototyping Techniques

Most commercially available rapid prototyping machines use one of seven techniques Stereolithography Laminated Object Manufacturing Selective Laser Sintering Fused Deposition Modeling Solid Ground Curing 3-D Ink-Jet Printing Vacuum casting

Stereolithography
Patented in 1986 The model built on a platform A low-power highly focused
UV laser traces the first layer. An elevator incrementally lowers the platform into the liquid polymer Sweeper re-coats the solidified layer with liquid. This process is repeated until the prototype is complete.

Laminated object manufacturing

Developed by Helisys of
Torrance, CA, Layers of adhesive-coated sheet material bonded together to form a prototype. Feeder/collector mechanism advances the sheet over the build platform . Heated roller applies pressure to bond the paper. Focused laser cuts the outline of the first layer into the paper and then cross-hatches the excess area.

Selective Laser sintering

Developed by Carl Deckard and was patented in 1989. Uses a laser beam to selectively fuse powdered materials, into a solid object. Parts built upon a platform. A laser traces the pattern of the first layer, sintering it together. Platform lowered by the height of the next layer and powder is reapplied. Process continues until part is complete.

Fusion Deposition Modeling

Filaments of heated
thermoplastic extruded from tip. Controlled extrusion head deposits very thin beads of material . Platform maintained at lower temperature and the thermoplastic hardens . The platform lowers, the extrusion head deposits a second layer upon the first .

Solid Ground Curing

Developed by Cubital, America Inc. of Troy Michigan . The Basic Steps : Spray The resin on the build platform. Develop photomask of the layer built. Expose the mask to UV light. Vacuums up the excess resin. Spray Wax in its place. Top surface milled flat.

3-D Ink-Jet Printing

Developed by MIT and licensed to Soilgen. Parts are build upon platform . Ink jet printing head deposits binder to fuse powder together . Unbound powder supports part . Platform lowered,powder added,leveled and process repeated . Finished parts infiltrated with Wax or sealants.

Vacuum Casting
A modification of pressure casting used for producing metal matrix composites. This technique of plastic casting under vacuum and with a silicone mold was developed at the Technical Universities of Dresden and Cottbus, the former German Democratic Republic, in the Sixties.

How Vacuum Casting Works?

Producing a silicone
mould. Patterns of any material . The pattern is fitted with the casting Gate and set up on the parting line, and then suspended in the mould casting frame.

How Vacuum Casting Works(Contd..)?

De-aerated silicone
rubber poured into the mould casting frame around the pattern.

The mould hardened

inside the heating chamber.

How Vacuum Casting Works(Contd..)?

Pattern removed from
the silicone casting by cutting along parting line. Resins are measured, the casting funnels placed and the mould closed and sealed. For coloured components dye is added.

How Vacuum Casting Works(Contd..)?

Computer controlled
equipment mixes and pours resin inside Vacuum chamber.

After casting, resin

mould moved to heating chamber.

How Vacuum Casting Works(Contd..)?

After hardening, casting
is removed from silicone mould.Gates and risers cut off to make an exact copy of pattern.

The required components

can be painted or plated.

Automotive Rear Reflectors

Clean the master model and
if necessary apply barrier coating. Establish the model`s eventual parting line. Casting frame constructed from laminated chipboard. The model is suspended in the casting frame . De-gassed Silicone Rubber is then poured into the casting frame .

Automotive Rear Reflectors(contd..)

The tool is removed to
the oven to cure. Fully cured and removed from frame, silicone rubber is cut following visible parting line . The master model is then removed. The tool is taped together and prepared for casting .

Automotive Rear Reflectors(contd..)

Vacuum casting resins
A+B precisely measured by weight into respective containers. Cups A+B are placed in top and tool in lower of vacuum casting chambers. After curing in oven cast resin prototype is removed from the tool. Cast component is exact reproduction of master model.

Automotive Rear Reflectors(contd..)

Finally, checked for dimensional accuracy to master model the component is now ready for final finishing. MCP offers all users the specialized technology of producing multi coloured castings.

Vacuum Casting Using RTV

RTV-Room Temperature Vulcanizing A Method to manufacture upto 20 prototypes Prototype need not be made from any production material or follow any production process. SLA model can be used as a pattern.

The Process with RTV

RTV produces 3-d copies of
the SLA model. The material of the copies is Poly Urethane Resins (PUR). De-aerated silicon rubber is poured around the SLA model to produce a flexible rubber tool. De-aerated PUR components are mixed and poured into the tool under vacuum.

Vacuum casting of Wax models

Using heated cup module
highly complex and thin walled wax components can be produced . For Prototype metal parts other processes are long and costly process. By using Vacuum casting technology highly complex,accurate parts can be manufactured in a fraction of time and considerably less cost .

Applications of Vacuum Casting

Coupe convertibles
rigid folding roof for Valmet Automotives Ltd from RPI Alphaform company.

Independently

functioning Trilobite Vacuum cleaner for Electrolux from RPI Alphaform company.

Applications of Vacuum Casting (Contd..)

Saab was able to launch
its 9-3 sports sedan just in time .RPI Alphaform supported Saab by delivering the prototypes of bumpers, a front spoiler, a rear bumper skirt, rocker panels and a rear spoiler which were exclusively prototyped using Vacuum casting.

Applications of Vacuum Casting

(Contd..)

Hand Held Scanner

In-Car Mobile phone speaker

Applications of Vacuum Casting

(Contd..)

Virtual Reality Viewer

and control unit Housings of automotive airconditioners In-line skater in polypropylene type Mobile phones- colour matched in ABS type

Vacuum Casting Machines

One of the first,relatively simple
Vacuum casting systems with manual mixing and tilting unit.

An Italian machine with injection

into the Vacuum from outside by means of Cartridge gun.

A Japanese machine with the

characteristic bulls eyes is the predecessor of all modern Vacuum casting systems.

Advantages of Vacuum Casting

Strength, Elasticity and Temperature
Resistance. Typical quantities Standard accuracy Time Savings Surface structure Cost Use any type of model

Limitations of Vacuum Casting

Minimum wall thickness:
To ensure the mould is filled properly a wall thickness of at least 0.5mm is necessary. Maximum dimensions: The size of the mould is constrained by the measurement of the vacuum machine (800 x 690 x 660mm) and by the volume of the product (maximum volume: 4 litres). Initial tool equipment cost is comparatively high. Maximum/Minimum part Weights: 6 Kg / 2g

Conclusion
The Features of Vacuum Casting Are: Communicate your design intentions to your clients, toolmakers and to other departments easily and highly effectively. Reduced time to market. Shorter development cycles. Lower development costs. Shorter lead times in comparison to using conventional methods. Allows simple and effective design changes before expense of tooling

References
Material incress manufacturing by rapid prototyping
Techniques- J.P. Kruth Lecture materials of summer programme organised by IIT, Kharagpur in 2001 Internet Websiteswww.mcpgroup.com www.me.psu.edu www.alphaform.com And a lot of other Internet PDF files.

THANK YOU VERY MUCH