EML 2023 – Rapid Prototyping Lecture 1 – Additive Rapid Prototyping

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 2

EML 2023 Department of Mechanical and Aerospace Engineering Selective laser sintering (SLS) additive technique layer of powder placed on base high power laser used to fuse selected parts of the powder the powder bed is lowered a small amount and a new layer of powder is spread does not require any support structures 3

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 4

EML 2023 Department of Mechanical and Aerospace Engineering Fused deposition modeling (FDM) additive technique material is laid down in layers plastic material is melted in a nozzle that moves in XY direction typically uses ABS plastic support material is required 5 stratasys

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 6

EML 2023 Department of Mechanical and Aerospace Engineering Stereolithography (SLA) additive process uses a vat of liquid UV-curable resin and a UV laser exposure to the laser causes the material to harden after a pattern has been traced, the platform descends and a resin filled blade recoats the top requires support structures 7

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 8

EML 2023 Department of Mechanical and Aerospace Engineering Laminated object manufacturing (LOM) sheet is adhered to substrate with a heated roller laser traces out the outline of the layer non-part areas are cross- hatched to facilitate removal of waste material next layer is pulled across and the process is repeated 9

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 10

EML 2023 Department of Mechanical and Aerospace Engineering Electron beam melting (EBM) metal parts are made from a metal powder a layer of powder is spread and the part region is melted together by a computer controlled electron beam 11

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 12

EML 2023 Department of Mechanical and Aerospace Engineering 3D printing (3DP) “inkjet” type process a fine powder of plaster or corn starch is bonded by “printing” an adhesive from the printhead considered the fastest technique 13 zcorp

EML 2023 Department of Mechanical and Aerospace Engineering Technologies Prototyping TechnologiesBase Materials Selective laser sintering (SLS)Thermoplastics, metal powders Fused deposition modeling (FDM)Thermoplastics, eutectic metals Stereolithography (SLA)Photopolymer Laminated object manufacturing (LOM)Paper Electron beam melting (EBM)Titanium alloys 3D printing (3DP)Various Materials 14

EML 2023 Department of Mechanical and Aerospace Engineering UF machines - FDM Dimension 1200es SST (Soluble Support Technology) 15 Building MAE-B Room 313

UF Rapid Prototyping Machines 16 8  6  8” build volume 10  10  12” build volume sodium hydroxide & water tank

EML 2023 Department of Mechanical and Aerospace Engineering former UF machine - FDM 17

Existing Equipment 2 Dimension sst 1200es Rapid Proto Machines –ABS plastic –10  10  12” build volume –.010” z-axis,.005” xy-axis resolution Roland MDX-540 Subtractive R.P. machine –plastic, wood, aluminum –4 axis ; 4 tool magazine –4  4  12” build volume –.0008” repeat accuracy

EML 2023 Department of Mechanical and Aerospace Engineering Existing Equipment Next Engine 3D Scanner –5  4” macro field of view –13.5  10” wide field of view –.005” accuracy

EML 2023 Department of Mechanical and Aerospace Engineering Equipment to be delivered Fortus 360mc Rapid Proto Machine –ABS plastic, Nylon, polycarbonate –16  14  16” build volume –.005” accuracy –1.5 speed compared to existing machines

EML 2023 Department of Mechanical and Aerospace Engineering Equipment to be delivered Medium Machinery Plastic Injection Molding –2 oz. shot capacity –12 ton clamping force –13,500 psi pressure –8  8  4” max mold size

EML 2023 Department of Mechanical and Aerospace Engineering MAE-B 313 Lab Renovation Plan

EML 2023 Department of Mechanical and Aerospace Engineering Steps to Create a Part 1.Model part (or assembly) in SolidWorks. 2.Save part (or assembly) file in.stl format. –Note: To save an assembly as one single.stl file, go to Options and check the box next to ‘ Save all components of an assembly in a single file’. 3.Run the Catalyst software. Orient the part on the build tray and send to rapid proto machine. 23

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