1. Rapid Manufacturing Processes: Gear 39-245 Spring 2000 Carnegie Mellon University Brian Oosterman Eric Egenolf Niti Yongvanich

2. Characteristics of Gears: 2.5D: a geometry that can be described without any overhangs. High yield strength and hardness Simple, uniform section Smoothness Ductility Fatigue

3. Impossible Process: Stereolithography (SLA) Brittle (photosensitive polymer) Cool, Unnecessary Features Enhance the geometric visualization of a product Easily modified (any last minute changes) Fast, a prototype can be made in a matter of days http://www.stereolithography.com/slainfo.htm

4. Preferable Process: JP Systems Low material cost (using paper) Suited for education Not likely to get a perfect prototype the first time No particular level of accuracy is guaranteed. http://www.schroff.com/jpsystem5/index.htm

5. Other Possible Processes: Fused Deposition Manufacturing (FDM) Accurate to the size of the thread (0.07 inches) Shape Deposition Manufacturing (SDM) Retains a 3-D representation LaserCamm 2-dimensional cutter http://www.cs.cmu.edu/~rapidproto/students.99/jburnett/project2

6. Other Possible Processes: CyberCut Dimensional Tolerance ~ 0.001” to 0.01” CNC Machining Mills both 2 and 3 dimensional parts for models Create different degrees of rotation, allowing for more flexible designs Molding Quick and inexpensive