2006-02 CAD/CAM RP (Rapid Prototyping)ocw.snu.ac.kr/sites/default/files/NOTE/218.pdf · Rapid...
Transcript of 2006-02 CAD/CAM RP (Rapid Prototyping)ocw.snu.ac.kr/sites/default/files/NOTE/218.pdf · Rapid...
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Prof. Sung-Hoon Ahn
2006-11-06
2006-02 CAD/CAM
RP (Rapid Prototyping)
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NASA: Fabrication in Space
FDM1600 test at zero gravityJohnson Space Center & Marshall Space Flight Center, 2000
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Requirements in Product Development
Functional or aesthetic assessmentCommunication aids, visualizationAssemblability checking
25 or 30% of product development budget are spent on physical prototypes and testing
Rapid Prototyping fabricates a part of arbitrary shape directly from CAD model by forming thin layers of the part layer by layer
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Introduction to RP
Other name of RPLayered Manufacturing Rapid Prototyping and ManufacturingSolid Freeform Fabrication (SFF)
Group of related technologies that are used to fabricate physical objects directly from CAD dataAdd and bond materials in layers to form objectsOffer advantages compared to classical subtractive fabrication methods
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Basic Idea
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Advantages of RP
No need to define a blank geometry
No need to define set-ups and material handling
No need to consider jigs, fixtures, and clamping
No need to design mold and die
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General System Configuration of RP
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Stereo Lithography Process
Geometry Input : STL file formatDeveloped for STereo LithographyDe facto standard for RP dataMost CAD systems support STL format
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Stereo Lithography Process (cont.)
STL file formats
(a) ASCII (b) Binary
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Stereo Lithography Process (cont.)
Typical Errors in STL file
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Stereo Lithography Process (cont.)
Surface roughness vs. build time
Stair-Step Effect
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Stereo Lithography Process (cont.)
Support Structures
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Stereo Lithography Process (cont.)
Post-processingDetermination of Build-up direction
AccuracyBuild-up speedTrapped volumeNecessity of support structure
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Issues in RP
Accuracy and Surface FinishMaterial
Stereo Lithography Resins Metals Ceramics and Paper
CostEquipment Maintenance
Time
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1. Stereo Lithography Apparatus (SLA)
Developed by 3D Systems, IncLaser beam will scan the surface following the contours of the sliceCommercial machines & Applications
Skull Manifold
SLA-3500
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Developed by 3D Systems, IncThe laser beam will scan the surface following the contours of the slice.
1. StereoLithography Appratus (SLA)
SLA-3500
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SLA(SL)
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Developed by The University of Texas at AustinPowders are spread over a platform by a roller. A laser sinters selected areas causing the particles to melt and then solidify.
2. Selective Laser Sintering (SLS)
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Developed by HelysisThe undersurface of the foil has a binder that when pressed and heated by the roller causes it to glue to the previous foil. The foil is cut by a laser following the contour of the slice.
3. Laminated Object Modeling (LOM)
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LOM process
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4. Fused Deposition Modeling (FDM)
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Fused Deposition Modeling (FDM)
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FDM head
foam bed
model head
support head
x-axis track
z-axis track
heating units
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5. 3D Printers
Developed at MITParts are built upon a platform situated in a bin full of powder material.
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6. Solid Ground Curing (SGC)
Developed and commercialized by Cubital Ltd. (Israel).Uses a Photopolymer, sensitive to UV-light.The vat moves horizontally as well as vertically.The horizontal movements take the workspace to different stations in the machine.
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SGS Process
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7. Shape Deposition Manufacturing (SDM)
Developed by Stanford University/CMUUses deposition and millingProvides good surface finish
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Issues in RP Materials
Rapid Fabrication of functional partsStructuralOpticalSurface RoughnessElectricalThermalColor… … …
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STL file – Tesselated Stereolithography file – export from solid modeling package
SSL file – Sliced Layer File, Support Calculation – Proper part orientation can drastically affect build time, support requirements, and part strength
SML file – Rastors, Build Parameters, time estimation
FDM Software – Three Levels
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Tesselated(Triangulated) formatStandardized Export TypeQuicksliceLayout
STL File – Collapsible Shovel Head
Source: Quickslice, Stratasys
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Vertically Sliced FileOrientation Important!Unsupported Material will fall
SSL File – Unsupported, Front View
Source: Quickslice, Stratasys
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Support Calculation45° Support ruleFoam SubstrateFoam Irregularities
SSL File – Supported, Front View
Source: Quickslice, Stratasys
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SSL File – Supported, Isometric View
Support Base (Blue)Removing Support MaterialCalculation and Removal can be time intensive
Source: Quickslice, Stratasys
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SML File – Supported, Isometric View
Road GenerationColored Layer of SSL file determines road orientationRoad type and orientation strongly affects build time and part strength
Source: Quickslice, Stratasys
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Rastorsoriented at 45° angle (FDM material behaves like a composite)Note loose fill of support material –easier to break and quicker to build
SML File – Supported, Top Layer
Source: Quickslice, Stratasys
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FDM Build Parameters - Software
Perimeters, Contours, Rastors (Road type)Perimeter: Follows outer shape of current slice-ideal for cosmetic outer surfaceContour: Follows shape of perimeter on part interior – not commonly used as it leaves gapsRastors: Standard back and forth part fill – adds strength to part, composite theory (rastor angles)
Road width - Dependant on nozzle size and feed rate –ranges from .012 to .0396 for T12 nozzleAir Gap – gap between roads – allows for tightly fused, strong surface, or sparse, quick building fill
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Micro Structure of FDM
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FDM Process
Assembled Part
PartPost-process of FDM
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Raw FDM ABSi After InfiltrationDuring Infiltration
0
0.1
0.2
0.3
0.4
0.5
0.6
800 760 720 680 640 600 560 520 480 440 400
Wave length(nm)
Tra
nsm
issiv
ity(
%)
0
5
10
15
20
25
-0.003 0 0.003
Air Gap(inch)
Tra
nsm
issi
vity
(%)
Raw material Infiltration Infiltration+Sanding
Resin Infiltration
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Post-process : 24 hours
Total prototyping time : 39 hours
CATIA modeling:
5 hours
FDM process:
10 hours
Flash Memory Reader
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Gallery
Z- corp (3D Printer)
Designed by Carlo H. Sequin
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Gallery (cont.)
Z- corp (3D Printer)
Designed by Carlo H. Sequin
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Gallery (cont.)
Z- corp (3D Printer)
Designed by Carlo H. Sequin
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Applications
Architectures
A machine mounted on rails might be used to build multiple houses.
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Applications (cont.)
Materialization of arts
The original Volomandra Kouros and the SLA replica
Lifting the kouros out of the Mammoth.
Source: Materialize
Source: Materialize
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Applications (cont.)
Micro component
Micro robot by Sandia Lab
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Applications (cont.)
Rapid Tooling (RT)
DTM's RapidTool™ process for rapid mold making
Core and cavity sets produced by RapidTool ™
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Applications (cont.)
Other Examples
PZT Sensor ; J. E. Smay et al. J. Am. Ceram. Soc.
Electrode ; A. Safari et al. IEEE
Sensor and Actuator
P. Kumar at al, Ann Arbor
Patterning with Ceramic
Artificial ear
Y. Tan et al.Am. Ceram. Soc.
Artificial Bone and Ear
Artificial bone
Microreactor
R. Knitter at al.RP Journal Bio-compatible Material
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Hybrid RP System
Dispenser
X and Y axis control
Z axis control
High speed spindle
Micro needle
UV lamp Microscope
Granite Base
Micro endmill
1㎛ resolution15 ~ 700 kPa
140 ㎛ ~ 800 ㎛100 ㎛ ~ 1000 ㎛
Max. 46,000rpm0 ~ 400 W, λ = 365 ㎚PMAC (Multi-tasking board)
3 Axes-stageDispenser
Micro needleMicro tool
High speed spindleUV curing system
Controller
SPECIFICATIONS
φφ φ
Deposition; Rapid Prototyping
Cutting; Milling
Hybrid; Both
Micro needle Micro endmill
φ
Hardware
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Hybrid RP System (cont.)
Micro needle
Air cylinder High speed spindle
Micro tool
Barrel I Barrel II
Micrometer
Hybrid process: depositing + machining
Conceptual process of NCDS
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Hybrid RP System (cont.)
Deposition Machining
Part material
Support material
3D MODEL
SLICING
DEPOSITION
CURING
POST-PROCESS
LAST LAYER ?
DEPOSITION
CURING
MACHINING
LAST LAYER ?
CONV
ENTI
ONAL
DEP
OSIT
ON S
YSTE
M
HYBR
ID S
YSTE
M
YES
YES
NO
NO
PROCESS PLANNING
3D PART
Machining
SupportMolding/ Casting
Heat Demolding
Part Deposition
Machining
Deposition and Machining
Process planning
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φ
φ
φ
φ
φ
3.4
mm
3.0mm
Microscope picture of microgearMicroscope picture of microgear
Geometry of stapes Geometry of stapes
Micro GearA gear geometry with 2.9mm was fabricated 5wt% MWCNT + Acrylic resinDispensing process using 300㎛ needle
micro milling using 100㎛ flat endmill
StapesThe smallest bone in human body, width 2.5mm/ height 3.5mm 40wt% Hydroxyapatite + Acrylic resinDispensing process using 140㎛ needle
micro milling using 100㎛ flat endmillMold (using wax) machining → part deposition → surface machining → demolding
Fabrication time
Parts Average Time (min)Micro Gear 2
Stapes 15
Nano composite parts
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Scaffold for Bone Growth
PLGA 85/15 PLGA 85/15 + 10wt% HA
Size; Φ 5mm × 10mm
Bio-degradable polymer
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Drug Delivery System (DDS)
Specimen for Zero-order Release Test
Scaffold Shape of DDS (Controlled Pore Size)
Container
Drug Delivery Device
Fabricated container and drug delivery device
Fabricated drug delivery device of scaffold shape (15layers, [0˚8/90˚7], 5mm×5mm)
Burst