Slective Laser Sintering

8/8/2019 Slective Laser Sintering

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Selective Laser Sintering (SLS, registeredtrademark by DTM of Austin, Texas, USA) is a

process that was patented in 1989 by Carl

Deckard, a University of Texas graduate student

The selective laser sintering stations (SLS) use aplastic powder to create prototype parts. The

powder is melted, layer by layer, by a computer-directed heat laser. Additional powder is depositedon top of each solidified layer and again sintered.


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PROCESSPROCESS

a laser beam is traced over the surface of a tightlya laser beam is traced over the surface of a tightlycompacted powder made of thermoplastic material .compacted powder made of thermoplastic material .

The powder is spread by a roller over the surface of aThe powder is spread by a roller over the surface of a

build cylinder .build cylinder . A piston moves down one object layer thickness toA piston moves down one object layer thickness to

accommodate the layer of powder.accommodate the layer of powder.

The powder supply system is similar in function to theThe powder supply system is similar in function to the

build cylinder. It also comprises a cylinder and piston.build cylinder. It also comprises a cylinder and piston.In this case the piston moves upward incrementally toIn this case the piston moves upward incrementally tosupply powder for the process.supply powder for the process.


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PROCESSPROCESS

Heat from the laser melts the powder where it strikesHeat from the laser melts the powder where it strikesunder guidance of the scanner system .under guidance of the scanner system .

The CO2 laser used provides a concentrated infraredThe CO2 laser used provides a concentrated infrared

heating beam. The entire fabrication chamber is sealedheating beam. The entire fabrication chamber is sealedand maintained at a temperature just below the meltingand maintained at a temperature just below the meltingpoint of the plastic powder.point of the plastic powder.

Thus, heat from the laser need only elevate theThus, heat from the laser need only elevate thetemperature slightly to cause sintering, greatly speedingtemperature slightly to cause sintering, greatly speeding

the process.the process. A nitrogen atmosphere is also maintained in theA nitrogen atmosphere is also maintained in the

fabrication chamber which prevents the possibility offabrication chamber which prevents the possibility ofexplosion in the handling of large quantities of powder.explosion in the handling of large quantities of powder.


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SINTERSTATION 2500SINTERSTATION 2500PLUSPLUS

Build chamber dimensionBuild chamber dimension 381 x 330 x 457 mm381 x 330 x 457 mm

LaserLaser 50 or 100 Watt CO50 or 100 Watt CO22 (beam dia= 0.420 mm)(beam dia= 0.420 mm)

Beam delivery systemBeam delivery system M3St Galvanometer 3 axis Scan speed =M3St Galvanometer 3 axis Scan speed =5.000mm/s positional accuracy = 50mm5.000mm/s positional accuracy = 50mm

SoftwareSoftware Windows NT DTM sinterstation system softwareWindows NT DTM sinterstation system software

materialize NV, magicsmaterialize NV, magics

Computer systemComputer system Pentium based controllerPentium based controller


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SINTERSTATION 2500SINTERSTATION 2500PLUSPLUS

System dimensionsSystem dimensions Process station =2133 x 1346 x 1981 mmProcess station =2133 x 1346 x 1981 mm

Computer cabinet =609 x 609 x 1828mmComputer cabinet =609 x 609 x 1828mm

Chiller = 533 x 838 x 914 mmChiller = 533 x 838 x 914 mm

PeripheralsPeripherals Breakout station/ air handler/ sifter, vacuum cleanerBreakout station/ air handler/ sifter, vacuum cleaner

Power requirementsPower requirements 240 VAC,12.5 KVA,50/60Hz, 3240 VAC,12.5 KVA,50/60Hz, 3--phasephase

Nitrogen requirementsNitrogen requirements Purity = 99.9%Purity = 99.9%Minimum pressure = 1.7 barsMinimum pressure = 1.7 bars

Continuous flow rate= 191lpmContinuous flow rate= 191lpm

AtmosphericAtmosphericrequirementsrequirements

Temperature range = 15Temperature range = 1500 to 27to 2700 CC

Relative humidity =


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EOSIHT P350EOSIHT P350

Building volumeBuilding volume 340 x 340 x 600 mm340 x 340 x 600 mm33

Laser typeLaser type COCO22,50W,50W

Laser scan speedLaser scan speed Up to 5m/sUp to 5m/s

Building speedBuilding speed 1010--25 mm height25 mm height

Layer thicknessLayer thickness 0.10.1--0.2 mm0.2 mm

Process computerProcess computer PCPC

Electrical supplyElectrical supply 400 V, 32 A400 V, 32 A


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EOSIHT P350EOSIHT P350

Compressed air supplyCompressed air supply Minimum 5.000 hPa, 6mMinimum 5.000 hPa, 6m33/h/h

Cooling water supplyCooling water supply 1.500hPa1.500hPa--4.000HpA, 5 l/min4.000HpA, 5 l/min

Dimensions mmDimensions mm Process cabinet 1.250 x 1.300 x 2.150Process cabinet 1.250 x 1.300 x 2.150Control cabinet 610 x 820 x 1.785Control cabinet 610 x 820 x 1.785

WeightWeight Approx. 800kg Approx. 800kg

WorkstationWorkstation Silicon graphics indigoSilicon graphics indigo

PCPC Windows 95, windows NTWindows 95, windows NT

Interface to CADInterface to CAD Standard : STL,CLIStandard : STL,CLI

Optional : VDAOptional : VDA--FS,IGES,CATIAFS,IGES,CATIA


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ADVANTAGESADVANTAGES

Parts and/or assemblies that move and work that have a goodParts and/or assemblies that move and work that have a goodsurface finish and feature detailsurface finish and feature detail

Selective laser sintering (SLS) gives the capability of flexibleSelective laser sintering (SLS) gives the capability of flexiblesnaps and living hinges as well as high stress and heat tolerancesnaps and living hinges as well as high stress and heat tolerance

Wide variety of materials such as flexible and rigid plastics,Wide variety of materials such as flexible and rigid plastics,electrometric materials, fully dense metals and casting patternselectrometric materials, fully dense metals and casting patterns

inexpensive materialsinexpensive materials

safe materialssafe materials

supports not neededsupports not needed reduced distortion from stressesreduced distortion from stresses

produce parts simultaneouslyproduce parts simultaneously


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DISADVANTAGESDISADVANTAGES

rough surface finish ("stair step effect")rough surface finish ("stair step effect")

porosity of partsporosity of parts

the first layers may require a base anchor tothe first layers may require a base anchor toreduce thermal effects (e.g. curl)reduce thermal effects (e.g. curl)

part density may varypart density may vary

material changes require cleaning of machinematerial changes require cleaning of machine


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APPLICATIONSAPPLICATIONS

Parts for mechanical and thermal testsParts for mechanical and thermal tests

Series of small plastic partsSeries of small plastic parts

Large and complex functional partsLarge and complex functional parts Master patterns for castings and secondaryMaster patterns for castings and secondary

processesprocesses

Functional models.Functional models.


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Case Study 1:Case Study 1:

One of the early products developed by ARAD was theOne of the early products developed by ARAD was theMoonshine and the Moonshine Magnum. These products wereMoonshine and the Moonshine Magnum. These products weredeveloped for a major aquatic product distributor and aredeveloped for a major aquatic product distributor and are

currently sold to marine/reef aquarists worldwide.currently sold to marine/reef aquarists worldwide. The design intent was to create a light source that providesThe design intent was to create a light source that provides

artificial moonlight to the reef aquarium. The light emittedartificial moonlight to the reef aquarium. The light emittedsimulates natural moonlight and promotes photosynthesis,simulates natural moonlight and promotes photosynthesis,healthy feeding and reproductive behavior in the life cycle ofhealthy feeding and reproductive behavior in the life cycle ofinvertebrates and other marine organisms.invertebrates and other marine organisms.

Responding to the client needs, ARAD was able to realize theResponding to the client needs, ARAD was able to realize thedesign objectives in a compact, convenient and cost effectivedesign objectives in a compact, convenient and cost effectivedevice using our design expertise and state of the art LEDdevice using our design expertise and state of the art LEDtechnology. The finished products were then produced bytechnology. The finished products were then produced by

ARAD at its US based facility.ARAD at its US based facility.


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Case Study 2:Case Study 2:

ARAD was asked if its LED moonlight technology could beARAD was asked if its LED moonlight technology could beretroretro--fitted to be housed in metal halide fixtures. The designfitted to be housed in metal halide fixtures. The designrequirement from the customer was to provide ARADsrequirement from the customer was to provide ARADsMoonlight technology in a structure that will withstand theMoonlight technology in a structure that will withstand the

extremely high temperature found inside metal halide assemblies.extremely high temperature found inside metal halide assemblies. There was no comparable product in existence and attempts byThere was no comparable product in existence and attempts by

other designers were unsuccessful. Drawing its expertise in metalother designers were unsuccessful. Drawing its expertise in metaldesign, ARAD designs a LED light encased in a sleek metaldesign, ARAD designs a LED light encased in a sleek metalhousing. The product becomes very popular as this is thehousing. The product becomes very popular as this is the

industrys first successful and productionindustrys first successful and production--ready combination ofready combination ofmetal halide and LED lights. To date there is still not a productmetal halide and LED lights. To date there is still not a productout there like it.out there like it.


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Slective Laser Sintering

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