SOLID AND LIQUID BASED

RAPID PROTOTYPE
SYSTEMS
TOPICS
• Working Principle
• Materials
• Advantages
• Limitations and Applications of Fusion Deposition Modelling (FDM)
• Laminated Object Manufacturing (LOM)
• Stereo lithography (SLA)
• Direct Light Projection System (DLP)
• Solid Ground Curing (SGC).
STEREOLITHO GRAPHY LIQUID (SLA)
STEREOLITHOGRAPHY(SLA) uses a laser to cure UV curable resin to build parts from a pool of liquid
resins .they are best for lower end function prototype ,patterns moulid and production tools. STEREOLITHO
GRAPHT LIQUID (SLA) provides product designers and engineers with the ability to rapid prototype parts
with the excellent surface finish and good dimensional accuracy.

RESIGN

Resign is a solid (or) highly viscous substance at plant on synthetic orgin that is typically convertible into
polymers.

POLYMER

polymer is any of a class of natural or synthetic substances composed of very large molecules called macro
molecules which are multiple at simpler chemical units called monomers
Polymers make up many of the materials in living organisms and are the basic at mans minerals and manmade
materials

EX:-
Polyethylene ,Rubber ,Nylon , silk ,wool ,DNA ,Cellulose
STEREOLITHO GRAPHY APPLICATIONS

• Fit /form proof of concept prototypes and engineering verifications.

• Investment casting patterns.
• Rapid tooling ,jigs and fixtures.
• Scale and exhibition models.
• Optics and transparent covers
• Molds and casting patterns.

MATERIALS

• Tough and durable resigns

• Flexible resins
• Elastic resins
• Rigid resins

ADVANTAGES
1. Reasonably priced
2. Quick faster is suitable for any cost metal
3. Excellent surface finish for AM(RP) parts
4. Mature technology with a comprehensive material selections
5. Accurate prototype
LIMITIONS / DISADVANTAGES OF STEREOLITHO GRAPHY (SLG)

❖ Low strengths compared to other rapid prototype technology limiting some functional testing
❖ Highly initial investment
❖ Overtime resign become brittle
❖ Require support structures and slower speed
❖ Not suitable for office environment

LAMINATED OBJECT MANUFACTURING(LOM)

Laminated object manufacturing uses a building platform onto which the sheets of material can be rolled
out. The materials are usually coated with the adhesive layers is heated by a feeding roller to melt the adhesive.
In this way each layer can be glued to previous one to build up an object.
ADHESIVE
Adhesive(or) Adhesive bonding is the process of joining two surfaces usually with the creation
of a smooth ,band . This may involve the use of use of give epoxy or one of a wide range of plastic
agents which band either through the evaporation of a solvent (or) through curing via heat time (or)
pressure .
WORKING PRINCIPAL OF LAMINATED OBJECT MANUFACTURING(LOM)
• A company called HELISYS [succeeded by an organ section called cubic technologies] created laminated object
manufacturing in 1991.
• Present MCCORMACK brothers continued to develop the process
WORK FLOW OF LAMINATED OBJECT MANUFACTURING(LOM)

A blade or laser is used to draw out the geometry of the object as well as cross hatching excess
material to facilitate the removal of waste.
Once a layer has been glued into place and the required dimensions drawn ,the build platform moves down
so another layer of material can be rolled into position with the heated roller. This process is repeated until the
model (or) prototype is complete.

MATERIALS

papers and polymers

APPLICATIONS OF LAMINATED OBJECT MANUFACTURING(LOM)

Despite the challenges and disadvantages of LOM

❖ The process remains an excellent option for conceptual prototyping due to the speed and low cost of the
process.
❖ Scale models can also be created using laminated object manufacturing.
❖ While the use of color inks and paper also allows for the creation of inexpensive yet eye – catting 3D
promotional items.
ADVANTAGES OF LAMINATED OBJECT MANUFACTURING(LOM)

• Quick and inexpensive manufacturing of large parts.

• No support material required.
• Companies can use a computer – generated and efficiently build a prototype from inexpensive build
materials like paper ,making LOM preferable for rapid prototyping than other manufacturing processes ,3D
printing.
• LOM process can be used to create both solid and Hallow objects ,including large parts ,faster and for less
cost than with stand and additive manufacturing.
• Relatively large parts can be created easily as there is no chemical reaction in the build process.

DISADVANTAGES OF LAMINATED OBJECT MANUFACTURING(LOM)

• Delicate wood –like parts often with insufficient strength ,wooden parts absorb moisture.
• Poor surface finish.
• Breaking out of parts is difficult.
• LOM is a subtractive process ,it is not as easy to produce complex geometric shapes as with other 3D
printing processes.
• LOM process depending on the material used.
FUSION DEPOSITION MODEL(FDM)
• Fusion deposition modeling is a liquid type or liquid based rapid proto type technology.
• Basically FBM is a liquid type but not fully liquid based.

INTERDUCTION OF FUSION DEPOSITION MODEL(FDM)

FDM is a rapid prototype manufacturing technology commonly used for modeling prototype and
production applications.

WORKING PRINCIPLE

The layer of materials are fused together in a pattern to create objects the material (filament) is melted in
the printer’s nozzle just past it’s glass transition temperature and then extruded in a pattern next to or on top of
previous extrusions creating objects layer by layer.

EXTRUSION AND DEPOSITION

WORKING PROCESS OF FDM
1. Heat the nozzle until it reaches the desired temperature. The filament will be fed to the extrusion head and
then it will be melts in the nozzle.
2. The extrusion head can move in the X,Y,Z directions. The extrusion head extrudes melted material in very
thin strands. The material is deposited layer by layer on the platform and then will be cool and solid.
3. When one layer is finished the build platform will move down and a new layer will be deposited. This
process repeats until the part is completed.
MATERIALS OF FDM

❖ ACRYLONITRILE BUTADIENE STYRENE(ABS)

Most widely used material in FDM. It has superior hardness ,gloss toughness and electrical insulation
properties .They are stable and highly resistant to wrapping ,moisture absorption and shrinkages.
❖ POLY LACTIC ACID
BIO –Degradable thermoplastic ,most environment friendly . But little brittle , Once it has cooled down.
APPLICATIONS
❖ AEROSPACE/DEFENSE/AUTOMOBILE INDUSTRY
• For concept modelling
• Airbus is using start a sys based FDM machines to print aircraft parts
• NASA is using FDM parts for their next project
❖ DIGITAL DENTISTRY
❖ EYE CARE
• Prosthetic eye balls
• Instrument for eye care
❖ PROTHEETIC HAND
• Hands
• Legs fingers..,etc

ADVANTAGES
• FDM technology is a safer process. No toxic fumes release in the process.
• Machines very less expensive compare to the other rapid prototype technology.
• FDM is faster than stereo lithography (SLI)
• Because of ABS material FDM process is water proof
• High strength compare to the other rapid prototypes
• We acquire multiple colors
DISADVANTAGES
• Dimensions tolerances are not ass accurate
• Surface finish is not as good
 DIRECT LIGHT PROJECTION(DLP)
Direct light processing is a set of a set of chipsets based on optical micro-electro-mechanical
technology that uses a “DIGITAL MICRO MIRROR device(DMD)”.

WORKING PRINCIPLE OF DIRECT LIGHT PROJECTION(DLP)

The DIRECT LIGHT PROJECTION(DLP) process accept STL files or CDA files that can be cut into
byers in preparation for printing using a SO. SO is called as “SLICING software”.
The printers build platform is submerged in a vat of liquid resin and a digital light source projects each laser
onto it. The light cause the resin to cure onto the platform creating a solid sliver of the port layers are built on top
of each other until and each layer has completed where the port is then removed from the build platform
For past processing DIRECT LIGHT PROJECTION(DLP) prints are sought after for their enhanced accurses and
resolution .

WORKING FLOW OF DIRECT LIGHT PROJECTION(DLP)

In Direct light projection Required a computer which gives input to the projector. In DLP the projector
plays a major (or) key role. In this process we have a moving table which is placed on top and it moves upwards
and downwards Vertically. The main process are happens in the DLP is "layer by layer process". It Require tank
and use liquid polymer and light Curing Resin. When the projector emitted the light through the DLP process
from the input of computers. They give desired shape which receive from the (SIL)"Standard tessellation
language" from 3D CAD by lager by layer process. In the process of DLP the 3D Model Extracted in the tank.
MATERIALS USED IN DIRECT LIGHT PROJECTION(DLP)
1. NYLON
2. ABS
3. THERMOPLASTICS

APPLICATIONS IN DIRECT LIGHT PROJECTION(DLP)

1. It can point objects with higher with higher “Resolution”.
2. It can useful in circuit design.
3. Best Surface finishing.
4. Complicated jeweler design easily.
5. Mil craft high Resolution 3D printer.
6. Envision Tech ultra.
7. LUNVAST XG-2.

ADVANTAGES IN DIRECT LIGHT PROJECTION(DLP)

1. Largest possible pictures.
2. Smaller Images a great option also.
3. Low Cost.
4. Space saving.
5. Easy to install.
DISADVANTAGES IN DIRECT LIGHT PROJECTION(DLP)

1. Dark room often Required.

2. Maintenance Required.
3. Rainbow artifacts.
4. Separate Audio System Required.

FUTHER PROCESSING IN DIRECT LIGHT PROJECTION(DLP)

1. It Improve surface finishing and astatic looks.

2. when the past an painted they are the further process like removing extra material.
3. It is the process of curing.
SOLID GROUND CURING(SGC)

Solid ground curing (SGC) curing system is produced by cubital ltd started in 1987 .SGC is very similar to
SLA in principle.

WORKING PRINCIPLE

When a light of appropriate wave length falls on liquid photopolymer , The energy absorbed causes
polymerization . The polymerized photopolymer will be in solid state .
WORK FLOW OF SGC
• A flood of UV light used in SGC as against the pointed laser in SLA. The associated change is the absence of
image scanning instead , The flood is made to pass through an object mask .This mask is the negative of the
region to be polymerized .The regions of liquid polymer where light falls become solid. The remaining liquid
can be drained and its place is filled by liquid wax.
• As the entire area is exposed together this process is very fast build time is proportional to the height of the
object and not volume.
• The power of the laser and exposure time decides the layer thickness.
• Explicit support structures are required this is achieved simply by pouring wax in the regions not affected by
the light no need for computing the region requinng support and modify the CAD model.
MATERIALS
• Plastic
• Polymers

APPLICATIONS
❖ Conceptual design presentation ,design proofing ,engineering test ,integration and fitting ,functional analysis
,exhibition and pre-production soles ,market research and inter-professional communication.

❖ TOOLING ANDCASTING APPLICATIONS

• Investment caring ,sand casting and rapid ,tool –free manufacturing of plastic parts

❖ MODLD AND TOOLING

Silicon rubber tooling ,epoxy tooling ,spray metal tooling ,acrylic tool and plaster mold casting

❖ MEDICAL IMAGING
Diagnostic ,surgical ,operation and reconstruction planning and custom prosthesis design.
ADVANTAGES
• Solid ground curing framework do not need a help structure . No extra support is needed since wax is utilized
to fill the voids.
• Accuracy of procedure the model create by SGC process is nearly precise in the Z-beaning in light of the fact
that the layer is processed after each light presentation process.
• The entire layer is addressed in one go hence very fast. This high speed allows production like fabrication of
many parts or large parts.
• No post cure is required as he polymerization is required as the polymerization is complete in the machine if
self.
DISADVANTAGES
• The process has two cycle and many sub-systems (mask cleaner ,polymer spreader ,polymer cleaner ,wax
spreader ,wax cooling ,milling head ,vacuum suction of chips) .Hence less reliable furthermore the requires a
fall time operator attention.
• Building time depends on only the height of the parts and not it’s volume.
• Dewaxing is time consuming
• Creates a lot of waste of wax