Advanced Manufacturing Choices.ppt

Advanced Manufacturing Choices MAE 156-256 Spring 2012, Dr. Marc Madou Class 9: Rapid Prototyping By Dr. Marc Madou Two Ways for Fabrication: Subtractive manufacturing Additive Manufacturing Rapid Prototyping Some other names: Additive manufacturing Computer controlled moldless additive manufacturing Part is produced by producing multiple “slices” i.e. cross sections From 3D model [STL file (see next slide)] to physical object, with a “click” Layered manufacturing Rapid prototyping: Variety of methods: more and more functional products rather than just prototypes STL File* The STL (stereo lithography) file format is supported by many other software packages; it is widely used for rapid prototyping and computer-aided manufacturing (CAM). STL files describe only the surface geometry of a three dimensional object without any representation of color, texture or other common CAD model attributes. *An STL file describes a raw unstructured triangulated surface by the unit normal and vertices (ordered by the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate system. Basic Principles of Rapid Prototyping Rapid Prototyping 3d model generated Sliced Each slice manufactured and layers are fused together A voxel (volumetric pixel or, more correctly, Volumetric Picture Element) is a volume element, representing a value on a regular grid in three dimensional space. This is analogous to a pixel, which represents 2D image data in a bitmap (which is sometimes referred to as a pixmap). Materials For Rapid Prototyping Materials covered: Thermoplastics (FDM, SLS) Thermosets (SLA) Powder based composites (3D printing) Metals (EBM, SLS) Sealant tapes (LOM) Stereolitography (SLA) Selective Laser Sintering (SLS) Fused Deposition Modeling (FDM) Laminated Object Modeling (LOM) 3D Printing Electron Beam Melting (EBM) Examples of Rapid Prototyping Applications: Prototyping (90 %) Concept models Architectural models Disney characters Movies—or