Post on 03-Apr-2018
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LENS - Principle
A High Powered Nd:YAG Laser focused onto
a metal substrate created a molten puddle on
the substrate surfaces. Powder is then
injected into the molten puddle to increase thematerial volume.
A Printing motion system moves a platform
horizontally and laterally as laser beam traces
the cross-section of the part being produced.After formation of layer powder delivery nozzle
moves upward prior to building next layer.
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Specification and Model
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Laser Engineered Net Shaping
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Applications: LENS
Build mould and die inserts
Producing Titanium components for biological
implants
Produce functionally gradient structure
Metallic parts- hip implant- example
Advantages: Dense material parts, complex
parts, reduce post-processing requirements
Disadvantages: Larger size, high power
consumption, limited material
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DSPC : Principle
It is based on 3D printing principle. This
technology invented, developed by MIT, USA.
It is suitable for metal casting. Binder from the
nozzle selectively binds the ceramic particlestogether to crate each layer. Layer after layer
is built and bound to the previous layer until
the ceramic shell completed. The shell is
removed from the DSPC machine and fired to
verification temperatures to harden and
remove all moisture. All excess ceramic
particles are blown away.
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SOLIGENS DIRECT SHELL
PRODUCTION CASTING ( DSPC)
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SOLIGENS DIRECT SHELL PRODUCTION CASTING (
DSPC)
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DSPC : Mechanism
A powder holder contains manufacturing
material powder
A powder distributor distribute a thin layer of
powder
Rollers which are used to compress each layer
before binding
A printer head which sprays binder on eachlayer
A bin which is used to hold the mold
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DSPC: Advantages &
Disadvantages
Pattern less casting: direct tooling, Functional
parts : metal tooling i.e, die for die-casting, Net
shaped integral model: No parting line, core
prints or draft angles re required Limited Material only : ceramic mold for metal
casting.
Applications: Automotive, Aero space,computer industries and medical prostheses.
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MULTIPHASE JET SOLIDIFICATION (
MJS)
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MJS: Principles & Process
The basic concept applies the extrusion of low viscosity
materials through a jet layer by layer. It is some what
similar to FDM process. Only difference is raw material
used to build and feeding systems. In MJS material is
supplied in different phases using powder-bindermixture or liquefied alloys instead of using material in
the wire form. Feeding and nozzle system also different.
Material is wax 50% with metal powder ( liquefied alloys
or powder binder mixture), chamber pressure, machinespeed, jet specification, material flow and operating
temperature.
Process : Data preparation, model building
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EBM
Principle: the parts are built up when an
electron beam is fired at the metal powder.
The computer controlled electron beam in
vacuum melts the layer of powder precisely. Alayer is added once previous layer has melted.
Application : H13 Tool steel injection and
compression molding tools, functional
prototype components
Product: Electron beam gun, vacuum chamber
with fabrication tank powder holder, vacuum
pumps, monitor, high voltage device etc.,
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Therics TheriForm Technology
Principle: It is based on 3D printing Technology
developed by MIT. Binder droplets are
selectively dispensed to bond the powders in
the same layer together as well as next layer. Process: The product are fabricated by printing
micro drops of binders, drugs and other
material and even lining cells onto an ultra-
thin- layer of powder polymers and
biomaterials in computer directed sequence.
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TheriForm Process
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ProMetal Process
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Prometal : Application
Printing Tool steel tooling parts, Injection
molds, extrusion dies, direct metal
components blow molding and repairing worn
out metal toolsAdvantages : Fast, flexible and reliable and
largest steel mold parts. ( 1016mm X 508 mm
X 254mm)
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STL File- ERRORS Missing
Facets
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Shell Puncture
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Overlapping , Non Manifold
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Valid and Invalid Model
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Model tessellated surface
without gaps
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Error Detection
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RP Machining Process
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RP Applications
Applications of rapid prototyping can be
classified into three categories:
1. Design
2. Engineering analysis and planning3. Tooling and manufacturing
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Design Applications
Designers are able to confirm their design by
building a real physical model in minimum time
using RP
Design benefits of RP:
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass properties
E i i A l i d
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Engineering Analysis and
Planning
Existence of part allows certain engineering
analysis and planning activities to be
accomplished that would be more difficult
without the physical entity Comparison of different shapes and styles to
determine aesthetic appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process
planning and tool design
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Indirect RTM Method
Pattern is created by RP and the pattern is used
to fabricate the tool
Examples:
Patterns for sand casting and investment casting
Electrodes for EDM
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Manufacturing Applications
Small batches of plastic parts that could not be
economically molded by injection molding
because of the high mold cost
Parts with intricate internal geometries thatcould not be made using conventional
technologies without assembly
One-of-a-kind parts such as bonereplacements that must be made to correct
size for each user
P bl ith R id
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Problems with Rapid
Prototyping
Part accuracy:
Staircase appearance for a sloping part surface due
to layering
Shrinkage and distortion of RP parts Limited variety of materials in RP
Mechanical performance of the fabricated parts is
limited by the materials that must be used in the RP
process
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Rapid Tooling
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Core and Cavity
Process yields excellent tool finish
Captures intricate detail
Core in Universal Base
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Core in Universal Base
600,000 shots and still running
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Cavity
Ideal for geometrically complex shapes
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Benefits
Versatility
Die casting
Thermoplastic injection molding
MIM (metal injection molding)
Fast turnaround, low cost
2 weeks from CAD file to part
Mold hardness Extended tool life
Quick cavity duplication
Ideal for multi-cavity molds
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MIM Metal Injection Molding
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MIM- Metal Injection Molding
Nickel/ Steel Alloy
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Metal Arc Spray Systems
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