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RAPID PROTOTYPING TECHNOLOGIES Prof. Dr. Bilgin KAFTANOĞLU www.mfge.atilim.edu.tr/kaftanoglu Manufacturing Engineering Department ATILIM UNIVERSITY ANKARA. WHAT IS PROTOTYPING? Essential part of the product development and manufactuing cycle;
Prof. Dr. Bilgin KAFTANOĞLU
Manufacturing Engineering Department
The objects have overhangs or undercuts which must be supported during the fabrication process by support structures.
These are either manually or automatically designed and fabricated right along with the object. Upon completion of the fabrication process, the object is elevated from the vat and the supports are cut off.
The platform at the end of a print run, shown here with several identical objects.
On the negative side,
The ultraviolet "oven" used to cure completed objects.
(in ultrasonic vibration tank)
A production cut in the middle
Before and after finish machining
120x120x120 cm LENS Machine
1) Laser beam is traced over the surface the tightly compacted powder to selectively melt and bond it to form a layer of the object.
2) Platform is lovered down one object layer thickness to accommodate the new layer of powder
3) A new layer of powder is coated on the surface of the build chamber.
4) The powder is supplied from the powder bins to the recoater.
This process is repeated until the entire object is fabricated.
Three Types of Laser Sintering Machines:
1) Plastic Laser Sintering Machine
2) Metal Laser Sintering Machine
3) Sand Casting Laser Sintering Machine
Support structure (red material), water-soluble, fused deposition modeling (FDM).
Support structure, stereolithography.
3) SYSTEM COSTS
RP systems cost from $30,000 to $800,000 when purchased new. The least expensive are 3D Printer and FDM systems; the most expensive are specialized stereolithography machines.
In addition, there are appreciable costs associated with training, housing and maintenance. For example it can cost more than $20,000 to replace a laser in a stereolithography system.
High cost. Available choices are limited.
A bone structure which was produced from ceramic powder embedded paper material in LOM.
Bone Structure with the cranial vasculature highlighted in red. This model was made using SLS with a special material called Stereocol. (Coloured when exposed to high power laser)
Actual living tissue cells are extracted from the patient and seeded onto a carrier which accomodates and guides the growth of new cells in 3D within laboratory environment.