3D Printing With Plastics
Deciding how to create a prototype of your new design can be a confusing because of all the available processes and materials. However learning the benefits and drawbacks of various options can simplify you choices. Below is some information on various 3D printing (or Additive Manufacturing) processes to help you. The members of frethot are designers and engineers and can help you choose the best method of prototyping. If you have any questions regarding the content of this blog or need assistance with the design, engineering, specifying for manufacturing, graphic design, packaging design, prototyping, or manufacturing of your product, please visit our website at www.frethot.com.
Additive manufacturing is the process of joining materials (usually layer upon layer) to make an object. It is also called additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. The process generally uses a support material to provide stability to the object while it is being manufactured. The various subcategories and their use of support material will be briefly discussed below.
Fused Deposition Modeling
Fused deposition modeling uses thermoplastics in filament form. The filament is fed through a tip that melts the plastic. The tip is moved across a platform, depositing the plastic one layer at a time. The platform moves downward after the application of each layer (determining the thickness of the next layer). The process is repeated until the last layer is deposited. After removing the support material an FDM part down not require any post treatment.
Laser Sintering
Laser sintering utilizes a laser to selectively fuse powder particles layer by layer. The powder that is not fused serves as support material. The loose powder must cool completely and then be removed. Removing the parts prematurely can result in warping. The cooling process can take hours (up to 40 hours for large parts). This can be a drawback. One benefit is that Laser sintering can serve as interim manufacturing while tooling is being produced because manufacturing can begin as soon as CAD data is ready. However, material costs need to be taken into consideration weighed against the benefits.
Inkjet Printing Technology
This technology is available from Solidscape and uses a thermoplastic-based wax to create parts. The wax is jetted through a single inkjet nozzle to build the part. A second nozzle is used to deposit the support material which can be dissolved in a special solution.
Poly-jet Systems
Poly-jet Systems are a family of 3D Printers by Objet Geometries. They are similar to those available from Solidscape in that they utilize inkjet print heads. Poly-jet systems however use a liquid polymer deposited layer by later. A UV lamp then cures the layers as they are deposited. Because these machines can produce extremely thin layers (as this as 16 microns or 0.0006 inches) they can accommodate very fine features. As a comparison Stereolithography (see below) creates layers with an average thickness of 0.004 inches. Poly-jet systems uses a soft wax-like support material which can be removed using a high-pressure water-jet system.
Stereolithography
Stereolithography uses one or more lasers to harden ultraviolet-sensative liquid polymer layer upon layer. Digital data directs the laser beam to strike uncured polymer, hardening it. After each layer the build platform is lowered into the vat of polymer and the process is repeated. The vat of polymer serves as the support material and most drains away when the parts are complete. Stereolithography parts are often used to prepare print and television ads before the production parts are available. However these parts are not stable long-term as sunlight, temperature and humidity can impact them.
If you have any questions regarding the content of this blog or would like to suggest a topic for a future post feel free to comment or contact us via our website www.frethot.com
Additive manufacturing is the process of joining materials (usually layer upon layer) to make an object. It is also called additive fabrication, additive processes, additive techniques, additive layer manufacturing, layer manufacturing, and freeform fabrication. The process generally uses a support material to provide stability to the object while it is being manufactured. The various subcategories and their use of support material will be briefly discussed below.
Fused Deposition Modeling
Fused deposition modeling uses thermoplastics in filament form. The filament is fed through a tip that melts the plastic. The tip is moved across a platform, depositing the plastic one layer at a time. The platform moves downward after the application of each layer (determining the thickness of the next layer). The process is repeated until the last layer is deposited. After removing the support material an FDM part down not require any post treatment.
Laser Sintering
Laser sintering utilizes a laser to selectively fuse powder particles layer by layer. The powder that is not fused serves as support material. The loose powder must cool completely and then be removed. Removing the parts prematurely can result in warping. The cooling process can take hours (up to 40 hours for large parts). This can be a drawback. One benefit is that Laser sintering can serve as interim manufacturing while tooling is being produced because manufacturing can begin as soon as CAD data is ready. However, material costs need to be taken into consideration weighed against the benefits.
Inkjet Printing Technology
This technology is available from Solidscape and uses a thermoplastic-based wax to create parts. The wax is jetted through a single inkjet nozzle to build the part. A second nozzle is used to deposit the support material which can be dissolved in a special solution.
Poly-jet Systems
Poly-jet Systems are a family of 3D Printers by Objet Geometries. They are similar to those available from Solidscape in that they utilize inkjet print heads. Poly-jet systems however use a liquid polymer deposited layer by later. A UV lamp then cures the layers as they are deposited. Because these machines can produce extremely thin layers (as this as 16 microns or 0.0006 inches) they can accommodate very fine features. As a comparison Stereolithography (see below) creates layers with an average thickness of 0.004 inches. Poly-jet systems uses a soft wax-like support material which can be removed using a high-pressure water-jet system.
Stereolithography
Stereolithography uses one or more lasers to harden ultraviolet-sensative liquid polymer layer upon layer. Digital data directs the laser beam to strike uncured polymer, hardening it. After each layer the build platform is lowered into the vat of polymer and the process is repeated. The vat of polymer serves as the support material and most drains away when the parts are complete. Stereolithography parts are often used to prepare print and television ads before the production parts are available. However these parts are not stable long-term as sunlight, temperature and humidity can impact them.
If you have any questions regarding the content of this blog or would like to suggest a topic for a future post feel free to comment or contact us via our website www.frethot.com
Labels: 3D printing, additive manufacturing, fused deposition modeling, laser sintering, plastics, stereolithography
posted by fre|thot at
12:11 PM
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