EML 2023 – Rapid Prototyping
Lecture 1 – Additive Rapid Prototyping
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
2
Selective laser sintering (SLS)
• additive technique
• layer of powder placed on base
• high power laser used to fuse
selected parts of the powder
• the powder bed is lowered a
small amount and a new layer of powder is spread
• does not require any support structures
EML 2023
Department of Mechanical and Aerospace Engineering
3
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
4
Fused deposition modeling (FDM)
• additive technique
• material is laid down in layers
• plastic material is melted in
a nozzle that moves in XY
direction
• typically uses ABS plastic
• support material is required
EML 2023
Department of Mechanical and Aerospace Engineering
stratasys
5
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
6
Stereolithography (SLA)
• additive process
• uses a vat of liquid UV-curable
resin and a UV laser
• exposure to the laser causes
the material to harden
• after a pattern has been traced,
the platform descends and a
resin filled blade recoats the top
• requires support structures
EML 2023
Department of Mechanical and Aerospace Engineering
7
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
8
Laminated object manufacturing (LOM)
• sheet is adhered to substrate
with a heated roller
• laser traces out the outline
of the layer
• non-part areas are crosshatched to facilitate removal
of waste material
• next layer is pulled across and the process is repeated
EML 2023
Department of Mechanical and Aerospace Engineering
9
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
10
Electron beam melting (EBM)
• metal parts are made from a metal powder
• a layer of powder is spread and the part region is melted
together by a computer controlled electron beam
EML 2023
Department of Mechanical and Aerospace Engineering
11
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
12
3D printing (3DP)
• “inkjet” type process
• a fine powder of plaster or corn starch is bonded by
“printing” an adhesive from the printhead
• considered the fastest technique
EML 2023
Department of Mechanical and Aerospace Engineering
zcorp
13
Technologies
Prototyping Technologies
Base Materials
Selective laser sintering (SLS)
Thermoplastics, metal powders
Fused deposition modeling (FDM)
Thermoplastics, eutectic metals
Stereolithography (SLA)
Photopolymer
Laminated object manufacturing (LOM)
Paper
Electron beam melting (EBM)
Titanium alloys
3D printing (3DP)
Various Materials
EML 2023
Department of Mechanical and Aerospace Engineering
14
UF machines - FDM
• Dimension 1200es SST (Soluble Support Technology)
Building MAE-B
Room 313
EML 2023
Department of Mechanical and Aerospace Engineering
15
UF Rapid Prototyping Machines
101012”
build volume
868”
build volume
sodium hydroxide
& water tank
16
former UF machine - FDM
EML 2023
Department of Mechanical and Aerospace Engineering
17
Existing Equipment
• 2 Dimension sst 1200es Rapid Proto
Machines
– ABS plastic
– 101012” build volume
– .010” z-axis, .005” xy-axis resolution
• Roland MDX-540 Subtractive R.P.
machine
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plastic, wood, aluminum
4 axis ; 4 tool magazine
4412” build volume
.0008” repeat accuracy
Existing Equipment
• Next Engine 3D Scanner
– 54” macro field of view
– 13.510” wide field of view
– .005” accuracy
EML 2023
Department of Mechanical and Aerospace Engineering
Equipment to be delivered
• Fortus 360mc Rapid Proto Machine
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ABS plastic, Nylon, polycarbonate
161416” build volume
.005” accuracy
1.5 speed compared to existing machines
EML 2023
Department of Mechanical and Aerospace Engineering
MAE-B 313
Lab Renovation Plan
EML 2023
Department of Mechanical and Aerospace Engineering
Steps to Create a Part
1. Model part (or assembly) in SolidWorks.
2. Save part (or assembly) file in .stl format.
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Note: To save an assembly as one single .stl file, go to Options
and check the box next to ‘ Save all components of an
assembly in a single file’.
3. Run the Catalyst software. Orient the part on the build
tray and send to rapid proto machine.
EML 2023
Department of Mechanical and Aerospace Engineering
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