Developing A Process For Laminated Object Manufacturing (Rapid Prototyping) Without De-Cubing.

2012 Final Year Project
Topic - Development of a process for Laminated Object Manufacturing without de-cubing.

Course BEng Honours Mechanical Engineering Technology
Name Sree Vishnu Muralidharan

Supervisor Dr. Dele Owodunni
Date 27th April, 2012
Final Year Project April 1, 2012
Abstract
The laminated object manufacturing (LOM) process is an effective rapid prototyping technology with a variety of possible applications. The main process of the LOM consists of at first, a slice material such as paper is transported onto the work table, the work table raise, and then a hot beam press and heat up s the shape into small piece in order to wipe them off after build all layers; after cutting is finished, the work table fall and repeat the first step. An alternate method is to collect all the cut layers of the prototype first and then stacking is done layer by layer with gluing them properly. As rapid prototyping also includes developing complex prototypes, LOM being a rapid prototyping process face difficulties in making complex prototypes as a cubing method is used to support prototype being made. But the cubes cannot support the overhanging or island structures in the prototype due to its structure. The removal process of cubes known as de-cubing is tedious, time consuming, labor intensive and also causes damages to the prototype during its removal. The LOM process here is developed by adopting powder as the support material eliminating the de-cubing method, as powder provides support to the prototype being made and also the overhanging structures in it. Two complex prototypes have been made and compare with the current Rapid prototyping technologies proving this process to be cost effective and time efficient.
Sree Vishnu Muralidharan | 000700290
Acknowledgement
I most humbly surrender with gratitude before my esquire professor Dr. Dele Owodunni who is my guiding inspiration who awaked my sub conscious mind & engineering talents through the inspiration, sincerity, spending precious time & imparting knowledge presenting a success system before which difficulties, failures & obstacles are powerless but stepping stones to success under extra stress. My professor taught me to relentlessly work hard under pressure to improve my capacity which I understand is incredible, formidable & impossible. Circumstances cannot change us but we can change the circumstance forgetting physical & mental pains to achieve the goal accurately within time with zero tolerance with genuine desire for success and inspiration. My emeritus professor changed my negative attitude to positive result oriented action with preference directing me to understanding, acceptance & direction. I express my genuine gratitude to staff & lab technicians for their co-operation. I am much delighted and obliged to this campus, lab & immaculate library, multicultural but friendly colleagues. By changing the attitude we can change the life for positive results. I have boundless love & obligation to my parents for arranging me education in this esteemed & prestigious Greenwich University. I am proud of being a student of a prestigious institution.
Table of Contents
Abstract ................................................................................................................................................... 2 Acknowledgement .................................................................................................................................. 3 Chapter 1 ............................................................................................................................................... 10 Introduction ....................................................................................................................................... 10 1.1 The main purpose (Aim): ............................................................................................................ 11 1.2 Objectives: .................................................................................................................................. 11 1.3 Deliverables ............................................................................................................................. 11 Chapter Two.......................................................................................................................................... 12 Background Concepts ....................................................................................................................... 12 2.0 Rapid Prototyping and its types .................................................................................................. 12 2.1 RP uses .................................................................................................................................... 14 2.2 Rapid prototyping technologies ............................................................................................... 16 2.3 Rapid Prototyping Pros and Cons- .............................................................................................. 19 2.4 The different Rapid Technologies ............................................................................................ 20 2.4.1 Stereolithography ................................................................................................................. 21 2.4.2 Selective laser sintering .................................................................................................... 23 2.4.3 Laminated object manufacturing (LOM) ............................................................................. 25 2.4.4 Three-dimensional printing .................................................................................................. 27 2.5 The Laser cutting machine used for cutting the layers ............................................................ 31 2.5.1 Purex - Fume extraction system ............................................................................................... 32 Chapter Three........................................................................................................................................ 34 Problem analysis and solution .......................................................................................................... 34 3.1 Problem analysis - ....................................................................................................................... 34 3.1.1 De-cubing in laminated object manufacturing ................................................................. 34 3.1.2 Supporting the overhanging structures .............................................................................. 35 3.1.3 Alignment of the paper sheets ............................................................................................ 36 3.2 Solution .............................................................................................................................. 36
3.2.1 Solution replacing the cubing method of supporting ........................................................... 36 3.2.2 Supporting the island structures ........................................................................................ 36 3.2.3 Paper alignment mechanism ............................................................................................. 36 Methodology......................................................................................................................................... 37 Sree Vishnu Muralidharan | 000700290 4
Final Year Project April 1, 2012 Chapter four .......................................................................................................................................... 38 Implementing the solution ................................................................................................................ 38 4.1 Eliminating de-cubing and adopting powder as support .......................................................... 38 4.2 Adapting technologies/methods used by other Rapid Prototyping systems .......................... 39 4.2.1 3D Printing ........................................................................................................................... 39 4.2.2 SLS (Selective Laser Sintering) ........................................................................................... 42 4.3 Powder Selection ..................................................................................................................... 44 4.4The Selection of method of deposition of powder into chamber .............................................. 45 4.5 Alignment Mechanism of paper sheets .................................................................................... 47 4.5. Prototypes to be made ......................................................................................................... 49 4.5.1 Cutting the papers to obtain the paper with correct thickness to get exact dimensional accuracy of prototype .................................................................................................................. 52 4.6 Stacking of papers .................................................................................................................... 66 4.7 Prototype made ........................................................................................................................ 66 4.7.1 The turbine (impellor) prototype ....................................................................................... 66 4.7.2 The Motorbike prototype .................................................................................................. 68 4.8 Supporting the island structures ............................................................................................... 69 Chapter 5............................................................................................................................................... 70 Results and Discussion ..................................................................................................................... 70 5.1 The prototypes made ................................................................................................................... 70 5.1.1 The turbine prototype.......................................................................................................... 70 5.1.2 The Motorbike prototype .................................................................................................... 70 5.2 Dimensional comparison of the CAD model of turbine and the prototype:- .............................. 71 5.2.1 Graphical Representation of quality of manually made turbine prototype and the turbine of proper dimensions ........................................................................................................ 72 5.3 Supporting the island structure ............................................................................................. 72
5.4 Comparison of dimensional accuracy of motorbike made in 3D printing machine and Motorbike made by Laminated Object Manufacturing (L.O.M) ................................................... 73 5.4.1 Variations in dimensions of motorbike made by 3d printing and motorbike by L.O.M ...... 74 5.4.2 The Time comparison in case of Motorbike built by 3d printing and LOM ........................ 75 5.4.3 Cost Comparison in case of Motorbike built by 3d printing and Laminated Object Manufacturing (L.O.M)- ............................................................................................................... 76 5.5 A comparison of manually made prototype with the prototype made by 3d printing ........ 77
Chapter 6 ............................................................................................................................................... 78 Conclusion and Future work .......................................................................................................... 78 Sree Vishnu Muralidharan | 000700290 5
Final Year Project April 1, 2012 Conclusion ........................................................................................................................................ 78 Future Work ................................................................................................................................... 78 Reference .............................................................................................................................................. 79 Appendix ............................................................................................................................................... 86
List of Figures
Figure 2.1 Rapid Prototyping chart..........................................................................................11 Figure 2.2 Result of introducing rapid prototyping in design..................................................12 Figure 2.3 the three stages of rapid prototyping system...........................................................13 Figure 2.4 Classification of different rapid prototyping systems.............................................17 Figure 1.5 Stereolithography machine.....................................................................................18 Figure 2.6 Method of Stereolithography..................................................................................19 Figure 2.7 Selective Laser Sintering Machine.........................................................................20 Figure 2.8 Selective Laser Sintering method...........................................................................21 Figure 2.9 A Helisys LOM machine........................................................................................22 Figure 2.10 Method of LOM (laminated object manufacturing process)................................23 Figure 2.11 3D printing machine.............................................................................................24 Figure 2.12 3D printing process...............................................................................................24 Figure 2.13 a roller layering powder over powder bed in 3D printing process.........................25 Figure 2.14 Comparison of different Rapid Prototyping Technologies...................................26 Figure 2.15 Material comparison charts....................................................................................27 Figure 2.16 the laser cutting machine......................................................................................28 Figure 2.17 fume extraction system.........................................................................................29 Figure 3.1 The de-cubing method....32 Figure 3.2 an overhanging structure.....33 Figure 3.3 (a) An object (b) the diagram showing the overhanging structure in the object to be support....3 3 Figure 4.1 A complex prototype made by sintering nylon powder.....35 Figure 4.2 the process of depositing powder in 3d printing technology.....36 Figure 4.3 A layer of powder being spread by roller...37
Sree Vishnu Muralidharan | 000700290 6
Figure 4.4Binder solution being deposited by the binder cartilage..37 Figure 4.5 Roller depositing another layer of powder over the previous one..38 Figure 4.6 the whole process of 3d printing at a glance...38 Figure 4.7 a selective laser sintering machine..39 Figure 4.8 the selective laser sintering process40 Figure 4.9 a scraper blade pushing the powder..42 Figure 4.10 a scraper blade pushing the powder42 Figure 4.11 the roller pushing (rolling) forward powder..43 Figure 4.12 the roller pushing the powder...43 Figure 4.13 Slice directions in paper alignment mechanism44 Figure 4.14 Object dimension..44 Figure 4.15 slicing of the object...45 Figure 4.16 paper alignment mechanisms45 Figure 4.15 slicing of the object...45 Figure 4.16 Turbine (impellor).46 Figure 4.17 gear (Differential).46 Figure 4.18 Snarl..46 Figure 4.19 motorbike..47 Figure 4.20 Pen Holder....47 Figure 4.21 the laser cutting machine powder.48 Figure 4.22 the laser cutter powder.48 Figure 4.23 paper thickness of 0.10 being cut to make turbine49 Figure 4.24 paper thickness of 0.20 being scored to make turbine..49 Figure 4.25 sticky paper of thickness 0.15 mm to make turbine.50 Figure 4.26 Top view of turbine...50
Figure 4.27 Wiper being used to push powder across build platform..51 Figure 4.28 roller used for pressing the stacked layers....51 Figure 4.29 paper alignment through nails placed on platform...52 Figure 4.30 Prototype being made using sticky papers of 0.15 mm thickness52 Figure 4.31 Side view of turbine..53 Figure 4.32 bottom view of the turbine....53 Figure 4.33 paper thickness of 0.15mm thickness being cut by laser..54 Figure 4.34 paper thickness of 0.05 adjusted in laser cutting machine being cut by laser..55 Figure 4.35 Thickness of paper 0.15 mm and 0.08 thickness adjustment made in machine....................................................................................................................................56 Figure 4.36 Thickness of paper 0.20 mm and 0.06 thickness adjustment made in machine....................................................................................................................................57 Figure 4.37 Thickness of paper 0.20 mm and power 20% adjustment made in machine58 Figure 4.38 papers being stacked, scoring done by the laser...59 Figure 4.39 thickness of 0.30 mm and power 16% adjusted in laser cutting machine60 Figure 4.40 thickness of 0.22 mm61 Figure 4.41 turbine prototype -front view62 Figure 4.42 turbine prototype -back view63 Figure 4.43 turbine prototype -top view...63 Figure 4.44 Motorbike prototype - top view64 Figure 4.45 Motorbike prototype - front view.64 Figure 4.46 prototype made by 3d printing..65 Figure 5.1 Turbine prototype made by LOM without de-cubing.66
Figure 5.2 Motorbike prototype made by LOM without de-cubing.66 Figure 5.3 turbine CAD model.67 Figure 5.4 turbine prototype made by LOM without de-cubing..67
List of tables
Table 2.1 the Emergence of Rapid Prototyping...10 Table 4.1 Selection of paper and proper parameters to make turbine..50 Table 5.1 dimensional comparison of Turbine CAD model and turbine made by LOM.....68 Table 5.2 dimensional comparison of motorbike made by 3d printing and LOM...69
List of Graphs
Graph 5.1 dimensional comparisons of Turbine CAD model and turbine made by LOM68 Graph 5.2 dimensional comparison of motorbike made by 3d printing and LOM..70 Graph 5.3 Comparison of time taken for motorbike made by 3d printing and LOM..71 Graph 5.4 Cost comparison of motorbike made by 3d printing and LOM..72 Graph 5.5 Quality, Cost and Time comparison of Prototype made by 3D Printing and L.O.M...73
Chapter 1
Introduction
The Laminated Object Manufacturing is the process which builds and layers three dimensional objects with the help of process like binding and fusing layers of paper or other materials that are brought into a new layered shape by laser without waste of material and accuracy. The layers which are rested on the platform was supported by cubes which were then de-cubed, but as this process is time consuming, tedious and damage causing and mainly restricts the manufacture of complicated prototype as the cubes could be done in island and overhanging structures in complex prototypes, thus a new machine with proper support material and a process is to be developed in this project so that any type of complex prototype can be made using the Laminated Object Manufacturing process. The Process of Laminated Object Manufacturing
The Laminated Object Manufacturing is the process which consist of laser (or cutter), heated roller, a support, a platform, and a roll of paper or material used for making prototype.
The process starts with a paper material which is brought onto a work table, the work table then tend to rise. The paper or the material is brought in-front of laser such that the laser cuts the paper or material layer by layer. These layers have adhesives underneath it or could be applied under it so that they are stacked after they are cut (cut and bond process). After cutting each layer the build platform goes down and the layer comes on for it to be cut. As these layers cannot be made into a prototype in air without any support, thus they were supported by cubes and after the whole process of cutting was over the build platform is made to rise above and the prototype is taken after the time consuming and tedious de-cubing process.
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1.1 The main purpose (Aim):

The purpose of this project is to develop a process for the laminated object manufacturing without the process of de-cubing. Thus, the main aim is to develop the process to create any type of complex prototype using the Laminated Object Manufacturing process without de-cubing.
1.2 Objectives:
Getting knowledge of Laminated Object Manufacturing (L.O.M) and the theory on it. Developing the process to show the prototype can be created without the decubing process in Laminated Object Manufacturing. Developing the process to save time and cost and making the prototype with proper accuracy. Making complex prototypes with proper accuracy using the methods that will save time and be cost effective. Finding and applying the methods to support island objects or overhanging structures in complex prototypes.
1.3 Deliverables
To provide a cost effective method of making prototypes To provide a process that is time consuming when compared to the current Laminated Object Manufacturing process and other rapid prototyping processes A report regarding the problems, solution, the methods of solving the problems and the comparison of the prototype being made with that of other rapid prototyping systems A log book with updated research details and changes made in the project methodology. A poster describing the project at a glance Complex prototypes to show prototypes that are complex in nature can be built without the process of de-cubing.
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Chapter Two
Background Concepts
2.0 Rapid Prototyping and its types

Need and Scope of Present Work Rapid prototyping was formed in 1986, but since its invention many techniques related to rapid prototyping have been established in the commercial world. Rapid prototyping are used to make the physical objects from the CAD models and have different names such as Addictive manufacturing, solid freeform fabrication, addictive fabrication, layered manufacturing and three dimensional printing. The Rapid prototyping offers a range of advantages when compared to the subtractive fabrication technologies Any complex object can be created. It manufactures the complex prototype in a fast process and is easily manageable and straightforward.
Table 1
Year of Inception 1770 1946 1952 1960 1961 1963 1988 Mechanisation First Computer
Technology
First numerical control (NC) machine tool First Commercial laser First commercial Robot First Interactive Graphics system First commercial Rapid prototyping system
Table 2.1 the Emergence of Rapid Prototyping [1]
Wax and resins are the raw materials that are used by some of the techniques in included in rapid prototyping. The functional testing mostly results in less mechanical strength and therefore it becomes a barrier for the rapid prototyping. The Rapid prototyping
technology has now opted to stop forming prototype only for visualisation; rather it focuses on the form-fit-functional approach to have a better future in rapid manufacturing. Rapid prototyping now uses the direct metal deposition methods worldwide to overcome these problems. Some technologies use lasers or electron beam technology in melting the metal known as Solid Freeform Fabrication (SFF). These technologies build slowly and are also expensive. Welding is one of the methods which was much before rapid prototyping and has been regarded as a solution to be used in the layered manufacturing process as a cost effective way. 3D welding does not give or proper dimensional accuracy and surface quality in spite of all the developments and improvements being made with regard to it.
Figure 2.1 Rapid Prototyping chart [1] Sree Vishnu Muralidharan | 000700290 13
Rapid tooling is a process of making the components which doesnt require conventional tolling and also it does require labours who are skilled model makers. Subtractive manufacturing process achieves the final shape by removing the parts of the material for modifying the object. The RP components are made layer by layer until the object is manufactured. This can also be built by different RP processes. Rapid prototyping starts with a 3D CAD model where any object is made using the techniques involved in rapid prototyping technologies. Rapid prototyping is also a helpful thing in medication as it is used in MRI. The source doesnt matter in rapid prototyping; it requires a STL file and then is sliced horizontally. The sliced things (papers sheets or metal sheets) are stacked together and are cut for a proper design of the material which is to be obtained and is finally stacked to form the object with respect to the CAD model of the STL file.
2.1 RP uses
The uses of Rapid Prototyping are Concept Models Rapid technologies are used to make any complex shaped object in a quicker way and cheap way. If any correction is to be made before the manufacture of the object, changes or necessary modifications could be made to the object in order to attain proper object. Even the RP parts can be distributed to the sales team in order to have feedback of it from the customers. Final or semi functional Components The Rapid prototype parts doesnt have the physical properties to make the final functional part, thus the semi-functional parts are made by rapid prototyping. Rapid prototyping can be used as assemblies which forms final function. The semi functional parts can be brought together and experimental tests can be done on the basis of the geometry of the part and not on the material properties. Mater patterns Rapid prototyping are used to make production tooling. They are used as masters in sand casting foundries, investment casting moulds. By the usage of reaction injection moulding process or vacuum moulding, silicon rubber moulds for low volume of functional parts can be produced with the help of rapid prototyping.
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Direct tooling There is soft tooling and hard tooling. The low production volume is made from soft tooling where its made from polymers. The hard tooling is done by new RP process like the injection moulding tooling is made in metal composites where one million shots are being done.
Figure 2.2 Result of introducing rapid prototyping in design [2]
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2.2 Rapid prototyping technologies

The Rapid prototype technology changes as time goes on with its modernization and high advancement done in it. There are five processes which is taking place at present Sintering Process Sintering process is the process where the heat source is used to sinter the powder. The process involves a laser beam to do so. Curing Process The polymer is hardened in this case by exposing the photo sensitive polymer to a light source. Binding Process - The powder is bind in this process by depositing liquid binder onto a powdered material Sheet Process The sheets are cut into shapes of the design and then stacked (cut then bond process), it also follows a process of stacking the paper sheets and then cutting it (bond then cut process) Dispensing process - In this process the metal is melted and is deposited as hot filament or as individual droplets.
Figure 2.3 the three stages of rapid prototyping system [3]
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RP systems listed in 1999:
3DP three-dimensional printing
3DWM three-dimensional welding and milling
BPM ballistic particle manufacture CAM-LEM computer aided manufacturing laminated engineering materials
CLOM curved laminated object manufacturing
DLF direct light fabrication
DLMS direct laser metal sintering
ECLD-SFF electrochemical liquid deposition for solid freeform fabrication
EDSSM extrusion and deposition of semi-solid metals
EFF extrusion free forming
EPDFF electrophotographic powder deposition for freeform fabrication
FDC fused deposition of ceramics
FDM fused deposition modelling
FDMet fused deposition of metals
FFF fast freeform fabrication

FI fast inkjet
LDM laser diode manufacturing
LENS laser engineered net shape
LM layered manufacture
LOM laminated object manufacturing
M2SLS multi material selective laser sintering
Meso SDM mesoscopic shape deposition manufacturing
PPD point wise powder deposition
RPBPS rapid pattern based powder sintering
RSLA refrigerative stereolithography
SGC solid ground curing
SLA stereolithography
SLPR selective laser powder remelting
SLS selective laser sintering
TIF temperature induced forming
TLP thick layer prototyping

2.3 Rapid Prototyping Pros and ConsRapid prototyping creates complex prototypes of any shapes due the advancement in their manufacturing and planning process which is automated. They create three dimensional prototypes which helps the designers to create any three dimensional prototypes rather than opting the two dimensional one. Pros related to Rapid Prototyping Designers can work on rapid prototyping in a faster and cost effective way. Speedy improvements in design It can test any physical object of any complexity in a very short period of time Product sales increases It minimizes the time consuming discussions and evaluations involved in manufacturing possibilities. Can eliminate from the design in a quicker way Increase in the speed of system development Reduces the labour in terms of manufacturing Quick modification of design Involvement of customer at early stages Product testing is very quick Parts that are made by rapid prototyping show great time, cost and material savings.
Cons related to Rapid Prototyping There are some challenges that are faced by rapid prototyping which should be overcome Other design ideas could be excluded if manufacturing is takes place quickly Design features are limited due to less scope of prototyping tool. The optimization of the programme could be hampered if there is too much of involvement
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2.4 The different Rapid Technologies
Figure 2.4 Classification of different rapid prototyping systems [2]
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2.4.1 Stereolithography It is one of the oldest rapid prototyping technologies being started in 1980s. It is short formed as SLA and can develop prototypes of complex shapes with a good surface finish when compared to other machines. It is a process which creates cross sections of a 3D object within space of liquid photopolymer using ultra violet laser. It builds layers ranging from 0.004 inches to 0.006 inches. The SLA is used as masters for the production of silicon moulds and reaction injection moulding.
Figure 6.5 Stereolithography machine [4]
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MethodThe part is built on a platform where a vat of polymer is there, the platform rises and falls within the vat. The movement of the platform takes place when its below the surface of liquid polymer. The cross section of one slice is then traced by the laser which results in solidification of the polymer as the laser hits it. The next layer of is traced when it moves down the one slice (0.050 0.250mm) and then moves to the fresh layer of liquid polymer. When the laser traces out the other layers it sits on the previous layers as the process continues. After the process is completed i.e. when all slices are traced by the laser the platform is taken out and the excess liquid polymer is removed or cleaned off. An ultraviolet oven is final part which remains after the removal of the waste.
Figure 2.6 Method of Stereolithography [5]
Advantages of Stereolithography Good surface finish Easily obtained Good accuracy of the geometry in general
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Disadvantages Support structures are needed to support the model and also contain the removal process. Resins and acrylate should be used to wrap the parts Resins need to be handled carefully as they are hazardous
2.4.2 Selective laser sintering The selective laser sintering (SLS) helps to make the most complex and small function parts with the help of powder as a support material. The SLS process which involves the metal powder can be used for making production tooling.
Figure 7.7 Selective Laser Sintering Machine [6]
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Method In the Selective laser sintering (SLS) system, a thin layer of powder is spread over the built platform using a roller mechanism. The powder changes into a solid form after it is fused by the laser as it heats it just below its melting point. The sliced part is cut and rests on the previous one. The un-sintered material settles as support material for it and after the process is complete, it can be removed.
Figure 2.8 Selective Laser Sintering method [7]
Advantages Achieves accuracy Good Surface Finish Additional support structures are not required to build the parts
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Disadvantages
Surface finish could be poor Requires post curing Limited Materials The machines could take long time for heating and then cooling down.
2.4.3 Laminated object manufacturing (LOM)
The Laminated Object Manufacturing (LOM) system was introduced in 1991 by Helisys, CA. The mechanism of the system starts with a sheet placed over a build platform, a laser to cut the sheets in the designed way as in the CAD model or in the STL file, a roller to put pressure on the sheets on the previous one which is cut by applying glue in between the sheets or using adhesive coated sheets so as to stack the layers properly. After the completion of cutting each layer the built platform lowers and then the new layer of sheet again sits on the previous one and the process continues. After the layers are cut the waste material around it supports the model and can be removed once the model is built. LOM is one of the cheapest systems in Rapid Prototyping to make parts of complex geometry.
Figure 2.9 A Helisys LOM machine [8]
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Method The process starts with the paper sheet being rolled over and is cut by a laser or a cutter and then similarly another paper sheet is rolled and is cut according to the design and stacked over to the previous one. The waste material around the final object is removed by a process called de-cubing which is time consuming and tedious. The surface finish, stability and accuracy of the paper are not better when compared with other rapid prototyping systems. One of the benefits is that they can be built by easily available materials. As there are limitations on materials such as plastics, ceramics, metals and composites are used for this work.
Variations have been cited by many companies in case of the LOM system as many companies use different cutting methods, Kara Corp. uses knife to cut the layers in place of lasers and Solidi 3d ltd. uses knife to cut the layers but uses a solvent to stack the layers of plastic film.
Figure 2.10 Method of LOM (laminated object manufacturing process) [9]
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Advantages of LOM Low maintenance cost Low labour cost It has high durability It possess low brittleness Parts can be made of variety of materials
Disadvantages Supports are needed for the models being made Poor surface finish Difficulty in producing hollow parts Difficulty in supporting overhanging structures 2.4.4 Three-dimensional printing It is the latest technique developed by Massachusetts Institute of technology (MIT). Z Corporation and Pro Metal took its license for prototyping applications and tooling respectively. 3D printing technology is an addictive manufacturing technology that was based from a rapid prototyping technique known as stereolithography.
Figure 2.11 3d printing machine [10]
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Method This method starts with the spreading of the powder layer by layer over the surface of powder bed. As in ink jet printing, the place where the object is formed is due to the joining of binding material and particles. A roller mechanism layers the powder on the platform and a piston mechanism lowers the powder bed so that other layers can be layered increasing the layers upon each other. This process of layering on each other is continued until the object is completed.
Figure 2.12 3D printing process [11]
Figure 2.13 a roller layering powder over powder bed in 3D printing process [12] Sree Vishnu Muralidharan | 000700290 28
Advantages It has strong build up compared to other rapid prototyping systems Complex shapes or objects can be created as they dont require support structures Disadvantages Surface finish is not good The parts that are newly printed are fragile and require infiltration
Figure 2.14 Comparison of different Rapid Prototyping Technologies [13]
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The chart shows materials that are offered by Xpress 3d. Ratings are given on the basis of application and uses. -
Figure 2.15 Material comparison chart [14]
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2.5 The Laser cutting machine used for cutting the layers
Figure 2.16 the laser cutting machine [15]
The benefits of Universals laser systems The laser traces objects with a print control and is software controlled. It can cut, score, mark, and produce photo images in a single step. Without applying any physical force the material can be modified. It has capacity to produce everything in the needed time and doesnt require waiting for hard tooling. The Universal laser system have excellent quality beam which has power distribution and good near and far field characteristics which is unique in their laser systems due to the air cooled and free space gas slab lasers. The laser has the power and potential to even trace out or cut the small spots because of the high power density optics in it.
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The laser system has a material based driver which traces or cuts the material according to the thickness that is being entered.
2.5.1 Purex - Fume extraction system:
Figure 2.17 fume extraction system [16]
Specifications of the fume extraction system Voltage = 230 volt
Rated Power = 1800 watt Frequency = 50-60 Hz
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Benefits of fume extraction system It can maintain constant extraction rate even if the filter blocks as it is equipped with automatic flow control. It can adjust the speed. During the time exhaust it can sense gas and particles. Capital costs and running costs are low It is equipped with carbon filters to remove the harmful gas Quite operation The fumes generated from the laser cutting machine when tracing out or cutting anything may lead to problems for the humans like asthma attacks or other respiratory diseases. Thus a fume extractor must be used so as to extract the fumes. The following are the functions that re done by the fume extraction system Protect the health of employee Offers good working environment Increases the speed of production Reduces the wastes and dust materials so that the complaint by the customers or the operators is reduced. Reduces the cost and time required for cleaning the laser senses, conveyors, soldering machines and other equipment Increases the speed of production Types of extraction system External Extraction system pumps the contaminated air outside the area. Internal extraction system Captures and filters the air and has (local exhaust ventilation) LEV LEV is the best system and is used in this process as it captures the fumes there itself, filters it and doesnt allow the fumes to flow in outside area.
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Chapter Three
Problem analysis and solution
Chapter Three gives description on the problems that are faced by current Laminated Object Manufacturing method of de-cubing, some other issues related to it and the proposed solution being suggested for the problem
3.1 Problem analysis The Laminated Object Manufacturing faces mainly two problems De-cubing - (Removal of waste materials after completion of process) Providing supports for island or overhanging structures in complex prototype Alignment of the paper sheets
3.1.1 De-cubing in laminated object manufacturing
The removal of waste material process in the laminated object manufacturing is known as De-cubing. De-cubing process Removal of the stack from the platform of the machine To expose the cubes of the excess material (waste material), the surrounding wall is removed. Removal of cubes from the surface of the parts
Figure 8.1 the de-cubing method [17] Sree Vishnu Muralidharan | 000700290 34
The process of de-cubing is labour intensive, time consuming and tedious process Laminated Object Manufacturing (LOM). The waste materials is not only strong as the final made part by LOM, it gets stick to the part. De-cubing is more complex due to the location and the size of the material. The waste material when trapped between the walls, blind holes, internal cavities with restricted areas etc. makes it much more difficult. 3.1.2 Supporting the overhanging structures
Figure 3.2 an overhanging structure [18]
Figure 3.3 (a) An object (b) the diagram showing the overhanging structure in the object to be supported [19]
The island structures inside and outside the object to be prototyped should be supported as they are linked to the object. If the supports are not given the prototype cannot be completed as the island structure cannot be built as its hanging.
3.1.3 Alignment of the paper sheets The paper sheets if not aligned properly will result in zero accuracy and no surface finish and a failure in making the prototype with respect to the design. 3.2 Solution 3.2.1 Solution replacing the cubing method of supporting De-cubing being one of the most tedious, time consuming and labour intensive method should be replaced with other method of supports that could provide a firm support to the object being manufactured and can also be easily removed. Rapid prototyping technologies like 3D Printing and Selective Laser Sintering uses powder deposition method by a roller and forms objects. Thus adapting the technology in Laminated Object Manufacturing is found as the solution to eliminate the de-cubing method. Application of powder around and in the holes, in cavities, between the walls of the object wont cause any problem in neither in deposition nor in the removal process. Thus replacing the powder with the current de-cubing method will be the ultimate solution for supporting the object. The powder can be easily deposited and removed. 3.2.2 Supporting the island structures The need for supporting the island structures is needed so as to make the prototype correctly according to the design. The solution for supporting the structure is by supporting the island or overhanging structures with sticky label type papers rolled under it so that when rolled on, its upper part sticks on to the under surface of the island object and the lower part of the paper roll rests on the bed firmly. The island could be easily removed and can be relied upon to have objects upon it. 3.2.3 Paper alignment mechanism The paper alignment mechanism is considered as a problem because if not sorted the papers in a proper manner the prototype shape could be distorted. Thus the Rapid Pro software has been used as the solution to this problem. The software divides the object into layers with an alignment mechanism in each layer.
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Methodology
Laminated Object Manufacturing
De- cubing
Overhanging Structures
Paper sheet alignment
3D Printing
Selective laser sintering
Types of supports that could be used
The paper alignment mechanism to avoid distortion of prototype
Powder Tabs Powder Rapid Pro Software
Sand
Flour
Sugar
Flour
Powder
Holes on upper side of layers
Frame around the layer
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Chapter four
Implementing the solution
Chapter four gives a description on the methods being considered for implementing the proposed solution
4.1 Eliminating de-cubing and adopting powder as support

De-cubing being a time consuming, tedious and labour intensive process should be eliminated and replaced by other supports in the rapid prototyping considering the technology where the prototype should be made in a rapid manner. De-cubing also causes problems in the prototype being made and also causes changes in its shape. Thus supports such as wax, powder should be tried to support the prototype in a faster and efficient manner so as to build the prototype quickly with the help of supports and also to remove the supports easily without causing any damage the prototype and also by not causing changes to its shape. Thus powder is chosen as the solution for supporting the object (prototype) in Laminated Object Manufacturing. Powder can be easily deposited, can enter deep holes and cavities and can easily be deposited between the walls of the complex prototypes
Figure 4.1 A complex prototype made by sintering nylon powder [20]
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The prototype in the image above shows how complex it is. It is nearly impossible to make the prototype with the de-cubing method. The powder can be deposited inside and around the holes and after the prototype is made and even if the prototype is delicate it can be simply tilted to remove the powder inside it. The uses of powder as a support in Laminated object Manufacturing is adopted from other rapid prototyping technologies i.e. 3D printing and Selective laser sintering. A brief of 3d printing and selective laser sintering is given below
4.2 Adapting technologies/methods used by other Rapid Prototyping systems

4.2.1 3D Printing The system consists of a feed chamber that consists of powder to be used, the type of the powder varies with the product or the prototype to be made. There is a build chamber that is adjacent to the feed chamber where the material or the prototype is built. The position of the build material that is to be built can be changed by the movement of the feed piston. The powder is deposited on the build platform by a by a roller which is carried by a horizontally reciprocating carriage. The material is swept down the overflow chute when it exceeds the level of the material.
Figure 4.2 the process of depositing powder in 3d printing technology [21]
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To match the design of the CAD model, a binder solution is deposited by a binder cartilage which is also mounted on the carriage. The feed piston then goes down a layer thickness varying from 0.100 to 0.250 and new layer is deposited as the build platform lowers. The process is repeated until the final prototype or object is formed. The roller being used to deposit powder in 3d Printing -
Figure 4.3 a layer of powder being spread by roller [22]
Figure 4.4Binder solution being deposited by the binder cartilage [22]
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Figure 4.5 Roller depositing another layer of powder over the previous one [22]
After the layering is finished the powder that is not used is removed from the build platform/chamber.
Figure 4.6 the whole process of 3d printing at a glance [23] Sree Vishnu Muralidharan | 000700290 41
4.2.2 SLS (Selective Laser Sintering) The selective laser sintering is the process in which a 3D CAD model is used for the prototype to be made. It is a process in which powder materials are sintered and fused with help of CO2 laser. Parts are generated by finely ground powders. The SLS machine consists of the following components Build piston Feed piston Laser scanner Levelling roller Powder cartilage A bin to collect the excess material CO2 laser
Figure 4.7 a selective laser sintering machine [24] Sree Vishnu Muralidharan | 000700290 42
Working of Selective laser sintering At first the built chamber is heated in order to reduce the energy so that the laser can sinter the material. The roller spreads a layer on the built platform and then the laser sinters the material. Once the laser has sintered the material another layer of powder is deposited/layered over the previous layer. After the completion of the process i.e. after the prototype is made, the prototype is taken and the excess powder material is removed.
Figure 4.8 the selective laser sintering process [25]
The SLS being a quick method creates prototypes with good accuracy but has bad surface finish due to its nature of sintering technology.
4.3 Powder Selection

Much type of powders is used in the rapid prototyping technology like 3D Printing, Selective Laser Sintering etc. But in 3Dprinting and Selective Laser Sintering the powder is used to make prototype and in case of Laminated Object Manufacturing the powder is only used for the purpose of supporting, to be replaced with the cubing method. Thus powders that are easily available can be used considering the firmness it can give to the object while supporting and also its cost. 3 types of powders could be considered being used for supporting the prototype in Laminated Object Manufacturing Sand Sugar Particles Flour The type of powder was chosen depending on the availability, cost and firmness.
Selection of type of powder

9 8 7 6
Rating
5 4 3 2 1 0
Availability Cost Firmness Removing the type of powder
Sand Particles
Flour Particles
Type of Powder
Sugar Particles
Graph 4.1 the type of powder was chosen depending on the availability, cost and firmness
Thus Flour has been chosen over sand particles and sugar particles mainly considering its firmness it offers to the prototype or the object being made and secondly due to its availability.
4.4The Selection of method of deposition of powder into chamber

Two approaches were used for the powder deposition mechanism in order to deposit the powder in proper manner so that it supports the object properly. The first approach is the use of a scrapper blade to push the powder to the piston bed/build platform where the prototype is to be made so as to support it.
Figure 4.9 a scraper blade pushing the powder [26]
The problems faced by the scraper blade are It requires a significant amount of powder in front of it. It increases the friction between powder and heap and the underlying layer. It results in increase in the weight of the material
Figure 4.10 a scraper blade pushing the powder [26] Sree Vishnu Muralidharan | 000700290 45
The second approach is using a rolling cylinder or a roller. The roller rolls the powder from initial to final position.
Figure 4.11 the roller pushing (rolling) forward powder [26]
The problem faced by the roller is The irregularities caused by the roller due to the contact between the powder and the roller
Figure 4.12 the roller pushing the powder [26]
The scraper blade (sharp wiper) has been chose for the deposition purpose as its easily available and even be used manually and easily.
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4.5 Alignment Mechanism of paper sheets

The alignment of the paper sheets is one of the most important steps to be looked at as the paper sheets if not aligned properly can lead in distorted shape of prototype. Software called Rapid Pro is used for the alignment mechanism. The following steps are followed for the alignment when the Rapid Pro software is used. 1. Selection of a STL file to be sliced and aligned (In this case a Motorbike have been chosen) 2. Selecting the slicing direction (top, left, back, right, bottom and front) of the object or model to be sliced
Figure 4.13 Slice directions in paper alignment mechanism
3. Selection of the material to be used, which gives the dimensions of the prototype to be made
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Figure 4.14 Object dimension
4. Calculating the number of slices the model has
Figure 4.15 slicing of the object
5. The papers are sliced with respect to the layer numbers with holes on the top so as to align the paper one upon another one so that the prototype has a proper shape with respect to the CAD model with dimensional accuracy.
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Figure 4.16 paper alignment mechanism
4.5. Prototypes to be made

The following 5 prototypes was been selected to be made 1. Turbine (impellor)
Figure 4.16 Turbine (impellor)
2. Gear (Differential)
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Figure 4.17 gear (Differential)
3. Snarl (Spherical ball)
Figure 4.18 Snarl
4. Motorbike
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Figure 4.19 motorbike
5. Pen Holder
Figure 4.20 Pen Holder
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4.5.1 Cutting the papers to obtain the paper with correct thickness to get
exact dimensional accuracy of prototype

Cutting the papers in the laser cutting machine so as to sack it after the parts to be stacked in each layer is traced out by the laser. Taking different parameters such that when the thickness is varied there is a change in laser cutting leading to cut the layers depending upon the set up on the machine. The objective is to cut the paper in a way that even if its thickness is increased by stacking more papers it cuts through all the layers except the last layer.
Figure 4.21 the laser cutting machine powder [27]
Figure 4.22 the laser cutter powder [28] Sree Vishnu Muralidharan | 000700290 52
Objective - To make a turbine (impellor) of 3.4 mm height. Serial Number Change in parameters and change in the paper type and paper thickness Observation or variation when changed the
parameters and paper thickness
1.
Thickness of paper - 0.10 mm A4 size normal paper Thickness in machine 0.113 mm
Laser cut this paper but the parts of it started blowing away due to the air inside the machine. As the density of paper is very less.
Power 4.4 % Speed 80 % Colour - red (Used for cutting)

Figure 9.23 paper thickness of 0.10 being cut to make turbine
2.
Thickness of paper 0.20 mm 2 papers of 0.10 mm each stacked to increase thickness
Two papers were stacked to increase the thickness. As the cutting of the paper was change to blue thus only scaring was done and it had no cuts on it. The only solution for this was to cut by blade or cutter for each and every layer but as this a time consuming process it was rejected.
Power 4.4% Speed 75 % Colour Blue (Used for scaring)

Figure 4.24 paper thickness of 0.20 being scored to make turbine Sree Vishnu Muralidharan | 000700290 53
3.
A sticky paper was used of 0.15 mm thickness
The Sticky paper is a kind of lalbel were its back side is eeled of and the sticky surface is sticked to the surface of machine so that the island parts on it are not blown out due to its lesser density. The laser cuts the sticky part and does its job but again there is tiime consuming process of removing the each island part which is stuck to the surface of machine due ti its glue effect. After the part is removed from there it should be properly put in between the boxed space so thatduring the time of arranging the layers one upon other proper paper allignment is followed.
Thickness adjusted in machine 0.113 mm
Power 12% Speed 75%
Figure 4.25 sticky paper of thickness 0.15 mm to make turbine Table 4.1 Selection of paper and proper parameters to make turbine
Result after the cutting of sticky papers The turbine 1. Top view of turbine
Figure 4.26 Top view of turbine
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The process of turbine making A piston arrangement was made onto a rectangular box container where a plastic pipe was inserted from its bottom acting as a piston moving up and down. The piston was connected to a piston bed or build platform which was a thick card board. The process starts with the first layer being placed on a paper taped on the built platform so that when the layers are stacked on it stays firm. The layers are stacked and are supported with powder around it and also supporting the overhanging and island structures. The layering of the powder is done by wiper mechanism so as to push the power uniformly everywhere. The wiper being used to push the powder across the built platform.
Figure 4.27 Wiper being used to push powder across build platform
A roller being used to suppress the layers in accordance to reduce the air gap and to stack the layers properly.
Figure 4.28 roller used for pressing the stacked layers Sree Vishnu Muralidharan | 000700290 55
The layer being aligned by two holes on its upper part being inserted through a nail so as to stack the layers above and under it properly in an order so that the final prototype being made has good accuracy.
Figure 4.28 paper alignment through nails placed on platform
Prototype being ready on the build platform
Figure 4.29 Prototype being made using sticky papers of 0.15 mm thickness
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2. Side View of the turbine
Figure 4.30 Side view of turbine
3. Bottom view of the turbine
Figure 4.31 bottom view of the turbine
Height 2.56 cm Width 4.5 cm Thickness of paper used 0.15 mm Verdict The turbine could not be the exact height of 3.14 metre. It had a height of only 2.56 metre and had less accuracy as it was manually built and also as it did not have layers of proper thickness (the original thickness that had to used was 0.229 mm and the thickness that was used was 0.15 mm). Thus the difference in thickness in terms of paper resulted in low height of the turbine (impellor) prototype.
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The following experiment was done by paper of different thickness and adjusting various parameters in the laser cutting machine to cut the paper layers and then form a prototype of motorbike by stacking the layers. 1. The changes made in the parameters in the laser cutting machine Paper thickness 0.15 mm Thickness 0.09mm Colour- blue
The observation In this case the laser cut through the 1st and the 2nd paper
Figure 4.32 paper thickness of 0.15mm thickness being cut by laser
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2. The changes made in the parameters
The thickness was changed to 0.05 mm
Paper thickness is 0.15 mm Colour blue
The Observation The laser didnt cut through the 1st and the 2nd part of the 0.15 mm paper i.e. the; laser didnt cut through the paper. Some other observations were
There was only an outline and a scaring on the paper surface As the laser didnt cut through it did not had any paper pieces sticking to the tack underneath it.
The laser didnt cut through and this it can be seen that the back side of the paper is as it is and has no marks of laser on it.
Figure 4.33 paper thickness of 0.05 adjusted in laser cutting machine being cut by laser
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3. Changes made in parameters in the laser cutting machine Machine adjusted thickness - 0.08mm
paper thickness 0.15 mm
Colour - blue
The Observation It took one minute and 25 seconds to cut the paper and the laser cut the paper throughout with parts of it being stack on the tack due to glue effect. Its clearly visible the parts of the paper that got stacked to the tack due to glue effect
Figure 4.34 Thickness of paper 0.15 mm and 0.08 thickness adjustment made in machine
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4. Changes in parameters Thickness adjusted in machine- 0.06mm power 4 %
thickness of paper - 20 mm
Colour - blue
The observation The paper was cut through by the laser and was stacked to the tack due to the glue effect
Figure 4.35 Thickness of paper 0.20 mm and 0.06 thickness adjustment made in machine
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5. Change in parameters Thickness of 0.05 mm
Power at 7.4 %
Colour - blue
The observation It just had a scar on the first part and leaving no marks on cuts on the second part.
Figure 4.36 Thickness of paper 0.20 mm and power 20% adjustment made in machine
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6. Change in parameters 5 papers stacked together - thickness of paper = 0.55 mm (Increased thickness = 0.55mm - 0.15mm = 0.40mm )
The increased thickness includes the 5 papers being stacked and the glue applied in between them.
Colour - blue
The observation Due to the increase in thickness of paper and also as there was tack underneath it, the laser when started cutting was very adjacent to the paper that it couldnt cut properly. It only had scars on 1st and 2nd paper
Figure 4.37 papers being stacked, scoring done by the laser
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7. Change in parameters 3 papers stacked,
Thickness of paper - 0.30 mm
Thickness being adjusted in machine to cut it - 0.10 mm
Power - 16 %
Colour - red
The Observation The colour of the laser cutting was set strong i.e. red colour and thus the laser cut through the three layers but the tack underneath didnt had much power to hold the paper being stacked to it as the force of air was very high which resulted in blowing of some parts of layers.
Figure 4.38 thickness of 0.30 mm and power 16% adjusted in laser cutting machine
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8. Change in parameters Thickness of paper 0.22 mm
Power - 9% colour blue
Thickness adjusted in machine - 0.30 mm
The Observation The approach was changed as the parts of the paper started blowing due to air pressure inside the machine, thus the island features in each layers were connected using bridges with the help of AutoCAD and was then converted to the dxl format for the paper to be cut. The island objects didnt blow off and thus this approach is used finally.
Figure 4.40 thickness of 0.22 mm
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4.6 Stacking of papers

The paper sheets should be placed one upon each other in such a way that the holes on top of layers goes exactly through the smooth and firm nails placed on the built platform of the machine which will avoid distortion of the prototype. The next paper sheet should be glued underneath it with a super glue in order to stick it on top of the previous layer such it fits it perfectly. Once the layer sits perfectly the unwanted parts of the layer (paper sheet) can be removed. The process is repeated until all layers are being stacked and the prototype is formed.
4.7 Prototype made

The paper that is chosen is a thick sheet of width 0.22 mm to make the prototype. The other 3 prototypes i.e. snarl, gear and the pen holder couldnt be made due to lack of time.
4.7.1 The turbine (impellor) prototype 1. Front view
Figure 4.41 turbine prototype -front view
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2. Back view
Figure 4.42 turbine prototype -back view
3. Top View
Figure 4.43 turbine prototype -top view
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4.7.2 The Motorbike prototype Top view
Figure 4.44 Motorbike prototypes - top view
Front View
Figure 4.45 Motorbike prototypes - front view
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The motorbike made by 3D Printing machine-
Figure 4.46 prototype made by 3d printing
4.8 Supporting the island structures

Two solutions were being found out for supporting the island structures or over hanging structures The first approach was - The island or the overhanging structures in the prototype can be supporting the island or the overhanging structures in the prototype by rolling the sticky paper and placing it correctly such that the peel off paper which is above the rolled paper is stick to lower part of layer (island) to be stacked and the sticky paper roll is stick to the platform. The paper can be rolled depending upon the height of the island structure form the built platform. After the island structure is connected to the prototype by the stacking process, the support structure can be removed using forceps or small pickups even if the island is in a complex place. The second approach was using the powder itself for supporting the prototype and also to give supports to the island structure as it can be easily deposited and removed. The powder has been chosen to support the island structures as it is been already considered as the support material replacing the de-cubing method. The powder can be removed from any complex places in the prototype as compared to the sticky paper roll. Thus adopting powder for even supporting the island objects is regarded as the better solution.
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Chapter 5
Results and Discussion 5.1 The prototypes made 5.1.1 The turbine prototype
Figure 10.1 Turbine prototype made by LOM without de-cubing
5.1.2 The Motorbike prototype
Figure 5.2 Motorbike prototype made by LOM without de-cubing
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5.2 Dimensional comparison of the CAD model of turbine and the prototype:Dimensional Parameter Original Object Prototype Difference
Figure 5.3 turbine CAD model
Figure 5.4 turbine prototype made by LOM without de-cubing
Inducer Diameter (millimetre) Exducer Diameter (millimetre) Shaft hole Diameter (millimetre) Shaft Hole Depth (millimetre)
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50
54-48 = 4
33
28
33-28 = 0.5
54
48
54-48 = 6
Overall Length 54 of the Turbine (millimetre)
48
54-48 = 6
Table 5.1 dimensional comparison of Turbine CAD model and turbine made by LOM
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5.2.1 Graphical Representation of quality of manually made turbine prototype and the turbine of proper dimensions
Dimensional Comparison(Quality)
6
Millimeter
Turbine made by LOM

2
Turbine Model
Inducer Diameter
Exducer Diamter
Shaft Shaft hole Exducer Hole depth Diamter Diamter
Dimensional Parametrs
Graph 5.1 dimensional comparisons of Turbine CAD model and turbine made by LOM
Reason for the difference in dimensional parameters Improper alignment Shaking built platform leading to misplacing of some layers Stacking not being done properly (small gaps in between some layers)
5.3 Supporting the island structure The island structures in the complex prototype is to be supported with powder as it can be easily deposited in the complex places like holes, in between walls etc. and it can also be removed by just tilting the prototype which will drew away the powder that was deposited in it.
5.4 Comparison of dimensional accuracy of motorbike made in 3D printing
machine and Motorbike made by Laminated Object Manufacturing (L.O.M)

Dimensional Parameters Motorbike made in 3D printing machine Motorbike made by (L.O.M) Differenc e
Diameter of Front tyre (Millimetre) Diameter of Rear tyre (Millimetre) Thickness of front tyre (Millimetre) Thickness of back tyre (Millimetre) Overall length of bike (Millimetre) Overall height of bike (Millimetre) Length of handle (Millimetre)
Table
66.85
56.94
9.91
52.64
45.10
7.54
12
10
12
10
150
146
62
59
51
48
5.2 dimensional comparison of motorbike made by 3d printing and LOM
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5.4.1 Variations in dimensions of motorbike made by 3d printing and motorbike by L.O.M
Dimensional Comparison (Quality)

160 140 120 100 80 60 40 20 0
Millimeter
Motorbike made by 3d printing Motorbike made by LOM
Dimensional Pramaters
Graph 5.2 dimensional comparison of motorbike made by 3d printing and LOM
The reasons for variations in dimensions are because Improper alignment mechanism of paper sheets Improper paper sheet stacking leading to space between some layers Manual process leading to movement in prototype when not placing the layers properly Bad surface finish The nails on the built platform were not properly arranged The built platform wasnt with correct dimensions with respect to the chamber
5.4.2 The Time comparison in case of Motorbike built by 3d printing and LOM
The total time took by 3d printing in building motorbike is 17 hours and 43 minutes i.e. 1063 minutes and the time taken for building the motorbike in Laminated Object Manufacturing is 13 hours and 35.minutes i.e. 815 minutes. Thus there is a time difference of 248 minutes i.e. 4 hours and 13 minutes. Therefore using Laminated Object Manufacturing over 3D Printing saves 248 minutes.
Time Comparison
1200
1000
800
Minutes
Mototrbike made by 3d printing

600
Motorbike made by L.O.M
400
200
Time taken
Graph 5.3 Comparison of time taken for motorbike made by 3d printing and LOM
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5.4.3 Cost Comparison in case of Motorbike built by 3d printing and Laminated Object Manufacturing (L.O.M)The material cost for building motorbike by 3D Printing Material required to make motorbike = 180 The cost of 997 is 270 pounds, = * 180 = 48.74 pounds
Therefore cost for 180
The material cost for building motorbike by L.O.M Energy cost = 0.167 pounds (in one hour the machine consumes 0.835 kilo watt, thus as one unit costs 10 pence; the energy cost = 0.835 * 0.10 * 2 = 0 167 pounds) Material cost = 10.60 pounds Total cost made to build the motorbike = 10.60+0.167 = 10.76 pounds. Thus the price difference between the motorbike made by 3D Printing when compared with that of L.O.M = (48.74 - 10.76) pounds = 37.98 pounds
Cost Comparison
50 45 40 35
Pounds
30 25 20 15 10 5 0
Motorbike built by 3d printing Motorbike built by L.O.M
Cost
Graph 5.4 Cost comparison of motorbike made by 3d printing and LOM Sree Vishnu Muralidharan | 000700290 76
5.5 A comparison of manually made prototype with the prototype made by 3d printing
6 Prototype made by Laminted Object Manufacturing
Prototype made by other rapid protyping systems(3D Printing)
0 Quality Cost Time
Graph 5.5 Quality, Cost and Time comparison of Prototype made by 3D Printing and L.O.M
The graph depicts that the prototype made by Laminated Object Manufacturing lacks a bit quality when compared with prototype made by 3D printing due to its poor surface finish which could be improved in future. The cost shows that prototype made by Laminated Object Manufacturing is much cost effective when compared to that made by 3D printing and the prototype made by Laminated Object Manufacturing is also time efficient when compared with that of 3D printing.
Chapter 6 Conclusion and Future work

Conclusion
The Laminated Object Manufacturing (L.O.M) can be regarded as one of the quick rapid prototyping systems where powder has been adopted as the new support for supporting the complex prototypes with the elimination of the de-cubing method. The prototype has been made in this process by eco-friendly and recyclable materials which are easily available and are cheaper ingredients as raw materials. It has been proved that any complex prototype could be made by L.O. M. in a cost effective way and also has proved to be time efficient. The only problem seen in this method was a poor surface finish which could be easily sorted out by proper alignment mechanism and providing improvements in some aspects of the machine where the built platform has proper dimensions with respect to the built chamber.
Future Work
The future work aims at advancement of this system by making it completely automated in order to save time and improve the surface finish The following changes shall be made considering the automation of the machine Automatic powder deposition with the scraper blade resulting in uniform deposition of powder across the platform. To automate the stacking process so as to avoid paper sheet alignment method problems when done manually so as to provide accurate paper alignment method. To make the machine more cost effective and time efficient Steps undertaken to increase the quality of the product, specially the surface finish. Papers which are used for stacking and making the prototype should be adhesive papers such that they are sticky enough to automatically getting stuck to the previous layer so that manual applying of adhesives is neglected A pipe with cork into a container for collecting the powder shall be provided such that it is connected to a small hole and cork under the chamber in order to properly remove the powder in the process so as to re-use the powder for the deposition process.
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Reference
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Appendix
The following table is the process of selecting a proper paper thickness for making turbine Serial number Change in Parameters and thickness of papers that are stacked Observation or variation when changed the parameters and paper thickness
1.
The observation of this parameter being chosen was that The thickness the laser cut through the whole 1st and 2nd part. was changed to 0.09 mm. Paper thickness 0.15 mm Colour - blue
2.
The thickness was changed to 0.05 mm Paper thickness is 0.15 mm Colour - blue
The Observation was that it didnt cut through the 1st and 2nd part of the 0.15 mm i.e. the laser didnt cut throughout the paper. i. There was only an outline and a scaring on the paper surface.
86
ii.
As the laser didnt cut through it did not had any paper pieces sticking to the tack underneath it.
iii.
The laser didnt cut through and this it can be seen that the back side of the paper is as it is and has no marks of laser on it.
3.
Machine adjusted thickness 0.08mm paper thickness 0.15 mm Colour - blue
It took one minute and 25 seconds to cut the paper and the laser cut the paper throughout with parts of it being stack on the tack due to glue effect.
87
Its clearly visible the parts of the paper that got stacked to the tack due to glue effect
4.
Thickness adjusted in machine0.06mm power 4 % thickness of paper - 20 mm Colour - blue
The paper was cut through by the laser and was stacked to the tack due to the glue effect.
88
5.
Thickness adjusted at 0.03 mm power at 4.4 % 75% speed
No difference was found from the previous one as it again cut through the paper and stacked to the tack.
6.
Thickness of 0.05 mm power at 7.4 % Colour - blue
It just had a scar on the first part and leaving no marks on cuts on the second part.
89
7.
5 papers stacked together thickness of paper = 0.55 mm (Increased thickness = 0.55mm 0.15mm = 0.40mm ) The increased thickness includes the 5 papers being stacked and the glue applied in between them. Colour - blue
Due to the increase in thickness of paper and also as there was tack underneath it, the laser when started cutting was very adjacent to the paper that it couldnt cut properly. It only had scars on 1st and 2nd paper.
8.
3 paper being stacked together with thickness of 30 mm, thickness adjusted in the settings 20 mm Power - 4.4% Colour - blue
It didnt cut through the 3rd paper but the laser cut through the 1st and 2nd paper.
90
9.
3 papers stacked Thickness = 0.30 mm Thickness adjusted = 20mm Power 4.4% Blue-tack underneath it Colour - blue
3 papers were stacked together and blue-tack was placed underneath it the laser didnt cut through any of the layers but had scars on the 1st paper.
10.
3 papers stacked, Thickness of paper - 0.30 mm Thickness being adjusted in machine to cut it 0.10 mm Power - 16 % Colour - red
The colour of the laser cutting was set strong i.e. red colour and thus the laser cut through the three layers but the tack underneath didnt had much power to hold the paper being stacked to it as the force of air was very high which resulted in blowing of some parts of layers.
91
11.
3 papers stacked, Thickness of paper - 0.30 mm Power - 25 %
The laser cut through 1st and 2nd paper and had scars on the 3rd paper. The results was repeated 5 times to make sure the parameters are correct and the layers can be cut with this parameter but after 2 times there was change were only the first layer was cut.
12.
Thickness of paper 0.22 mm Power - 9% colour blue Thickness adjusted in machine - 0.30 mm
The approach was changed as the parts of the paper started blowing due to air pressure, thus the island features in each layers were connected using bridges with the help of AutoCAD and was then converted to the dxl format for the paper to be cut. The island objects didnt blow off and thus this approach is used finally.
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2012 Final Year Project

Topic - Development of a process for Laminated Object Manufacturing without de-cubing.

Name Sree Vishnu Muralidharan

Date 27th April, 2012

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

1.1 The main purpose (Aim):

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

2.0 Rapid Prototyping and its types

Table 2.1 the Emergence of Rapid Prototyping [1]

Final Year Project April 1, 2012

Final Year Project April 1, 2012

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

Figure 2.2 Result of introducing rapid prototyping in design [2]

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

2.2 Rapid prototyping technologies

Figure 2.3 the three stages of rapid prototyping system [3]

Sree Vishnu Muralidharan | 000700290

Final Year Project April 1, 2012

RP systems listed in 1999:

3DP three-dimensional printing

3DWM three-dimensional welding and milling

CLOM curved laminated object manufacturing

DLF direct light fabrication

DLMS direct laser metal sintering

ECLD-SFF electrochemical liquid deposition for solid freeform fabrication

EDSSM extrusion and deposition of semi-solid metals

EFF extrusion free forming

EPDFF electrophotographic powder deposition for freeform fabrication

FDC fused deposition of ceramics

FDM fused deposition modelling

FDMet fused deposition of metals

FFF fast freeform fabrication

Final Year Project April 1, 2012

LDM laser diode manufacturing

LENS laser engineered net shape

LOM laminated object manufacturing

M2SLS multi material selective laser sintering

Meso SDM mesoscopic shape deposition manufacturing

PPD point wise powder deposition

RPBPS rapid pattern based powder sintering

RSLA refrigerative stereolithography

SGC solid ground curing

SLPR selective laser powder remelting

SLS selective laser sintering