APPLICATIONS

Selective Laser Sintering is the ideal solution for

Fully functional prototypes and series.
Rapid Manufacturing.

Fully functional prototypes and series

1. Parts for mechanical and thermal tests
The polyamide material allows the production of strong, durable parts that can be
used for extensive functional testing. Sintered products have mechanical
properties comparable to those of injection moulded PA12 parts. Typical
applications are snap fits but it is also possible to produce working hinges.
Polyamide parts with glass filling have a much higher thermal resistance and are
perfectly suited for lighting elements and ventilation systems or products that
require high thermal loads. Apart from their use as test products, the functional
SLS parts often also need to be used at the same time for a visual/esthetical
control or dimensional check.

2. Series of small plastic parts

SLS is an interesting and cost-effective alternative to injection moulding (Rapid
Tooling). With the P 700 machine which has a large build area, a series of small
pieces can be built in one
single laser sintering process. This dramatically decreases the price, as the cost
of an SLS part depends on its volume. Or in other words, the cost is defined by
the amount of powder it takes to build it and not by an initial investment in an
injection moulding tool. Moreover, series of SLS parts are available in a few days.
So no need for high start-up investments, no long lead times to produce a mould
and injection mould the parts, no difficulties in case the parts are complex.

Component of a vacuum cleaner, built on the EOSINT P700

with a build volume of 700x380x580mm
3. Large and complex functional parts
The EOSINT P 700 machine can build large, complex geometries in one piece,
up to 700x380x580mm. The number of layers to be built is significantly reduced
as large parts can be built horizontally, which considerably shortens the building

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process. Parts exceeding the P 700' maximum dimensions can be built in multiple
pieces and put together afterwards. The process of gluing sub-parts and
assembling components can be done in the most accurate and secure way using
the RapidFit system. RapidFit allows to firmly position the parts on a unique
support system with individualized fixtures, supporting the part on wellpositioned
points.

Torus.MGX
Rapid Manufacturing
3D Printing techniques are used more and more in Rapid Manufacturing
environments. This technique has proven to be an ideal solution especially for
design and trend objects. Unique, personalised designs are built as once-only
products or in a very small number of parts. The process of Selective Laser
Sintering offers more freedom in terms of design and shape than traditional
production techniques. In this view the Materialise.MGX collection came into
being. This label stands for unique lighting designs manufatured with 3D printing
technologies, like Stereolithography and Selective Laser Sintering that offer a
new freedom to create shapes. This freedom also allows us to easily customise
products in function of the customer's personal environment.

Selective Laser Sintering (SLS) uses a laser to sinter powder based materials together,
layer-by-layer, to form a solid model. The system consists of a laser, part chamber, and
control system.

The part chamber consists of a build platform, powder cartridge, and leveling roller. A
thin layer of build material is spread across the platform where the laser traces a two-
dimensional cross section of the part sintering the material together. The platform then
descends a layer thickness and the leveling roller pushes material from the powder
cartridge across the build platform, where the next cross section is sintered to the
previous. This continues until the part is completed.

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Once the model is complete, it is removed from the part chamber and finished by
removing any loose material and smoothing the visible surfaces.

SLS Highlights
• Ideal for durable, functional parts with a variety of applications. Capable of
producing snap fits and living hinges.
• Maximum dimension for instant quote: 11”x13”x17”
• SLS Material choices include Duraform, DuraformGF and NEW! SLS Flex.
• Standard Tolerances of +/- 0.005" for the first inch,
and +/- 0.003" for each additional inch.
• In the z height (vertical), standard tolerances of
+/- 0.01" for the first inch, +/- 0.003” on every inch thereafter.
• Layer Thickness: 0.004”
• Good Choice for high-heat & chemically resistant applications.

• Samples available upon request.

RAPID PROTOTYPING WITH
SELECTIVE LASER SINTERING (SLS)

Acu-Cast Technologies is offering (SLS) Selective Laser Sintering for

applications that require functional testing. These prototypes are durable, rugged
and able to withstand the harshest testing environments. With the widest
selection of material properties of any rapid prototyping process, and the use of
(SLS) Selective Laser Sintering; Acu-Cast Technologies can be extremely
versatile with your next prototyping project by turning an idea into a rugged
physical model with good detail and surface finish.

How it works:

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The SLS technology uses a CO2 laser to sinter (fuse) a variety of thermoplastic
and metal powders to "grow" 3D objects layer-by-layer from 3D electronic data
(STL files). Because this is an additive process, highly complex geometries can
be built without issue; and, because the powder holds the parts, no support
structures have to be added and removed. The key advantage of SLS is its ability
to rapidly produce durable, functional objects for a wide variety of applications.

Working parts and assemblies with good detail and surface finishing

• Variety of material: rigid and flexible plastics, fully dense metal, rubber-like
elastomer, foundry friendly patterns
• Capable of living hinges, high-flex snaps, high stress and heat tolerance
and service as short-run tooling
• Can be finished and painted for presentation, demonstration and video
reproduction
• Dimensional tolerancing with thousandths of a inch

• Delivery of most parts and patterns in just a few working days

STL Files

The .STL file format has become the Rapid Prototyping industry's defacto standard data
transmission format and is the format required to interact with Quickparts.com This
format approximates the surfaces of a solid model with triangles. For a simple model
such as the box shown in figure 1, its surfaces can be approximated with twelve triangles,
as shown in figure 2. The more complex the surface, the more triangles produced as
shown in figure 3.

Almost all of today's CAD systems are capable of producing an STL file. For the user the
process is often as simple as selecting File, Save As, and STL. Below are steps for
producing high quality STL files from a number of today's leading CAD systems. In all
cases, export your STL file as a Binary file. This saves on time and file size.

As a general rule, changing options such Chord Tolerance or Angular Control will
change the resolution on your STL file. The larger the STL file, the more triangles placed
on the surface of the model. For simple geometry (not a lot of curves) the file may only
be a couple hundred kilobytes. For complex models, files sizes in the range of 1-5MB

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will produce good parts. For many geometries, files larger then 5MB are unnecessary and
will often just result in more time to get your quote and parts back.

Also, for most RP process and materials, the minimum feature thickness is 0.020”.
Anything less then this, features will not develop. Please check your models and make
appropriate changes to critical features. An exception is the High Resolution SLA, which
will make features down to 0.010” and the SLS Somos 201 material, which needs 0.040”
thickness to produce features.

(Please note, these are only general guidelines and may not work or produce the best
possible STL file in some cases. Please consult you user's guide or the software's
developers for more information or technical support. Should we determine that your
STL file is not adequate for production we will contact you for an updated file.)

Alibre

1. File
2. Export
3. Save As > STL
4. Enter File Name
5. Save

AutoCAD
Your design must be a three-dimensional solid object to output an STL file.

1. Make sure the model is in positive space

2. Set “Facetres” to 10
3. At the command prompt type “STLOUT”
4. Select Objects
5. Choose “Y” for Binary
6. Choose Filename

CADKey

1. Choose Stereolithography from Export options

2. Enter the filename
3. Click OK

I-DEAS

1. File > Export > Rapid Prototype File > OK

2. Select the Part to be Prototyped
3. Select Prototype Device > SLA500.dat > OK
4. Set absolute facet deviation to 0.000395
5. Select Binary > OK

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Inventor

1. Save Copy As
2. Select STL
3. Choose Options > Set to High
4. Enter File Name
5. Save

IronCAD

1. Right Click on the part

2. Part Properties > Rendering
3. Set Facet Surface Smoothing to 150
4. File > Export
5. Choose .STL

Mechanical Desktop

1. Use the AMSTLOUT command to export your STL file.

2. The following command line options affect the quality of the STL and should be
adjusted to produce an acceptable file.
o Angular Tolerance - This command limits the angle between the normals
of adjacent triangles. The default setting is 15 degrees. Reducing the angle
will increase the resolution of the STL file.
o Aspect Ratio - This setting controls the Height/Width ratio of the facets.
A setting of 1 would mean the height of a facet is no greater than its width.
The default setting is 0, ignored.
o Surface Tolerance - This setting controls the greatest distance between
the edge of a facet and the actual geometry. A setting of 0.0000 causes this
option to be ignored.
o Vertex Spacing - This option controls the length of the edge of a facet.
The default setting is 0.0000, ignored.

ProE

1. File > Save a Copy

2. Set type to STL
3. Set chord height to 0. The field will be replaced by minimum acceptable value.
4. Set Angle Control to 1
5. Choose File Name
6. OK

Rhino

1. File > Save As

2. Select File Type > STL

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 3. Enter a name for the STL file.
4. Save
5. Select Binary STL Files

SolidDesigner

1. File > External > Save STL

2. Select Binary mode
3. Select Part
4. Enter 0.001mm for Max Deviation Distance
5. Click OK

SolidEdge

1. File > Save As

2. Set Save As Type to STL
3. Options
4. Set Conversion Tolerance to 0.001in or 0.0254mm.
5. Set Surface Plane Angle to 45.00
6. Save

SolidWorks

1. File > Save As

2. Set Save As Type to STL
3. Options > Resolution >Fine > OK
4. Save

Think3

1. File > Save As

2. Set Save As Type to STL
3. Save

Unigraphics

1. File > Export > Rapid Prototyping

2. Set Output type to Binary
3. Set Triangle Tolerance to 0.0025
4. Set Adjacency Tolerance to 0.12
5. Set Auto Normal Gen to On

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 6. Set Normal Display to Off
7. Set Triangle Display to On

Stereolithography (SLA)

Stereolithography (SLA) is often considered the pioneer of the Rapid Prototyping

industry with the first commercial system introduced in 1988 by 3D Systems. The system
consists of an Ultra-Violet Laser, a vat of photo-curable liquid resin, and a controlling
system.

A platform is lowered into the resin (via an elevator system), such that the surface of the
platform is a layer-thickness below the surface of the resin. The laser beam then traces
the boundaries and fills in a two-dimensional cross section of the model, solidifying the
resin wherever it touches. Once a layer is complete, the platform descends a layer
thickness, resin flows over the first layer, and the next layer is built. This process
continues until the model is complete.

Once the model is complete, the platform rises out of the vat and the excess resin is
drained. The model is then removed from the platform, washed of excess resin, and then
placed in a UV oven for a final curing. The model is then finished by smoothing the
"stair-steps."

SLA Highlights
• Excellent for Fit and Form Testing.
• Maximum dimensions for instant quotes: 20"x20"x20".
• DSM Somos material choices include: Flexible, Durable, Rigid, ABS-Like,
WaterClear, High Resolution (NEW! ABS-like, Durable & Rigid), NEW!
Elastomeric, & NEW! Composite (High Heat / High Strength)
• Standard Tolerances of +/- 0.005" for the first inch, +/- 0.002” on every inch
thereafter.
• In the z height (vertical), standard tolerances of +/- 0.01" for the first inch, +/-
0.002” on every inch thereafter.
• Layer Thickness: High-Resolution: 0.002” - 0.004”; Standard Resolution: 0.005”
- 0.006”
• Show Quality parts via painting and texturing.
• Chrome and nickel plating available upon request.
• Samples available upon request.

* Elastomeric and Composite are new experimental SLA materials. Quickparts does not
guarantee tolerances for experimental materials.