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    Selective Laser Sintering

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    Sreedhar Pugalendhi
    Selective laser sintering is an additive manufacturing technique that uses a high-power laser to fuse powdered materials like plastic, metal, or ceramic into a mass representing a 3D object. Parts can be functional prototypes made from production materials. The process works by using a laser to sinter powdered material layer by layer on a platform until the object is complete, requiring little post-processing. A variety of materials can be used depending on the application.

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    Selective Laser Sintering

    Uploaded by

    Sreedhar Pugalendhi
    499 views21 pages
    Selective laser sintering is an additive manufacturing technique that uses a high-power laser to fuse powdered materials like plastic, metal, or ceramic into a mass representing a 3D object. Parts can be functional prototypes made from production materials. The process works by using a laser to sinter powdered material layer by layer on a platform until the object is complete, requiring little post-processing. A variety of materials can be used depending on the application.

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    Selective laser sintering is an additive manufacturing technique that uses a high-power laser to fuse powdered materials like plastic, metal, or ceramic into a mass representing a 3D object. Parts can be functional prototypes made from production materials. The process works by using a laser to sinter powdered material layer by layer on a platform until the object is complete, requiring little post-processing. A variety of materials can be used depending on the application.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    499 views21 pages

    Selective Laser Sintering

    Uploaded by

    Sreedhar Pugalendhi
    Selective laser sintering is an additive manufacturing technique that uses a high-power laser to fuse powdered materials like plastic, metal, or ceramic into a mass representing a 3D object. Parts can be functional prototypes made from production materials. The process works by using a laser to sinter powdered material layer by layer on a platform until the object is complete, requiring little post-processing. A variety of materials can be used depending on the application.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 21

    Selective laser sintering is an additive rapid prototyping technique that uses a high power laser to fuse small particles

    of thermoplastic, metal, polyamide (nylon), ceramic, or glass filled nylon. SLS offers the key advantage of making functional parts in essentially final materials, depending on use of the part.

    Selective Laser Sintering

    SLS prototypes like many rapid prototyping processes are constructed from a .STL file. A .STL file is is simply a mesh of triangles wrapped around a CAD model (this was defined by 3D CAD systems in 1980s). .STLs name is derived from a rapid prototyping process, StereoLithography, also known as abbreviation of Standard Triangulation Language. This very simple format has become an industry standard for the Rapid Prototyping sector.
    The Solid Models as a: (a) Solid Model, (b) an STL file, and (c) in Sliced Layers.

    The process of Selective Laser Sintering (SLS) is somewhat similar to sterolithography, in that a prototype is produced rapidly through layering of material.
    From thermoplastic powders mostly, although SLS is useful in that many different materials can be used.

    A thermoplastic is a plastic that melts to a liquid when heated and freezes to a brittle, very glassy state when cooled sufficiently.

    Such as, polyamide (Nylon), material allows the production of fully functional prototypes with high strength.
    Glass Filled Nylon is suitable for high thermal resistance and high impact strength prototypes. SLS Somos 201 is used for functional rubber like parts.

    Depending on the use of the part being constructed these parts may be functional, a capability which is exceptionally useful.

    Price - Multiple pieces of the same part are much cheaper than ordering a single piece. Even various SLS models ordered at the same time as a single batch are much cheaper to make than ordering separately. Speed - It could be few hours or a day it really depends upon the build size, shape, and accuracy needed.

    Size of SLS singlemade parts are generally 13.3 x 13.3 x 2. Although larger parts can be constructed by making many smaller parts to assemble, and form a larger part. The thickness of an individual SLS layer is 0.15 to 0.2 mm layer thickness, depending upon the material used.

    The process of Selective Laser Sintering is actually quite simple. The entire internal system is heated to below the melting point of whatever substance is being used. So that when heat is applied by the high energy CO2 laser melts and fuses (sinters) the substance. To do this two piston-like platforms, a roller, an optical sensor, and whatever material is being used to form a part are used in co-ordination with the laser.

    The first piston contains most of the substance. When this piston is raised it makes the substance available to the roller. The roller moves the material over the second piston to cover the part being constructed. The material which has been moved to the second piston will then be sintered by the laser, to form an additional layer on the part.

    SLS Material
    variety of different types of materials available for use in the selective laser sintering (SLS) process. The most beneficial characteristic of selective laser sintering (SLS) is how durable and functional the materials are. DuraForm and DuraForm glass-filled (GF) which are nylon based materials that create plastic prototypes. Other selective laser sintering (SLS) materials are CastForm used for investment casting patterns, selective laser sintering (SLS) Flex for elastomeric, rubber-like parts, and selective laser sintering (SLS) LaserForm which makes metal prototypes.

    SLS Processing
    Each of selective laser sintering (SLS) materials requires little to no post build processing to be ready to use which cuts out several steps in post processing of selective laser sintering (SLS) parts as compared to stereolithography (SLA). However, all of the selective laser sintering (SLS) materials can be finished in multiple ways to meet the desire or needs of selective laser sintering (SLS) users. Among other types of post processing, selective laser sintering (SLS) parts can be sanded, painted, plated, tapped, or even machined. This allows for a higher grade of smoothness and appearance to selective laser sintering (SLS) parts and assemblies and also gives users an unlimited number of ways to use selective laser sintering (SLS) parts.

    MERITS OF SLS

    SLS can produce parts from a relatively wide range of commercially

    available powder materials, including polymers (nylon, also glass-filled


    or with other fillers, and polystyrene), metals (steel, titanium, alloy mixtures, and composites) and green sand.

    SLS is a direct tool for Rapid Tooling

    Injection mould tooling (inserts). Die casting mould inserts. Other tooling, e.g. sheet metal forming, blow moulding etc. Tooling fixtures etc.

    Applications of SLS
    Concept model: Physical representation of design ideas, form
    and style.

    Functional model and working prototype: Parts that can


    withstand limited functional testing, or fit and operate within an assembly.

    Polycarbonate (RapidCasting) patterns: Patterns produced


    using polycarbonate, then cast in to metal of choice through investment casting process. Faster than wax process, ideal for thin and fine features. Durable and heat resistant.

    Metal Tools(Rapid Tool): Direct RP of tool of molds for small or


    short production runs

    Laser Engineered Net Shaping


    Sandia National Laboratories new technology to fabricate 3-dimensional metallic components directly from CAD solid models. LENS exhibits enormous potential to revolutionize the way in which metal parts, such as complex prototypes, tooling, and small-lot production items, are produced. metal parts directly from the CAD solid models using a metal powder injected into a molten pool created by a focused, high-powered laser beam.

    LENS Process
    Additive process Nd-YAG laser used Free-form metal fabrication Deposition head supplies the metal powder Focus of laser beam on area to be melted Laser focusing by fibre optics or precision angled mirrors Laser focused on a particular spot by series of lens

    LENS Process Continuation..


    A motion system underneath the platform moves horizontally and laterally as the laser beam traces cross section of the part. Fabrication in low pressure argon chamber for oxygen free operation in melting zone to ensure good adhesion. When a layer is complete, the deposition head moves up and continues with next layer. Process is continued till part is complete.

    LENS Materials
    Wide variety of metals are used in this technique. Wide variety of materials that, at minimum,include: stainless steel alloys (316, 304L, 309, 17-4), maraging steel (M300), nickel-based superalloys(Inco designations 625, 600, 718, 690), tool steel alloys (H13), titanium alloy (6Al- 4V), and other specialty materials.

    Impeller

    Fixtures

    H13 tool steel

    Housing

    Principle of LENS
    High powered Nd-YAG laser focused onto a metal substrate creates a molten puddle on substrate surface. Powder is then injected in to molten puddle to increase material volume. A printing motion system moves platform horizontally and laterally as laser beam traces the cross-section of part. After a layer formation,the machine powder delivery nozzle moves upwards proir to building next layer.

    Applications of LENS
    Build mold and die inserts Producing titanium parts in racing industry Fabricate titanium components for biological implants Produce functionally gradient structures

    Merits and Demerits


    Merits of LENS Demerits of LENS

    Superior material properties Complex parts Reduced postprocessing requirements

    Limited materials:
    narrow focus only on metal parts

    Large physical unit size: large area to house the unit High power consumption: requires
    very high wattage

    Bibliography
    http://www.conceptual-reality.com/sls.htm http://home.att.net/~castleisland/sls_int.htm http://www.arptech.com.au/slshelp.htm http://www.me.utexas.edu/~rbarr/rapid/Types_O f_RPS.html http://www.3drg.com/our_process.php

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