Rapid Prototype

Classification
• Liquid-Based

• Solid-Based

• Powder-Based
Liquid Based
Liquid-based RP systems have the initial form of its material in liquid state. Through a process
commonly known as curing, the liquid is converted into the solid state.
The following RP systems fall into this category:
• 3D Systems’ Stereolithography Apparatus (SLA)
• Cubital’s Solid Ground Curing (SGC)
• Sony’s Solid Creation System (SCS)
• CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)
• Autostrade’s E-Darts
• Teijin Seiki’s Soliform System
• Meiko’s Rapid Prototyping System for the Jewelry Industry
• Denken’s SLP
• Mitsui’s COLAMM
• Fockele & Schwarze’s LMS
• Light Sculpting
• Aaroflex
• Rapid Freeze
• Two Laser Beams
• Microfabricatio
Solid-Based
The solid form can include the shape in the form of a wire, a roll, laminates and pellets
The following RP systems fall into this definition:
• Cubic Technologies’ Laminated Object Manufacturing (LOM)
• Stratasys’ Fused Deposition Modeling (FDM)
• Kira Corporation’s Paper Lamination Technology (PLT)
• 3D Systems’ Multi-Jet Modeling System (MJM)
• Solidscape’s ModelMaker and PatternMaster
• Beijing Yinhua’s Slicing Solid Manufacturing (SSM), Melted Extrusion Modeling (MEM) and Multi-Functional
RPM Systems (M-RPM)
• CAM-LEM’s CL 100
• Ennex Corporation’s Offset Fabbers
Powder-Based
Powder is by-and-large in the solid state. However, it is intentionally created as a category outside the solid-based
RP systems to mean powder in grain-like form.
The following RP systems fall into this definition:
• 3D Systems’s Selective Laser Sintering (SLS)
• EOS’s EOSINT Systems
• Z Corporation’s Three-Dimensional Printing (3DP)
• Optomec’s Laser Engineered Net Shaping (LENS)
• Soligen’s Direct Shell Production Casting (DSPC)
• Fraunhofer’s Multiphase Jet Solidification (MJS)
• Acram’s Electron Beam Melting (EBM)
• Aeromet Corporation’s Lasform Technology
• Precision Optical Manufacturing’s Direct Metal Deposition (DMDTM)
• Generis’ RP Systems (GS)
• Therics Inc.’s Theriform Technology
• Extrude Hone’s Prometal TM 3D Printing Process
Liquid-based SLA

Advantages Disadvantages
• Round the clock operation: The SLA can be used continuously • Requires support structures: Structures that have overhangs
and unattended round the clock. and undercuts must have supports that are designed and
fabricated together with the main structure.
• Good user support: The computerized process serves as a
good user support. • Requires post-processing: Post-processing includes removal
of supports and other unwanted materials, which is tedious,
• Build volumes:The different SLA machines have build timeconsuming and can damage the model.
volumes ranging from small to large to suit the needs of
different users. • Requires post-curing: Post-curing may be needed to cure the
object completely and ensure the integrity of the structure.
• Good accuracy: The SLA has good accuracy and can thus be
used for many application areas.
• Surface finish: The SLA can obtain one of the best surface
finishes amongst RP technologies.
• Wide range of materials:There is a wide range of materials,
from general-purpose materials to specialty materials for
specific applications.
Principle
The SLA process is based fundamentally on the following principles
• Parts are built from a photo-curable liquid resin that cures when exposed to a laser beam
(basically, undergoing the photopolymerization process) which scans across the surface of the
resin.
• The building is done layer by layer, each layer being scanned by the optical scanning system and
controlled by an elevation mechanism which lowers at the completion of each layer
Process
Apparatus Video
Terms Used
• Photopolymers : SU-8

• Photopolymerization : Polymerization is the process of linking small molecules (known as

• Layering Technology : The basic principle is the availability of computer software to slice a CAD
model into layers and reproduce it in an “output” device like a laser scanning system. The layer
thickness is controlled by a precision elevation mechanism. It will correspond directly to the slice
thickness of the computer model and the cured thickness of the resin.
Solid-based LOM - LAMINATED OBJECT
MANUFACTURING -Principle
The LOM process is based on the following principles:
 Parts are built, layer-by-layer, by laminating each layer of paper or other sheet-form materials and
the contour of the part on that layer is cut by a CO2 laser.
 Each layer of the building process contains the cross-sections of one or many parts. The next
layer is then laminated and built directly on top of the laser-cut layer.
 The Z-control is activated by an elevation platform, which lowers when each layer is completed,
and the next layer is then laminated and ready for cutting. The Z-height is then measured for the
exact height so that the corresponding cross sectional data can be calculated for that layer.
 No additional support structures are necessary as the “excess” material, which are cross-hatched
for later removal, act as the support.
Solid-based LOM - LAMINATED OBJECT
MANUFACTURING
• Pre-processing : The pre-processing phase comprises several operations. The initial steps include generating an image
from a CAD-derived STL file of the part to be manufactured, sorting input data, and creating secondary data structures.
• Building : In the building phase, thin layers of adhesive-coated material are sequentially bonded to each other and
individually cut by a CO2 laser beam
• The build cycle has the following steps:
 LOM Slice creates a cross-section of the 3D model measuring the exact height of the model and slices the horizontal plane
accordingly. The software then images crosshatches which define the outer perimeter and convert these excess materials
into a support structure.
 The computer generates precise calculations, which guide the focused laser beam to cut the cross-sectional outline, the
crosshatches, and the model’s perimeter. The laser beam power is designed to cut exactly the thickness of one layer of
material at a time. After the perimeter is burned, everything within the model’s boundary is “freed” from the remaining
sheet.
 The platform with the stack of previously formed layers descends and a new section of material advances. The platform
ascends and the heated roller laminates the material to the stack with a single reciprocal motion, thereby bonding it to the
previous layer.
 The vertical encoder measures the height of the stack and relays the new height to LOMSlice, which calculates the cross
section for the next layer as the laser cuts the model’s current layer.
• Post-processing : The last phase, post-processing, includes separating the part from its support material and
finishing it. The separation sequence is as follows
 The metal platform, home to the newly created part, is removed from the LOM machine. A forklift may be
needed to remove the larger and heavier parts.
 Normally a hammer and a putty knife are all that is required to separate the LOM block from the platform.
However, a live thin wire may also be used to slice through the double-sided foam tape, which serves as the
connecting point between the LOM stack and the platform.
 The surrounding wall frame is lifted off the block to expose the crosshatched pieces of the excess material.
Crosshatched pieces may then be separated from the part using wood carving tools.
Video
Advantages Disadvantages
• Wide variety of materials. In principle, any material in • Precise power adjustment.
sheet form can be used in the LOMTM systems.
• Fabrication of thin walls.- No Suitable
• Fast build time. The laser in the LOMTM process does not
scan the entire surface area of each cross-section, rather • Integrity of prototypes
it only outlines its periphery. Therefore, parts with thick • Removal of supports.
sections are produced just as quickly as those with thin
sections.
• High precision.
• Support structure. There is no need for additional
support structure as the part is supported by its own
material that is outside the periphery of the part built.
• Post-curing. The LOMTM process does not need to
convert expensive, and in some cases toxic, liquid
polymers to solid plastics or plastic powders into sintered
objects. Because sheet materials are not subjected to
either physical or chemical phase changes, the finished
LOMTM parts do not experience warpage, internal
residual stress, or other deformations
Applications
• Visualization. Many companies utilize LOMTM’s ability to produce exact dimensions of a potential
product purely for visualization.

• Form, fit and function. LOMTM parts lend themselves well for design verification and
performance evaluation.
• Manufacturing.
• Rapid tooling.
POWDER-BASED RAPID PROTOTYPING SYSTEMS-
SELECTIVE LASER SINTERING (SLS) -Principle
The SLS® process is based on the following two principles:

• Parts are built by sintering when a CO2 laser beam hits a thin layer of powdered material. The interaction of
the laser beam with the powder raises the temperature to the point of melting, resulting in particle bonding,
fusing the particles to themselves and the previous layer to form a solid.

• The building of the part is done layer by layer. Each layer of the building process contains the cross-sections
of one or many parts. The next layer is then built directly on top of the sintered layer after an additional layer
of powder is deposited via a roller mechanism on top of the previously formed layer.
POWDER-BASED RAPID PROTOTYPING SYSTEMS-
SELECTIVE LASER SINTERING (SLS)
Disadvantages
Advantages
 Good part stability. Parts are created within a precise controlled
environment. The process and materials provide for directly
 Large physical size of the unit. The system requires a
produced functional parts to be built. relatively large space to house it. Apart from this,
additional storage space is required to house the inert gas
 Wide range of processing materials. A wide range of materials tanks used for each build
including nylon, polycarbonates, metals and ceramics are
available, thus providing flexibility and a wide scope of functional  High power consumption. The system requires high
applications. power consumption due to the high wattage of the laser
 No part supports required. The system does not require required to sinter the powder particles together.
CADdeveloped support structures. This saves the time required  Poor surface finish. The as-produced parts tend to have
for support structure building and removal.
poorer surface finish due to the relatively large particle
 Little post-processing required. The finishing of the part is sizes of the powders used.
reasonably fine and requires only minimal post-processing such
as particle blasting and sandingNo post-curing required. The
completed laser sintered part is generally solid enough and does
not require further curing.
 Advanced software support.Apart from the basic features, it
allows for streamlined parts scaling, advanced nonlinear parts
scaling, in-progress part changes, build report utilities and is
available in foreign languages
Video
Process
• The SLS process creates three-dimensional objects, layer by layer, from CAD-data generated in a CAD software using powdered materials
with heat generated by a CO2 laser within the Vanguard system. CAD data files in the STL file format are first transferred to the Vanguard
system where they are sliced.
• A thin layer of heat-fusible powder is deposited onto the partbuilding chamber.

• The bottom-most cross-sectional slice of the CAD part under fabrication is selectively “drawn” (or scanned) on the layer of powder by a
heat-generating CO2 laser. The interaction of the laser beam with the powder elevates the temperature to the point of melting, fusing the
powder particles to form a solid mass. The intensity of the laser beam is modulated to melt the powder only in areas defined by the part’s
geometry. Surrounding powder remain a loose compact and serve as supports.

• When the cross-section is completely drawn, an additional layer of powder is deposited via a roller mechanism on top of the previously
scanned layer. This prepares the next layer for scanning.

• Steps 2 and 3 are repeated, with each layer fusing to the layer below it. Successive layers of powder are deposited and the process is
repeated until the part is completed.

As SLS materials are in powdered form, the powder not melted or fused during processing serves as a customized, built-in support structure .
After the SLS process, the part is removed from the build chamber and the loose powder simply falls away. SLS® parts may then require some
post-processing or secondary finishing, such as sanding, lacquering and painting, depending upon the application of the prototype built
Materials
• Polyamide: Trade named “DuraFormTM”, this material is used to create rigid and rugged plastic parts for functional engineering
environments. This material is durable, can be machined or even welded where required. A variation of this material is the polyamidebased
composite system, incorporating glass-filled powders, to produce even more rugged engineering parts. This composite material improves
the resistance to heat and chemicals.

• Thermoplastic elastomer: Flexible, rubber-like parts can be prototyped using the SLS. The material produces parts with high elongation. Yet,
it is able to resist abrasion and provides good part stability. The material is impermeable to water and ideal for sports shoe applications and
engineering seals.

• Polycarbonate: An industry-standard engineering thermoplastic. These are suitable for creating concept and functional models and
prototypes, investment casting patterns for metal prototypes and cast tooling.

• Nylon: Another industry-standard engineering thermoplastic. This material is suitable for creating models and prototypes that can
withstand and perform in demanding environment. It is durable, resistant to heat and chemicals, and is excellent when fine detail is
required
• Ceramics: Trade named “SandFormTM Zr” and “SandformTM Si”, these use zircon and silica coated with phenolic binder to produce
complex sand cores and molds for prototype sand castings of metal parts.
Applications
• Concept models. Physical representations of designs used to review design ideas, form and style.

• Functional models and working prototypes. Parts that can withstand limited functional testing, or fit and
operate within an assembly.

• Polycarbonate (RapidCastingTM) patterns. Patterns produced using polycarbonate, then cast in the metal of
choice through the standard investment casting process. These build faster than wax patterns and are ideally
suited for designs with thin walls and fine features. These patterns are also durable and heat resistant.

• Metal tools (RapidToolTM). Direct rapid prototype of tools of molds for small or short production runs.