ADDITIVE MANUFACTURING TECHNOLOGY

UNIT – III

Syllabus: Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and
specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies.
Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications,
Advantages and Disadvantages, Case studies.

3D SYSTEMS’ SELECTIVE LASERSINTERING SLS

Model and Specifications

In the last decade, the SLS® system has gone through three generations of products: the Sinterstation
2000, Sinterstation 2500 and theSinterstation 2500plus (see Figure 5.1). The latest and fourth generation
SLS® system is the V anguar dTM. The system is capable of producing objects measuring up to 380 mm
(15 inches) length by 330 mm (13inches) width by 380 mm (15 inches) in height, accommodating most
rapid prototyping applications. The new V anguard TM system offers several significant improvements over
the previous generation systems such as improved part accuracy, higher speed, smoother surface finish
and finer resolution.
Principle

• 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

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.

CAD data files in the STL file format are first transferred to the system where they are sliced. SLS
process starts and operates as follows:

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1. A thin layer of heat-fusible powder is deposited onto the part building chamber.

2. 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.

3. 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.

4. The intensity of the laser beam is modulated to melt the powder only in areas defined by the
part’s geometry.

5. Surrounding powder remains loose compact and serve as supports.

6. 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.

7. This prepares the next layer for scanning.

8. Steps 2 and 6 are repeated, with each layer fusing to the layer below it.

9. Successive layers of powder are deposited and the process is repeated until the part is
completed.

Applications

(1) Concept models. Physical representations of designs used to review design ideas, form and style.

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

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

(4) Metal tools (RapidToolTM). Direct rapid prototype of tools of molds for small or short

production runs

Advantages:

1)Good part stability. Parts are created in a precise controlled environment. The process and materials
provide for directly produced functional parts to be built

(2) Wide range of processing materials. A wide range of materials including polyamide, glass-filled
polyamide composite, polystyrene, metals and foundry sands thus providing flexibility and a wide scope
of functional applications

(3) Support structures not required. The EOSINT RP methods do not require support structures or uses
only simplified support structures as in the case of the Direct Croning Process®. This increases the
efficiency of the system by reducing the processing time of the build.

(4) Little post-processing required. The finishing of the part is very good thus requiring only minimal
post-processing.

(5) High accuracy. For EOSINT P system, the polystyrene it uses can be laser-sintered at a relatively low
temperature, thereby causing low shrinkage and high inherent building accuracy.

(6) No post-curing required. The completed part is by itself solid enough and does not require post-
curing.

(7) Large parts can be built. The large build volume allows for relatively larger and taller parts to be built.
Large single parts can

be built at one go rather than by the building of smaller parts to be later joined together.

Disadvantages

01.Dedicated systems : Only dedicated systems for plastic, metal and sand are available respectively.

(2) High power consumption: The EOSINT systems, especially the M model, require relatively high laser
power in order to directly sinter the metal powders.

(3) Large physical size of the unit : The system requires a relatively large space to house.

Case studies

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 FKM Sintertechnik Uses EOSINT P 700 to Build Fuel Tank Prototype

 FKM Sintertechnik GmbH of Biedenkopf-Breidenstein belongs to the first owners and users of
EOSINT P700 pre-series system.

 In a project for an automotive manufacturer, FKM was asked to conduct thorough functional
testing.

 At the same time, they wanted to verify the CAD data and check the design of the later series
tooling.

 Since the tank had to be filled with an aggressive liquid, the customer paid great attention to the
material’s chemical properties.

 FKM therefore built the entire fuel tank in one piece on their EOSINT P 700 directly from
polyamide and was able to deliver it within only four days.

 As an alternative, the tank could have produced with the help of a laminating tool.

 In this case, the customer would have had to wait two weeks for the first functional prototype

Z CORPORATION’S Three dimensional Printing (3DP)

 Z Corporation was incorporated in 1994 by Hatsopoulos, WalterBornhost, Tim Anderson and

Jim Brett. It commercialized its first 3DPrinter, the ZTM402 System, based on three-
dimensional technology(3DP) in 1997.

 This core technology was invented and patented at the

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 Massachusetts Institute of Technology.

 It was subsequently licensed and

 further developed by Z Corporation. Z Corporation’s distributors are headquartered in

Australia, the Benelux area, France, Germany, Hong Kong, Italy, Japan, Korea, Malaysia,
Russia, Singapore, South Africa,Spain, Taiwan, and United Kingdom

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Z406 3D Printer

 The Z406 System is a premium 3D Printer with the capability of printing in full-color,
communicating important information about parts, including engineering data, labeling,
highlighting and appearance simulation.

 It can print in six million colors and uses a new pigment system developed by Cabot Corporation
for fuller and brighter colors.

 The software interface included with the new machine, MAGICS Z allows users to add color
information to STL files.

 It also includes a labeling option that lets users add text such as dates or revision

 coding directly to STL files.

 Figure 5.11 shows a photograph of ZCorporation’s ZTM 406 3D printer.

Advantages

(1) High speed. Fastest 3D printer to date. Each layer is printed in seconds, reducing the prototyping
time of a hand-held part to 1 to 2 hours.

(2) Versatile. Parts are currently used for the automotive, packaging, education, footwear, medical, and
aerospace and telecommunications industries. Parts are used in every step of the design process for
communication, design review and limited functional testing. Parts can be infiltrated if necessary,
offering the opportunity to produce parts with a variety of material properties to serve a range of
modeling requirements.

3) Simple to operate. The office compatible Z corp system is straightforward to operate and does not
require a designated technician to build a part. The system is based on the standard, off the shelf
components developed for the ink-jet printer industry, resulting in a reliable and dependable 3D printer.

(4) No wastage of materials. Powder that is not printed during the cycle can be reused.

(5) Color. Enables complex color schemes in RP-e d parts from a full 24-bit palette of colors.

Demerits

01)Limited functional parts. Relative to the SLS, parts built are much weaker, thereby limiting the
functional testing capabilities.

(2) Limited materials. The materials available are only starch and plaster-based materials, with the added
option to infiltrate wax using the ZW4 Waxer.

(3) Poor surface finish. Parts built by 3D printing have a relatively

Applications

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Sports Shoe Industry : The 3D printer has been used by designers, marketers, manufacturers,

and managers in the footwear industry

Case studies:

Javelin uses the Z402 System to produce computer-sculpted models to assist artists with complex
modeling. Parts produced find applications with computer gamers, animators, pre-Hollywood mock-ups
designers, and sculpturing artists

Optomec Inc. was incorporated in 1992. Since 1997, Optomec has focused on commercializing a direct
fabrication process, the Laser Engineered Net Shaping (LENSTM) process originally developed by
Sandia National Laboratories

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Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid
Tooling Classification; Indirect Rapid Tooling Methods: Spray Metal Deposition, RTV Epoxy Tools,
Ceramic tools, Investment Casting, Spin Casting, Die casting, Sand Casting,3D Keltool process. Direct
Rapid Tooling: Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct
Metal Tooling using 3DP

Introduction:

 The prototype tooling industry is about 300 Billion dollar a year industry.

 Prototype parts are often used by designers to test alternative designs.

 Prototype parts can range from conceptual to functional.

Types of Prototypes

 Simple models or mockups are conceptual parts which can be made from the simplest materials
and processes. They can be made of plastics, paper, etc.

◦ The primary purpose for conceptual parts are “look and feel” attributes.

◦ They are typically used in the early part of the design cycle

 Subsystem prototypes are typically used for testing concept function or local part/subsystem
function. They are typically made very quickly from foams and epoxy plastics
 Mechanical prototypes are functional prototypes which typically support all the functions of the
final model but do not necessarily represent the final size or shape of the actual part.
 Engineering prototypes are classes of models which are functional prototypes like the
mechanical prototypes but are typically made out the same engineering material as the final part.
These prototypes are used as final design checks or limited field testing.
 Production prototypes are prototype parts which are made from the same engineering material
that the final part will be made and manufactured from similar processes. The purpose of these
parts is to test the manufacturing process and production part quality.

Cost of prototype design change

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The Need for Rapid Tooling:

 Concurrent or simultaneous engineering have multi-discipline design teams.

 Conventional tooling methods are too costly and require too much lead time to practically use
them to construct prototype parts. A typical die cast insert can take upto 4 months to build and
heat treat.

 Testing preliminary designs with conventional tooling methods would eventually reduce the
number of prototypes possible during limited design times.

 Alternative method is RAPID TOOLING.

Definition: The term Rapid Tooling (RT) is typically used to describe a process which either uses a
Rapid Prototyping (RP) model as a pattern to create a mold quickly or uses the Rapid Prototyping process
directly to fabricate a tool for a limited volume of prototypes.

Classification of Rapid Tooling

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Classification of Rapid Tooling

RAPI
Soft D Hard
Tooli TOOLTooli
Dire Indir Dire Indi
ING ctng rect
ct ng ect
Soft Soft Har Har
Tool Tool d d
ing ing Too Too
ling ling

 Soft Tooling: Tooling for short manufacturing runs is often known as soft tooling.

 These tools are often made from materials such as silicon rubber, epoxy resins, low-
melting-point alloys, or aluminium, which are easier to work with than tooling steels.

 Hard Tooling: Tooling for longer manufacturing runs is known as hard tooling and is usually
made of hard tooling steels

 Direct Tooling: In direct tooling, the tool or the die is created directly by the RP process.

 Example, in the case of injection molding, the core and cavity, together with the gating and
ejection system, are produced in the RP process.

 Indirect Tooling: In indirect tooling, only the master is created using the RP technology.
From this master, a mould is made out a material such as silicone rubber, epoxy resin, soft metal,
or ceramic.

Direct Soft Tooling

 Selective Laser Sintering of sand casting molds

 Direct AIM

 SL Composite Tooling

Selective Laser Sintering of sand casting molds

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 Laser energy initiates a reaction in the polymeric binder which then binds the individual sand
grains together.

 The systems build sand casting moulds just like those produced using conventional methods.

 The castings are identical to conventional castings in term of surface finish and accuracy.

 The system is suitable for producing functional prototypes.

Direct AIM

 Direct AIM (AIM stands for ACES Injection Molding. ACES stands for "Accurate Clear Epoxy
Solid” ) .

 In the AIM process, the mould is "grown" using the SLA process.

 The mould is similar to a regular part SLA, but is the negative image and cut into two halves.

 The cavity can be filled with a variety of materials, including: Thermoplastics , Aluminum-filled
epoxy, Ceramics , Low-melt temperature metals.

Figure 2: Direct AIM

Direct AIM :

 Tooling Cost: INR 50,000 to INR 75,000 for a typical consumer product part of 12.7 x 12.7 x 7.6
mm dimensions.

 Production Rate: 10 parts each day per cavity.

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 Tool Life: < 100 parts.

 Accuracy: Similar to that of an SLA: ±0.127 mm

 Mold Fabrication Time: 1-2 weeks.

Direct AIM…

Motorola Switch Actuator

Personal Radio

SL Composite Tooling

 It uses a thin shell of resin with the required surface geometry which is then backed up with
aluminium powder filled epoxy resin.

 Aluminium shot can also be added to improve further the thermal conductivity of the mould.

 In this way, faster SLA built times can be achieved, as only a thin shell is required.

 Thermal conductivity can be improved by at least 3 times over SLA resins.

 The mould strength is also higher than that of SLA resin.

 Tool development cost can also be reduced as aluminium epoxy and aluminium shots are
considerably less expensive than SLA resins

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 Short runs -prototypes and production parts in a variety of true engineering thermoplastics

 Quickly iterate on final product design

 Ideal for tight tolerances, complex surfaces

 Save months in tooling

Indirect Soft Tooling

 The master pattern is made using RP process and then, a mould is made out of a material such as
silicone rubber, epoxy resin, soft metal, or ceramic.

 Types of Indirect soft tooling are:

 Arc Spray Metal Tooling

 RTV Molding

 Sand casting molds

 Shell Investment casting

 Evaporative pattern casting

 Spin Casting with Vulcanised Rubber Moulds

 Castable Resin Moulds

 Castable Ceramic Moulds

 Plaster Moulds

Arc Spray Metal Tooling:

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 The arc spray system comprises a low voltage d.c. power supply much like that of an arc welder,
a console for regulating compressed air, an arc spray gun, and a wire feedstock.

 The spray gun is approximately the size of a paint sprayer and can easily be manipulated by hand
or mounted on a robot.

 The wire feedstock feeds the material into the spray gun and two spools are required to operate
the equipment.

 In the sprayed metal process, air-driven rollers feed two electrically isolated wires into the spray
gun; the wires intersect to form an arc at the front of the gun.

 The arc melts the wire and the molten material is blown off as fine particles by an atomizing jet to
form a dense metallic coating (approx. 0.5 mm) on the sprayed shell.

 The master pattern produced by any RP process is mounted onto the base and bolster, which are
then layered with a release agent. A coating of metal particles using the arc spray is then applied
to the master pattern to produce the female form cavity of the desired tool

 Depending on the type of tooling application, a reinforcement backing is selected and applied to
the shell.

 Types of backing material include filled epoxy resins, low-melting point metal alloys and
ceramics.

 This method of producing soft tooling is cost and lead time saving

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Figure 4: Metal Arc Spray Process

Parameters affecting the Metal Arc Spray

 Arc Voltage: The arc voltage influences the amount of heat within each particle and may burn
off volatile elements from the wires. A setting of 19-21V is usually recommended.

 Arc Current: The current determines the material deposition rate. Increasing the current
increases the deposition rate and the heat input to the pattern. A setting of usually 100 A is
typically recommended

 Wire Feed Rate: The wire feed rate is linked to the arc current so that if the arc current is
changed, the arc spraying equipment automatically adjusts the wire feed rate to suit the selected
current

 Atomising Air Pressure: The atomising air pressure affects the size of the particles being
sprayed. Increasing the atomizing pressure decrease the particle size and vice versa. Particle size
may also be influenced by the nozzle and cap configuration

 Stand Off Distance: The distance between the tip of the spray gun and the pattern is the
standoff distance. A typical recommended value is approximately 200 mm. This is particularly
important for avoiding excessive heat input and associated thermal stress.

Typical Part Made Using Spray Metal Deposition

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RTV (Room Temperature Vulcanization) Molding

RTV Rubber Molds

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Sand Casting Molds:

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Investment Casting Process

 Investment casting molds can be made from RP pattern masters.

 The pattern is usually wax, foam, paper or other material that can be easily melted or
vaporized.

 The investment casting process is ideal for casting miniature parts with thin sections and
complex features.

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Evaporative Pattern Casting:

 It uses an evaporative pattern, such as polystyrene foam, as the master pattern.

 The master pattern is attached to sprue, riser and gating systems to form a “tree”.

 A variety of metals such as titanium, steel, aluminium, magnesium and zinc can be cast
using this method.

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Castable Resin Moulds:

 The master is mounted in a mould box with the parting line marked out in plasticine.

 Resin is poured over the master until there is sufficient material for one half of the mould. The
process is then repeated.

 Different tooling resins provide different mechanical and thermal properties, and they may be
loaded with aluminium powder or pellets which improve thermal conductivity and also reduce the
amount of expensive resin required.

 These tools are usually suitable for runs of 100-200 parts made by injection moulding.

 Ceramic materials that are essentially mixtures of sand and cement can be poured over a master to
create a mould.

 Various techniques are used to reduce the water content of the mixture so as to control shrinkage,
and plasticine is used to ensure that the cavity is properly filled.

 The ceramic material may be poured in a vacuum and vibration can also be used to help pack the
material around the master.

Plaster Molds

 Plaster mould castings can be used for creating prototypes which are ultimately produced by die
casting.

 A silicon rubber mould is first created from the master pattern, then a silicon rubber pattern is
created from this mould and a plaster mould is then made from this silicon rubber pattern.

 Molten metal is poured into the plaster mould which is broken once the metal has solidified.

 The intermediate stage of a silicon rubber pattern is required because the pattern can be easily
separated from the plaster mould.

Direct Hard Tooling

 The potential advantage of using RP techniques for hard tooling:

 Capable of building highly complex shapes to create the tools that simply could not be
made using conventional machining and polishing methods. Speed with which the tools
can be produced

Some examples of direct hard tooling are:

 Direct Metal Laser Sintering (DMLS) Tooling

 RapidTool

 Laminated Metal Tooling

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 ProMetal Rapid Tooling

Direct Metal Laser Sintering (DMLS) Tooling:

 The process uses a very high-powered laser to sinter metal powders directly.

 The powders available for use by this technology are the bronze-based and steel-based materials.

 Upon sintering of the bronze powder, an organic resin, such as epoxy, is used to infiltrate the part.

 For steel powders, the process is capable of producing direct steel parts of up to 95% density.

Rapid Tool

 The DTM Corporation has introduced a technology known as RapidTool to produce a metal
mould for plastic injection moulding directly from the company's Sinterstation 2000.

 The moulds are capable of producing multiple parts of the final product using the actual intended
manufacturing process as well as the intended material. The process involves building parts from
CAD data in powdered metals encased in a polymeric binder, at room temperature

 Shrinkage is not more than 2%, which is compensated for in the software.

 Complex moulds can be produced in 2 weeks (as opposed to 12-15 weeks using conventional
techniques).

 The finished mould is capable of producing up to 50 000 injection molded parts.

Laminated Metal Tooling

 Another technique which may prove promising for RT applications lies in the possibility of using
metal sheets in conjunction with LOM for RT.

 Steel or any other sheet material can be cut by suitable means (e.g. CO 2 laser, water jet, milling)
in a similar way to the LOM process.

 The sheets are cut in accordance with the computer-derived layer information.

 However, instead of bonding each layer as it is cut, the layers are all assembled after cutting and
either bolted or bonded together.

ProMetal Rapid Tooling

 The ProMetal Rapid Tooling System is capable of creating steel parts for tooling of plastic
injection molding parts, lost foam patterns and vacuum forming.

 It uses an electrostatic ink jet print head to eject liquid binders onto the powder, selectively
hardening slices of an object a layer at a time.

 A fresh coat of metal powder is spread on top and the process repeats until the part is completed.

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Indirect Hard Tooling

 Indirect methods for producing hard tools for plastic injection molding generally make use of
casting of liquid metals or steel powders in a binder system.

 Some examples of Indirect hard tooling are:

 3D Keltool

 EDM Electrodes

 Ecotool

3D Keltool

 The word "Keltool" refers to the proprietary powder metal sintering process, which involves
infiltrating a fused metal part with copper alloy.

 The alloy fills in the voids in the otherwise porous material, producing a surface with the finish
and hardness necessary for an injection mold.

 The process requires a master pattern, typically an ACES, SLA model, that can be used to
develop a silicone mold that will then be used to produce the Keltool mold.

 The Keltool mold is then processed with a copper infiltration and sintered to increase its strength
and cure the mold.

 The finished Keltool part has the hardness of a A6 Tool Steel and can be machined like a
traditional hard tool.

 Utilizing the 3D Keltool process, mold inserts can be turned around in two weeks time.

 Inserts can be fit into a mold base and can be producing injection molded plastic parts in just four
weeks.

 Tool Life Expectancies: 100,000 to 10,000,000 shots depending on material.

 Accuracies: The accuracy of Keltool is a function of the master pattern incorporating the
appropriate shrinkages for the pattern itself, the silicone mold, Keltool process, and the
thermoplastic material.

 are typically 0.005 to 0.015 inches.

 Size: The Keltool part (mold) is limited to 6 inches in all directions.

The Keltool Process

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EDM Electrodes

 Manufacturing of copper electrodes for EDM processes using RP Technology.

 To create the electrode, the RP-created part is used to create a master for the electrode.

 An abrading die is created from the master by making a cast using an epoxy resin with an
abrasive component.

 The resulting die is then used to abrade the electrode. A specific advantage of the SLS procedure
is the possible usage of other materials.

 Using copper in the SLS process, it is possible to quickly and affordably generate the electrodes
used in electrode EDM.

Ecotool

 The process uses a new type of powder material with a binder system to rapidly produce tools
from RP models.

 An RP master pattern is used and a parting line block is produced. The metal powder-binder
mixture is then poured over the pattern and parting line block is produced

 The metal powder-binder mixture is then poured over the pattern and parting block and left to
cure for an hour at room temperature.

 The process is repeated to produce the second half of the mold in the same way.

 The pattern is then removed and the mold is baked in a microwave oven.

Comparison of RT Techniques

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 Criteria of tool life,

 Cost of tool development and

 Tool development time.

Criteria of tool life

Cost of Tool Development

 The cost of tooling for the direct soft tooling technologies is mainly due to the longer RP
equipment machining time which equates to higher cost.

 For hard tooling technologies, the cost of tool development is higher owing to the cost of the
hard tool as well as the long tool fabricating time on the RP equipment.

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 The direct soft tooling RT has the shortest tool development time as very little manual work is
needed to produce these tools.

 The indirect soft tooling technologies, a tool development time of between 1 and 2 weeks is
needed for the additional manual operations to produce the tool from the RP master.

 For the hard tooling, the lead time is longer, as additional process time is needed for post-curing
operations, such as firing, to produce the hard tool.

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Study Material for IV B.Tech -I Sem : Prepared by Mr.M.Ravikumar Goud : JBREC-ME Dept
 ADDITIVE MANUFACTURING TECHNOLOGY

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Study Material for IV B.Tech -I Sem : Prepared by Mr.M.Ravikumar Goud : JBREC-ME Dept