Methods of Selective Laser Sintering

Prototyping

Rapid Prototyping or SLS is said to be a free-form manufacturing technology which is developed by 3D systems. SLS is a method of layered manufacturing which creates a solid 3D object by blending powdered substances along with carbon dioxide. In other words SLS is one of the famous mechanisms of Rapid Prototyping in which a laser beam carefully sinters or fuses the powdered substances such as elastomer, nylon etc. A thin layer of that powdered substances is being laid down and the laser sketches on the layer sintering together the elements hit by the laser. SLS can provide a persons manufacturing company with most important perimeter by producing metal or rapid plastic prototyping which narrowly matches their molded complements.  
    
Stereolithography V/S Selective Laser Sintering: One of the foremost benefits of Selective Laser Sintering over Stereolithography is that it constructs prototypes in powered materials such as nylon etc. It is likely to create structurally useful parts like functioning springs, living hinges and snap fit components along with nylon substances by utilizing Selective Laser Sintering. This procedure is actually very easy as there is no need of tooling or molding involved. You will find that the nylon substance that is useding during the SLS process can be machined and drilled just like you can in SLA. These substances are fragile as they are curved with Ultra Violet light and created with liquid photopolymers.  
 
Since it has been introduced by DR Carl Deckard in the year 1989, this SLS technology has become one of the most recognized and utilized procedures for product development and rapid prototyping in most of the manufacturing industries. Rapid Prototyping technology has also become one of the most trusted and reliable forms of rapid prototyping due to its structural importance. SLS is generally helpful when a particular design has to be customized or is complex and requires being short run or functional production. 

Procedure: In the procedure of Selective Laser Sintering or Selective Laser Sintering, three dimensional parts are formed when an infrared laser beam fuses or sinters powdered substances. The ultimate object is being formed by continually sintering or fusing those thin layers by utilizing the infrared laser beam. This particular procedure is also known as additive manufacturing, creating parts which regularly enhances in size until it reaches the arranged size. These rapid prototypes are formed directly from the STL file acquired from three dimensional CAD models.

One of the most important features of Selective Laser Sintering is how functional and durable the substances are. These substances normally include versions of new DuraForm glass-filled, which is a nylon based substance that creates functional and highly durable plastic prototypes. LaserForm, Flex Plastic, and Rubber like parts that create metal prototypes are some of the other substances available with SLS.    

Benefits: Lots of people are trying hard to get some of these new SLS substances into the manufacturing market. Whats nice about thses substances is that after they are created, they need no post processing methods so you get another advantage over SLA. However, this does not mean that these substances cannot be developed. There are good things about the SLS substances we have mentioned because they all can be completed in many methods. They can be machined, painted, tapped, drilled and even plated. This allows for a superior grade of manifestation to these substances therefore giving the users a limitless potential to utilize these substances.

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3D Scanner, 3D Scanning, and 3D Scanners along with technology for 3D Scanners

Prototyping Design

Prototyping can be defined as the process wherein a device’s, object’s, or system’s technological principles are discovered by analyzing its operation, function, and structure. It often refers to detaching something, say- a software program, electronic equipment, or mechanical device and carrying out the analysis of its workability in detail. This is done in order to manufacture a new program or device which performs the same function without doubling anything from original.

Motivation: Reasons behind the emergence of reverse engineering include interoperability, lost documentation which means loss or non-existence of documentation of the concerned device, product analysis, security auditing, exclusion of protection of copy, circumvention of restrictions regarding access, and fraud.

Prototyping of ‘mechanical devices’ : With the ever-increasing popularity of CAD, ‘reverse engineering’ has proven to be a blessing for creation of ‘3D virtual model’ of the on hand physical part to be used in 3D CAE, CAM, CAD and many other soft wares. The measuring of physical object can be done by making use of ‘#D scanning technologies’ such as computed tomography, ‘structured light digitizers’, laser scanners, and CMMs. The data that is measured usually gets represented as ‘point cloud’. It is devoid of topological information. That’s why, the processing and modelling takes place into usable format like a ‘triangular faced mesh’, CAD model, or a collection of surfaces of NURBS. Applications such as Polyworks, Image ware, Geomagic, or Rapidform are used for processing the ‘point clouds’ into the formats that can be used in applications like 3D CAE, CAM, CAD or visualization.

Reverse Engineering of ‘software’  : The term ‘reverse engineering’ differs from person to person when applied in terms of software. Reverse engineering is a bit complicated but simply it is the process that involved looking at the subject system in order to create its representation at the higher level. There are people out there that will call this level the level of abstraction. As far as software is concerned, reverse engineering can be described as an examination process only. Really if you look at things from the software point of view there is no modification needed. The use of ‘software anti-tamper technology’ takes place in order to deter reengineering and reverse engineering of the software-powered systems and proprietary software.

Two major reverse engineering types exist in the present scenario. In the first type, source code is available, but program’s greater level aspects are poorly documented or invalidated. In the second type, source code does not exist. Any efforts made in this direction would be termed as ‘reverse engineering’. The 2nd use is that which majority of people know. ‘Reverse Engineering of software’ is implied at making use of ‘clean room design’ technique for avoiding infringing copyrights. In today’s world, around 95% of reverse engineering consists of ‘reverse engineering of software’.

On the other hand, ‘black box testing’ in ‘software engineering’ has many similarities to reverse engineering. The tester normally possesses the API. However, their main goal is to locate undocumented features and bugs by smashing the products from the outside. This process is used for customizing the embedded systems as well. 

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Flexible Manufacturing, Rapid Manufacturing, Direct Manufacturing

Flexible Manufacturing

Rapid Manufacturing can be described as an ‘Additive Fabrication Technique’ to manufacture solid objects through the chronological delivery of material and/or energy to precise points in the space for producing that part. At present, the practice of controlling the process of manufacturing with the help of computer by making use of mathematical model that has been created through the computer’s aid is being followed. Rapid manufacturing, if done with the help of Parallel Batch Production is capable of providing a huge advantage in terms of cost and speed in comparison with alternative techniques of manufacturing like die casting or Plastic Injection Molding.

Origin: Prototyping process was first demonstrated at The AUTO FACT show. The venue was Detroit, MI. The year was 1987. A company called 3D Systems Company is who created this technique. The technologies available now are inclusive of processes such as Laminated Object Manufacturing, Shape Deposition Manufacturing, and Selective Laser Sintering. 

The present scenario: Prototyping might involve replacement parts, custom parts, series production, or Short Run Production. This process can be referred to as Rapid Prototyping only if the use of the part is for development. Rapid Manufacturing carried out for big products with Layer-based Manufacturing from composite materials, plastics, or metals is widely used for numerous industrial applications pertaining to aerospace (Boeing) and military (MPH-Optomec) sectors. Micro system applications and small products are well known in medicines, sensor technologies (micro TEC), and diagnostics. Batch production regarding tiny parts by techniques of rapid manufacturing like RMPD give vent to advantages related to time and cost.

Now days, collectibles, consumer products, orthodontics, dentistry, jewelry, motor sports, and automotives are being experimented with rapid manufacturing. Amazing results are expected in future. The world economy is becoming competitive day by day. As customer demands have increase, manufacturers everywhere are tyring to deliver customized products faster than ever before. A late delivery or development might could mean failure of business. Rapid manufacturing has been devised with the objective of shortening the production cycle and design, and promising to revolutionize the age-old manufacturing procedures.

The initial process: Before starting with the construction of product, a prototype or sample is required quite often as a portion of design cycle, for allowing evaluation, testing, or demonstration of proposed product. This process is iterative, as a chain of prototypes gets built up. One way that prototypes can be used is for testing and loking at various options.

Rapid Manufacturing is also inclusive of rapid application of tools needed for production on a large scale, like jigs, dies, and specially shaped molds. Several Layer manufacturing Processes are being developed now, by making use of a wide range of materials. These parts are extremely durable and have proved to be strong as well. The size has also been increasing. Due to all these successes, layer manufacturing is the most sought after technique for fabricating the parts for functional prototypes as well as production tools. Rapid Tooling is where you apply layer manufacturing for making components that are used in production. It is being applied to investment casting, injection molding, and many processes related to mold casting.

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Techniques for Additive Fabrication

prototyping

Rapid Prototyping can be defined as an assortment of techniques of making solid objects through the chronological delivery of material and/or energy to specific points in the space for production of that solid. Additive fabrication is also known as solid freeform fabrication, layered manufacturing, rapid manufacturing, and rapid prototyping.

Techniques: Additive fabrication is carried out using a number of techniques. Let some of them be studied in detail.

‘Electron Beam Melting’: EBM (Electronic Beam Melting) can be described as the ‘rapid prototyping’ for metals. It is better known as Additive Fabrication method. The parts are manufactured by having the metal powder melted layer by layer through a beam of electron in high vacuum. The parts produced acquire strength, solidity, and are void-free as well. The electrons have a very high speed; around 5 to 8 times the light speed. The bombardment of these electrons takes place on the work material’s surface. What happens is that this creates a lot of heat that is enough for melting the part's surface and causing it to locatlly vaporize. Vacuum is required for the operation of EBM. This means that the size of work piece is directly proportional to vacuum used. You will find that this technique works not only on metals but also on composites, ceramics, and non-metals.

Fused Deposition Modeling: Fused Deposition Modeling (FDM) can be described as a kind of rapid manufacturing (RP) or rapid prototyping technology which is generally used in engineering design. S.Scott Crump had founded this technology in 1980s. It caught the commercial market in 1990. Like most of the RP processes, the principle of working of FDM is the ‘additive principle’. The material, in this case, will need to be laid down in layers. The metal wire or plastic filament is then unwound and material is supplied through it to the extrusion nozzle that can turn off and on the flow.

The nozzle’ then is heated for melting the material. It could be moved in vertical and horizontal directions with the help of a mechanism which is numerically controlled. This numerical control is obtained through ‘Computer Aided Design’ software package. Like stereo lithography, the building of the model takes place from layers. This happens because the material starts hardening after getting extruded from nozzle.

Numerous materials are offered with diverse trade-offs between temperature and strength. One can use the Additive Fabrication with polycaprolactone, polycarbonates, polyphenylsulfones, and Acrylonitrile butadiene styrene (ABS). Temporary supports can be made by using a ‘water-soluble’ material. These supports are needed and need to be kept as the manufacturing is still going on. Servo or Stepper Motors are some of the prototypes that are made in commercial applications.

‘Selective Laser Sintering’: Selective Laser Sintering can be defined as an additive type of rapid manufacturing wherein a ‘high power laser’ (like carbon dioxide laser) is used for fusing tiny particles of ceramic, metal, or plastic powders into mass representing the desired three-dimensional object. In comparison to other methods of rapid manufacturing, ‘selective laser sintering’ has the capacity of producing parts from several powder materials available. They include polymers (polystyrene and nylon), metals (composites, alloy mixtures, titanium, steel), and not to forget- green sand. This physical process could be liquid-phase sintering, partial melting, or full melting. 

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3D Printer and 3D Printer Technologies discussion on the advances in 3D Prints

3D Rapid Prototyping

3D Printing can be referred to as method of getting virtual 3D model printed onto a 2D object. Prototyping falls in the category of ‘rapid prototyping’ technology. The function typically performed by 3D printers is that of printing consecutive layers on the previous ones for building up a 3D object. It is easier, more affordable, and faster to use 3D printers as compared to other technologies related to additive fabrication.

Technologies: Initially, production of a prototype required a lot of man-hours, tools, and experienced labor. For instance, after designing a novel Street Light Luminaire digitally, drawings used to be sent to accomplished craftsmen where the paper design used to be followed with utmost pains and a Rapid Prototyping used to be formed in wood through the utilization of the entire shop that is full of costly tools and working machinery. One can easily make out that this process consumed a lot of time. Moreover, the skillful labor was not all that cheap. These shortcomings necessitated the need of rapid prototyping.

3D printing has a variation called Inkjet Printing System. It involves binding of fine powder layers (resins, cornstarch, or plaster) by the way of printing a gum from inkjet print head as per the shape of every cross-section as spotted by the CAD file. This is the only technology allowing full color prototypes to be printed. The school of thought is that this is the quickest method.

On the other hand, the liquids are fed by these machines. Photopolymer is one of such kind. These machines make use of UV (ultraviolet) flood lamp. It is mounted in print head for curing each layer on its deposition. A new technology called Fused Deposition Modeling uses a nozzle to deposit molten polymer layer by layer to the supported structure. The other approach is Selective Fusing of Print Media in the granular bed. Here, the media that has been unfused supports thin walls and overhangs in the piece which is being produced, thereby reducing need for temporary auxiliary supports for the work piece.

Ultimately, 3D Micro fabrication technique having a photo polymerization of 2-photons might be used to make ultra small features. Here, the preferred 3D object gets traced out by a completely focused laser in a gel block. The curing of gel into a solid takes place only in places where laser had been focused, owing to photo excitation’s non-linear nature. The gel that is left out gets washed away.

Resolution: Resolution is measured in terms of layer thickness. The X-Y resolution is given in dpi. 100 microns is the characteristic layer thickness. The X-Y resolution is compatible with laser printers. Diameter of the particles, i.e. You can assume that 3D dots is around 50-100 microns.

Applications: Standard applications are inclusive of design visualization, metal casting, CAD/prototyping, architecture, geospatial, education, healthcare, retail/entertainment, etc. Off late, 3D printing technology is being used in artistic expressions. Its biotechnological applications include bio-printing, computer-aided Tissue engineering, and organ printing.

Self-replication: The main purpose behind using 3D printing technology is its ability to replicate itself. RepRap is one such printer. It has the ability to print plastic parts and circuit boards. It is believed to print metals in future.

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Invention Prototypes and the process of Invention Prototypes

Invention Prototype

Invention Prototype cannot be ignored because they sought to prove the concept of the inventor to potential customers, suppliers, and investors-and most importantly, to the inventor himself. This has been the opinion of majority of experts. The idea behind creating a prototype is the accomplishment of a lot from the point of view of creativity, that too without having to put on so much of money in the idea of product or going for its commitment early on.

Construction of an ‘invention prototype’ at the appropriate time: It’s essential to construct an ‘invention prototype’ much before buying the tooling for building the product or seeking contract manufacturers. Many a times, it so happens that the inventor might, in reality want to build a prototype much before getting too fancy regarding computer drawings. He is likely to burn up loads of cash on ‘engineering drawings’ when possibly what he needs 1st is the papier-mache clearly showing him what is being tried by him. If that is the case, he is advised to revert to computer-aided drawings. Assessing the proper time for prototype is not all that tough. It just requires a proof of workability of the product invented by the concerned person.

The proper Invention Prototype for proper audience: An ‘invention prototype’ should be aimed towards the proper audience for doing its job. It means that the tailoring should be done in such a way that the requirements of the customers get fulfilled much to their satisfaction. Not only that, the prototype should be able to bear the critics of potential partners, investors, suppliers, and customers. This is a very important point: real appraisals should be done and friendly appraisals are not what you want to happen. The more slicker looking and operable the prototype, the ‘better’. Its always important to not let all of the praises go to your head. It’s better to spend less on this production, as there would be many other places for spending the start up capital.

Let >1 prototype be made

If the overheads are not very much, let the Invention Prototype be made into multiple versions. In the next few desings you will see that the creator will improve the designs. Due to this, the latest product arrived at would fetch more money owing to its modern and sharp design. Some people also have the habit of making two prototypes at a time. The first one would be meant for ‘show’ and the second one for ‘go’, i.e. the 1st one could be made to look like the end product and the 2nd one for demonstrating the functionality.

For instance- Battery Buddy had a ‘looks-like’ and ‘works-like’ prototype. The 1st one was created at ‘University of Michigan’. A box was fashioned to proper exterior dimensions as per the engineering drawings. It was painted with fancy, fine graphics. This version could fit on around 90% of vehicles in market. On the second tirial the outcome was a simple plastic box. It was grey-colored and around 4 times bigger than actual Battery Buddy. Finishing was not the issue then. The workability had to be checked; and it happened! Hence, the two versions made the task simpler from the buyer’s as well as seller’s point of view. 

 
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Home Foundry Information

Home Foundry

The most noticeable item in any backyard foundry is the furnace. This is no surprise really, because without the furnace the entire Backyard Foundry operation would be nonexistent. The furnace can take really any size and form depending upon the need and budget of the metal caster. What really makes home DIY Metal Casting furnaces really unique is how many of them come into creation.

Sure there are plenty of companies that will gladly sell furnaces for the hobby metal caster and while this can be a viable solution to your furnace needs many metal casters prefer another method.

Making your own furnace is not as far fetched as it may seem and if you already a Do It Yourselfer, chances are you will have the needed skills and tools in your workshop or garage already. The reasons are endless as to why people decide to make their own casting furnaces. The most common reason is fulfilling a need.

Many hobbyist and metal workers find out, to their dismay, that the local commercial foundries can not make the needed part or if they do, they feel the need to charge an outrageous sum. Not to mention the fact that the traditional methods of DIY Metal Casting is quickly becoming forgotten as the industry turns to electric furnaces. So many hobbyists find that constructing their own furnace is an absolute necessity and a great way to preserve a piece of craftsman history. The artisans who use metal casting to create sculptures and other pieces find that making their own furnace grants them a greater amount of control over the entire process. This is actually how many people get into metal casting to begin with.

Lots of times, your first furnace will be very simple and small as you are just getting started. There is really no need to run before you can walk when it comes to something that will be using intense heat and melting iron which can be rather dangerous.

Home made furnaces have been constructed from coffee cans to trash cans or sheet metal welded together. While there are a few components that really should be bought like the retractor to line the furnace walls which should be resistant to high temperature for a prolonged period of time along with special connectors and regulators, most of the furnace can be created in your own home. You should be able to find most of the components that you can not make at hardware stores or plumbing supply stores for relatively cheap.

The parts for the casting furnace are only part of what you need to get as you also need to get a crucible for holding the metal and all of the tools needed to handle the hot crucible. While you are at it you might as well buy all the safety equipment like gloves, protective eye wear, and leather shoes. There is other safety equipment that you will need depending on the type of work and the type of furnace you are going to make.

Most likely, your first furnace is going to be a simple cupola variation. The cupola furnace which is going to resemble a smoke stack is a simple design and is relatively easy to make for anyone with mild craft skill. This type of furnace will not require a crucible since you will be able to pour the molten metal from the furnace itself into a ladle that can then be poured into the mold.

DIY casting furnaces are a great way to connect yourself with your metal casting work giving you more control. While building the furnace can be complicated at first, once you delve into it you will find the experience enjoyable and fascinating.

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