ME310

Manufacturing Processes
Rahul Panat

School of Mechanical and Materials Engineering

Washington State University
1

NOTES
Exam #1 back today you did well in general. Please take this as
an opportunity to work on areas that you think needs greater
attention.
Manufacturing Processes Project; March 13th
There will be one group project (5 students per team). The project might
involve researching on recent advances in traditional manufacturing
methods or entirely new (modern) manufacturing methods and making a
report and a 10-15 min presentation at the end of the semester

Modern Manufacturing Methods

Rapid Prototyping
Week 7

OUTLINE
What is rapid prototyping?
Types of rapid prototyping equipment/processes
Consumer/Hobby Printers
Printers for Corporations

Newmancraneins.com

WHAT IS RAPID PROTOTYPING

Subtractive Manufacturing
Any process of removing material
Milling, Cutting, Drilling, etc

Additive Manufacturing
Any process of adding material
Filament, Laminate, Liquid, Powder, etc

Rapid Prototyping Original name

Additive Manufacturing Best name
3D Printing Most common name

ADDITIVE VS SUBTRACTIVE

Additive

Subtractive

TYPES

Liquid (SLA, DLP)

3D Systems

Powder (Inkjet Binder)

Z-Corp, ExOne

Powder (Sintered SLS or Electron beam)

Eos, Arcam

Laminated
Solido, Mcor

Liquid (Inkjet) Objet,

Solidscape

Filament (FDM, FFF)

Stratasys, RepRap, Makerbot, 3D Systems

Owned by Stratasys
Owned by 3D Systems 7

MATERIALS

http://www.shapeways.com/materials

REPRAP VS STRATASYS

~$15000 uPrint Stratasys

~$550 RepRap Prusa

Sept 2011

A 0.254 mm layer is the smallest Stratasys can go.

REPRAP VS SLA

~$900 RepRap Prusa

~$650,000 3D Systems SLA-7000

3D Systems SLA-7000 @ 0.1mm vs RepRap Mendel Prusa @ 0.15 mm (RepRapBCN version)

http://reprapbcn.wordpress.com/2012/05/24/reprap-mendel-prusa-vs-3dsystems-sla-7000-stereolithography/

PROTOTYPE: SUBSTRACTIVE PROCESS

Series of material removal by machining and nishing
operations
Typical Steps
Computer-based drafting packages, which can produce threedimensional representations of parts
Interpretation software, which can translate the CAD le into a format
usable by manufacturing software
Manufacturing software, which is capable of planning the operations
required to produce the desired part shape
Computer-numerical-control (CNC) machinery, with capabilities necessary
to produce the parts

Usually a soft material (usually a polymer or wax) is used as the

work-piece

PROTOTYPE: ADDITIVE PROCESS

Parts are built layer by layer

Stereolithography
Multi Jet/polyJet modeling
Fused-deposition modeling
Ballistic-particle manufacturing
Three-dimensional printing
Selective laser sintering
Electron-beam melting
Laminated object manufacturing

Differences in the method of producing individual slices

Typically 0.10.5 mm (0.0040.020 in.)

Operations require dedicated software

Much faster than subtractive processes
Few minutes to a few hours

FUSED DEPOSITION MODELING (FDM)

Gantry-robot controlled extruder head moves in two principal directions over a table,
which can be raised and lowered as required
Extruder head is heated, and extrudes polymer lament at a constant rate through a
small orice.
Head follows a predetermined path
Extruded polymer bonds to the previously deposited layer

Drawbacks
Complex parts may be difcult to build directly because once the part has been constructed up to height
a, the next slice would require the lament to be placed at a location where no material exists
underneath to support it
Needs support material separately extruded

https://www.youtube.com/watch?v=WHO6G67GJbM

STEREOLITHOGRAPHY
Curing (hardening) of a liquid photopolymer into a specic shape
Photocurable liquid-acrylate polymer
The liquid is a mixture of acrylic monomers, oligomers (polymer intermediates), and a photoinitiator (a compound that
undergoes a reaction upon absorbing light)

The platform is lowered sufciently to cover the cured polymer with another layer of liquid
polymer, and the sequence is repeated
Part is removed from the platform, blotted, and cleaned ultrasonically and with an alcohol bath
Total cycle times in stereolithography range from a few hours to a day, without post-processing
steps such as sanding and painting
Depending on their capacity, the cost of the machines is in the range from $100,000 to $400,000!

https://www.youtube.com/watch?v=NM55ct5KwiI

MULTIJET/POLYJET MODELING
Print heads deposit the photopolymer on the build tray; UVt bulbs, alongside the jets, instantly
cure and harden each layer
No need for post-modeling curing
Smooth surface of layers as thin as 16 m
Two different materials are used: one for the actual model, and a second gel-like resin for
support
Each material simultaneously jetted and cured, layer by layer
Support material removed later removed, with an aqueous solution

https://www.youtube.com/watch?v=Som3CddHfZE
Undoprototipos.com

SELECTIVE LASER SINTERING

Sintering of non-metallic or, less commonly, metallic powders selectively into an
individual object
Materials: Polymers (such as ABS, PVC, nylon, polyester, polystyrene, and epoxy), wax,
metals, and ceramics, with appropriate binders
With ceramics and metals: common practice to sinter only a polymer binder that has
been blended with the ceramic or metal powders ceramic/metal sintered in a
furnace

Wikipedia

https://www.youtube.com/watch?v=srg6fRtc-oc

ELECTRON BEAM MELTING

E-beam, melting uses the energy source associated with an electron
beam to melt titanium or cobalt-chrome powder to make metal prototypes. The
workpiece is produced in a vacuum

Hindawi.com
Fraunhofer. gov
https://www.youtube.com/watch?v=jSH2vrtVNqQ

LAMINATED OBJECT MANUFACTURING

Roll-to-roll process is applied with heat activated glue or vinyl cutters

https://www.youtube.com/watch?v=4ebj6hH0HnY

THREE DIMENSIONAL PRINTING

A print head deposits an inorganic binder material onto a layer of polymer, ceramic, or
metallic powder
Allows considerable exibility in the materials and binders used
A piston, supporting the powder bed, is lowered incrementally, and with each step, a
layer is deposited and then fused by the binder

LASER ENGINEERED NET-SHAPING

Metal powder sprayed on a part
Lasers used to sinter the powder

LENSTM system creates near net

shape manufacturing
Turbine blade made by LENS at
Sandia National Lab

https://www.youtube.com/watch?v=SYbw1oSzPVA

LENSTM: Laser enabled net-shaping (courtesy Optomec Inc)

MESOSCALE ADDITIVE
MANUFACTURING
10-100um length scales required for 3-D antennas/ IoT devices/ smart goods
Inkjet or Aerosol jet
Antenna structure on
Polymer cylinder on a chip

Foldable fabric
substrate

Structures integrated with Si

Chip
Metal Line
(25mm wide)

Polymer Pillar (75 mm diameter)

http://www.optomec.com/additive-manufacturing/printedelectronics/aerosol-jet-core-applications/printed-antennas/

Images from Advanced Manufacturing Lab (Rahul Panat) unpublished research