SFFSFF Commercial SFF Processes (cont.)Commercial SFF Processes (cont.)

Additive Methods with Sacrificial Supports

Stereolithography

Fused Deposition Modeling (Stratasys)

Solidscape (Sanders Prototype, Inc.)

Solid Printing / Imaging (3D Systems)

Powder-Bed Based Approaches

3D Printing (Z-Corporation)

Selective Laser Sintering

SFFSFF SFF: Fused Deposition ModelingSFF: Fused Deposition Modeling

Principle:

Beads of semi-liquid ABS* plastic get deposited by a head moving in x-y-plane.

Supports are built from a separate nozzle.

Schematic view ==>

Key player: Stratasys: http://www.stratasys.com/

* acrylonitrile-butadiene-styrene

SFFSFF Fused Deposition ModelingFused Deposition Modeling

SFFSFF Looking into the FDM MachineLooking into the FDM Machine

SFFSFF Zooming into the FDM MachineZooming into the FDM Machine

SFFSFF Single-thread Figure-8 Klein BottleSingle-thread Figure-8 Klein Bottle

As it comes out of the FDM machine

SFFSFF Support = ScaffoldingSupport = Scaffolding

The areas in each layer where scaffolding is neededis calculated by “Quickslice”(Stratasys’ FDM software).

SFFSFF Layered Fabrication of Klein BottleLayered Fabrication of Klein Bottle

Support material

SFFSFF Klein Bottle Skeleton (FDM)Klein Bottle Skeleton (FDM)

Support removal can be tedious and painful !

SFFSFF Positioning for StrengthPositioning for Strength

Desired part geometry

Necessary support material

Trade-offs: part strength <-> amount of support material

potential breaking point

partrotatedthru 90°

SFFSFF FDM: The Software InterfaceFDM: The Software Interface

Stratasys Quickslice

Good “tutorial” for layered manufacturing

Offers all the knobs a professional needs

Several entry points:

STL: B-rep in triangle soup

SSL: Per-layer outline contours

SML: Actual x-y-path of head to fill each layer

Too much automated clean-up “smarts” for overlapping contours

Not convenient enough editing of contours

SFFSFF Newest FDM Machines (Stratasys)Newest FDM Machines (Stratasys)

The FDM Maxum™ is the fastest prototyping system offered by Stratasys, operating 50 percent faster than previous systems.

Its WaterWorks™ soluble support systems offers virtually hands-free prototyping.

Also offers a larger build volume (600x500x600 mm) able to construct a whole monitor.

SFFSFF Stratasys WaterWorks™Stratasys WaterWorks™

This wrench was built in

assembled form, using

the new “WaterWorks”

soluble support system.

After the support material

was dissolved, the three

parts were already fully

assembled and movable!

Working Adjustable Wrench

SFFSFF Stratasys FDM Titan SystemStratasys FDM Titan System

One System:

Multiple high-performance materials.

One of the largest FDM build chambers.

SFFSFF Stratasys: Another MaterialStratasys: Another Material

Polycarbonate Ratchet Knob

A fully functional mechanism built from high impact-strength material.

SFFSFF Fused Deposition ModelingFused Deposition Modeling

An Informal Evaluation Easy to use

Rugged and robust

Could have this in your office

Good transparent software (Quickslice)with multiple entry points: STL, SSL, SML

Inexpensive to operate

Slow

Think about support removal !

SFFSFF What Can Go Wrong ?What Can Go Wrong ?

Black blobsat nozzle …

may topple supports …

which then leads to“Angel hair”

SFFSFF Error in Support CalculationError in Support Calculation

A thin downward knife-edge may be missed in thesupport calculation!

Hanging “telephone wires”.

SFFSFF Solid Object PrintingSolid Object Printing

ModelMaker II (Solidscape)

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

ModelMaker II (Solidscape)

Alternate: { Deposition / Planarization } Steps Build envelope: 12 x 6 x 8.5 in.

Build layer: 0.0005 in. to 0.0030 in.

Achievable accuracy: +/- 0.001 in. per inch

Surface finish: 32-63 micro-inches (RMS)

Minimum feature size: 0.010 in.

Key Player:Solidscape*: http://www.solid-scape.com/

* formerly: Sanders

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

Projection of 4D 120-cell, made in “jewelers wax.”

(2” diam.)

SFFSFF SFF: Solid Scape (Sanders)SFF: Solid Scape (Sanders)

An Informal Evaluation

The most precise SFF machine around

Very slow

Sensitive to ambient temperature

Must be kept running most of the time

Poor software

Little access to operational parameters

Based on comments by B. G.: http://www.bathsheba.com/

SFFSFF SFF: Solid Object-Printing / ImagingSFF: Solid Object-Printing / Imaging

Droplets of a thermoplastic material are sprayed from a moving print head onto a platform surface.

Need to build a support structures where there are overhangs / bridges.

These supports (of the same material) are given porous, fractal nature.

They need to be removed (manually).

Key player: 3D Systems: http://www.3dsystems.com/

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

Supports made from same material, but with a fractal structure

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

Thermojet Printer (3D Systems)

Technology: Multi-Jet Modeling (MJM)

Resolution (x,y,z): 300 x 400 x 600 DPI

Maximum Model Size: 10 x 7.5 x 8 in (13 lb)

Material: neutral, gray, black thermoplastic: ThermoJet 88: smooth surfaces for casting

ThermoJet 2000: more durable for handling

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

That’s how partsemerge from theThermojet printer

After partial removalof the supportingscaffolding

SFFSFF 9-story Intertwined Double Toroid9-story Intertwined Double Toroid

Bronzeinvestment casting from wax original made on 3D Systems“Thermojet”

SFFSFF Micromechanical Flying Insect Micromechanical Flying Insect

Polyurethanemicro-fly,

cast in silicone rubber mold,

formed around wax original made on 3D Systems’“Thermojet”

Ron Fearing, U.C. Berkeley

SFFSFF SFF: Solid Object PrintingSFF: Solid Object Printing

An Informal Evaluation

Fast

Inexpensive

Reliable, robust

Support removal takes some care( Refrigerate model beforehand! )

Thermojet 88 parts are fragile

Good for investment casting

SFFSFF Powder-based ApproachesPowder-based Approaches

Key Properties:

Needs no supports that must be removed!

Uniform bed of powder acts as support.

This powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part.

SFFSFF SFF: 3D Printing -- PrincipleSFF: 3D Printing -- Principle

Selectively deposit binder droplets onto a bed of powder to form locally solid parts.

Powder Spreading Printing

Build

Feeder

Powder

Head

SFFSFF 3D Printing: Some Key Players3D Printing: Some Key Players

Z Corporation: http://www.zcorp.com/Plaster and starch powders for visualization models.

Soligen: http://www.zcorp.com/Metal and ceramic powdersfor operational prototypes.

Therics Inc.: http://www.therics.com/Biopharmaceutical products,tissue engineering.

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

The Z402 3D Printer Speed: 1-2 vertical inches per hour

Build Volume: 8" x 10" x 8"

Thickness: 3 to 10 mils, selectable

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

Digging out

SFFSFF Optional Curing: 30 min. @ 200ºF Optional Curing: 30 min. @ 200ºF

Keep some powder in place

<-- Tray for transport

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

Cleaning up in the de-powdering station

SFFSFF 3D Printing:3D Printing: Z CorporationZ Corporation

The finished part

Zcorp,

6” diam.,

6hrs.

SFFSFF 120 Cell -- Close-up120 Cell -- Close-up

SFFSFF 3D 3D ColorColor Printing: Z Corporation Printing: Z Corporation

The Z402C 3D Color Printer

Differences compared to mono-color printer:

Color print head with: Cyan, Yellow, Magenta, Black, and Neutral.

Smaller build area.

Specs:

Speed: 0.33 - 0.66 vertical inches per hour

Build Volume: 6" x 6" x 6"

Thickness: 3 to 10 mils, selectable

Color depth: 80 mils

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Use compressed air to blow out central hollow space.

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors.

SFFSFF 3D Color Printing: Z Corporation3D Color Printing: Z Corporation

“Lizard-Frame”: Final Infiltrated Part

SFFSFFWhat Can Go Wrong ? What Can Go Wrong ? -- -- Parts may brake before infiltrationParts may brake before infiltration

SFFSFF What Else Can Go Wrong ?What Else Can Go Wrong ?

Blocked glue lines

Crumbling parts

SFFSFF 3D Printing: Z Corporation3D Printing: Z Corporation

An Informal Evaluation

Fast !

Running expenses: moderate,(but overpriced powder)

Color print head and tubes need some care in maintenance.

Somewhat messy cleanup !

Lot’s of dust everywhere ...