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Two specialized kinds of equipment are needed for DSPC: a dedicated computer called a shell-design unit (SDU) and a shell- or moldprocessing unit (SPU). The CAD file is loaded into the SDU to generate the data needed to define the mold. SDU software also modifies the original design dimensions in the CAD file to compensate for ceramic shrinkage. This software can also add fillets and delete such features as holes or keyways that must be machined after the prototype is cast. The movable platform in DSPC is the piston within the build cylinder. It is lowered to a depth below the rim of the build cylinder equal to the thickness of each layer. Then a thin layer of fine aluminum oxide (alumina) powder is spread by roller over the platform, and a fine jet of colloidal silica is sprayed precisely onto the powder surface to bond it in the shape of a single mold layer. The piston is then lowered for the next layer and the complete process is repeated until all layers have been formed, completing the entire 3D shell. The excess powder is then removed, and the mold is fired to convert the bonded powder to monolithic ceramic. After the mold has cooled, it is strong enough to withstand molten metal and can function like a conventional investment-casting mold. After the molten metal has cooled, the ceramic shell and any cores or gating are broken away from the prototype. The casting can then be finished by any of the methods usually used on metal castings. DSPC is a proprietary process of Soligen Technologies, Northridge, California. The company also offers a custom mold manufacturing service.
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Ballistic Particle Manufacturing (BPM)
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There are several different names for the Ballistic Particle Manufacturing (BPM) process, diagrammed in Figure 8. Variations of it are also called inkjet methods. The molten plastic used to form the model and the hot wax for supporting overhangs or indentations are kept in heated tanks above the build station and delivered to computercontrolled jet heads through thermally insulated tubing. The jet heads squirt tiny droplets of the materials on the work platform as it is moved by an X-Y table in the pattern needed to form each layer of the 3D object. The droplets are deposited only where directed, and they harden rapidly as they leave the jet heads. A milling cutter is passed over the layer to mill it to a uniform thickness. Particles that are removed by the cutter are vacuumed away and deposited in a collector. Nozzle operation is monitored carefully by a separate fault-detection system. After each layer has been deposited, a stripe of each material is deposited on a narrow strip of paper for thickness measurement by opti-
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Figure 8 Ballistic Particle Manufacturing (BPM): Heated plastic and wax are deposited on a movable work platform by a computer-controlled X-Y table to form each layer. After each layer is deposited, it is milled to a precise thickness. The platform is lowered and the next layer is applied. This procedure is repeated until the 3D model is completed. A fault detection system determines the quality and thickness of the wax and plastic layers and directs rework if a fault is found. The supporting wax is removed from the 3D model by heating or immersion in a hot liquid bath.
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cal detectors. If the layer meets specifications, the work platform is lowered a distance equal to the required layer thickness and the next layer is deposited. However, if a clot is detected in either nozzle, a jet cleaning cycle is initiated to clear it. Then the faulty layer is milled off and that layer is redeposited. After the 3D model is completed, the wax material is either melted from the object by radiant heat or dissolved away in a hot water wash. The BPM system is capable of producing objects with fine finishes, but the process is slow. With this RP method, a slower process that yields a 3D model with a superior finish is traded off against faster processes that require later manual finishing. The version of the BPM system shown in Figure 8 is called Drop on Demand Inkjet Plotting by Sanders Prototype Inc, Merrimac, New Hampshire. It offers the ModelMaker II processing equipment, which produces 3D models with this method. AeroMet Corporation builds titanium parts directly from CAD renderings by fusing titanium powder with an 18-kW carbon dioxide laser, and 3D Systems of Valencia,
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