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Introduction
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California, produces a line of inkjet printers that feature multiple jets to speed up the modeling process.
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Directed Light Fabrication (DLF)
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The Directed Light Fabrication (DLF) process, diagrammed in Figure 9, uses a neodymium YAG (Nd:YAG) laser to fuse powdered metals to build 3D models that are more durable than models made from paper or plastics. The metal powders can be finely milled 300 and 400 series stainless steel, tungsten, nickel aluminides, molybdenum disilicide, copper, and aluminum. The technique is also called Direct-Metal Fusing, Laser Sintering, and Laser Engineered Net Shaping (LENS). The laser beam under X-Y computer control fuses the metal powder fed from a nozzle to form dense 3D objects whose dimensions are said to be within a few thousandths of an inch of the desired design tolerance. DLF is an outgrowth of nuclear weapons research at the Los Alamos National Laboratory (LANL), Los Alamos, New Mexico, and it is still in the development stage. The laboratory has been experimenting with the
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Figure 9 Directed Light Fabrication (DLF): Fine metal powder is distributed on an X-Y work platform that is rotated under computer control beneath the beam of a neodymium YAG laser. The heat from the laser beam melts the metal powder to form thin layers of a 3D model or prototype. By repeating this process, the layers are built up and bonded to the previous layers to form more durable 3D objects than can be made from plastic. Powdered aluminum, copper, stainless steel, and other metals have been fused to make prototypes as well as practical tools or parts that are furnace-fired to increase their bond strength.
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Introduction
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laser fusing of ceramic powders to fabricate parts as an alternative to the use of metal powders. A system that would regulate and mix metal powder to modify the properties of the prototype is also being investigated. Optomec Design Company, Albuquerque, New Mexico, has announced that direct fusing of metal powder by laser in its LENS process is being performed commercially. Protypes made by this method have proven to be durable and they have shown close dimensional tolerances.
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Research and Development in RP
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Many different RP techniques are still in the experimental stage and have not yet achieved commercial status. At the same time, practical commercial processes have been improved. Information about this research has been announced by the laboratories doing the work, and some of the research is described in patents. This discussion is limited to two techniques, SDM and Mold SDM, that have shown commercial promise.
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Shape Deposition Manufacturing (SDM)
The Shape Deposition Manufacturing (SDM) process, developed at the SDM Laboratory of Carnegie Mellon University, Pittsburgh, Pennsylvania, produces functional metal prototypes directly from CAD data. This process, diagrammed in Figure 10, forms successive layers of metal on a platform without masking, and is also called solid free- form (SFF) fabrication. It uses hard metals to form more rugged prototypes that are then accurately machined under computer control during the process. The first steps in manufacturing a part by SDM are to reorganize or destructure the CAD data into slices or layers of optimum thickness that will maintain the correct 3D contours of the outer surfaces of the part and then decide on the sequence for depositing the primary and supporting materials to build the object. The primary metal for the first layer is deposited by a process called microcasting at the deposition station, Figure 10(a). The work is then moved to a machining station (b), where a computer-controlled milling machine or grinder removes deposited metal to shape the first layer of the part. Next, the work is moved to a stress-relief station (c), where it is shot- peened to relieve stresses that have built up in the layer. The work is then transferred back to the deposition station (a) for simultaneous deposition of primary metal for the next layer and sacrificial support
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