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Figure 10 Shape Deposition Manufacturing (SDM): Functional metal parts or tools can be formed in layers by repeating three basic steps repetitively until the part is completed. Hot metal droplets of both primary and sacrificial support material form layers by a thermal metal spraying technique (a). They retain their heat long enough to remelt the underlying metal on impact to form strong metallurgical interlayer bonds. Each layer is machined under computer control (b) and shot-peened (c) to relieve stress buildup before the work is returned for deposition of the next layer. The sacrificial metal supports any undercut features. When deposition of all layers is complete, the sacrificial metal is removed by acid etching to release the completed part.
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metal. The support material protects the part layers from the deposition steps that follow, stabilizes the layer for further machining operations, and provides a flat surface for milling the next layer. This SDM cycle is repeated until the part is finished, and then the sacrificial metal is etched away with acid. One combination of metals that has been successful in SDM is stainless steel for forming the prototype and copper for forming the support structure The SDM Laboratory investigated many thermal techniques for depositing high-quality metals, including thermal spraying and plasma or laser welding, before it decided on microcasting, a compromise between these two techniques that provided better results than either technique by itself. The metal droplets in microcasting are large enough (1 to 3 mm in diameter) to retain their heat longer than the 50-mm droplets formed by conventional thermal spraying. The larger droplets remain molten and retain their heat long enough so that when they impact the metal surfaces they remelt them to form a strong metallurgical interlayer bond. This process overcame the low adhesion and low mechanical strength problems encountered with conventional thermal metal spraying. Weld-based deposition easily remelted the substrate
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material to form metallurgical bonds, but the larger amount of heat transferred tended to warp the substrate or delaminate it. The SDM laboratory has produced custom-made functional mechanical parts and has embedded prefabricated mechanical parts, electronic components, electronic circuits, and sensors in the metal layers during the SDM process. It has also made custom tools such as injection molds with internal cooling pipes and metal heat sinks with embedded copper pipes for heat redistribution.
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The Rapid Prototyping Laboratory at Stanford University, Palo Alto, California, has developed its own version of SDM, called Mold SDM, for building layered molds for casting ceramics and polymers. Mold SDM, as diagrammed in Figure 11, uses wax to form the molds. The wax occupies the same position as the sacrificial support metal in SDM, and water-soluble photopolymer sacrificial support material occupies and supports the mold cavity. The photopolymer corresponds to the primary metal deposited to form the finished part in SDM. No machining is performed in this process. The first step in the Mold SDM process begins with the decomposition of CAD mold data into layers of optimum thickness, which depends on the complexity and contours of the mold. The actual processing begins at Figure 11(a), which shows the results of repetitive cycles of the deposition of wax for the mold and sacrificial photopolymer in each layer to occupy the mold cavity and support it. The polymer is hardened by an ultraviolet (UV) source. After the mold and support structures are built up, the work is moved to a station (b) where the photopolymer is removed by dissolving it in water. This exposes the wax mold cavity into which the final part material is cast. It can be any compatible castable material. For example, ceramic parts can be formed by pouring a gelcasting ceramic slurry into the wax mold (c) and then curing the slurry. The wax mold is then removed (d) by melting it, releasing the green ceramic part for furnace firing. In step (e), after firing, the vents and sprues are removed as the final step. Mold SDM has been expanded into making parts from a variety of polymer materials, and it has also been used to make preassembled mechanisms, both in polymer and ceramic materials. For the designer just getting started in the wonderful world of mobile robots, it is suggested s/he follow the adage prototype early, prototype often. This old design philosophy is far easier to use with the aid of RP tools. A simpler, cheaper, and more basic method, though, is to use
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