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Rapid prototyping is now also seen as an integral part of the even larger but not well defined rapid tooling (RT) market. Concept modeling addresses the early stages of the design process, whereas RT concentrates on production tooling or mold making. Some concept modeling equipment, also called 3D or office printers, are self-contained desktop or benchtop manufacturing units small enough and inexpensive enough to permit prototype fabrication to be done in an office environment. These units include provision for the containment or venting of any smoke or noxious chemical vapors that will be released during the model s fabrication.
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Computer-Aided Design Preparation
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The RP process begins when the object is drawn on the screen of a CAD workstation or personal computer to provide the digital data base. Then, in a post-design data processing step, computer software slices the object mathematically into a finite number of horizontal layers in generating an STL (Solid Transfer Language) file. The thickness of the slices can range from 0.0025 to 0.5 in. (0.06 to 13 mm) depending on the RP process selected. The STL file is then converted to a file that is compatible with the specific 3D printer or processor that will construct the model. The digitized data then guides a laser, X-Y table, optics, or other apparatus that actually builds the model in a process comparable to building a high-rise building one story at a time. Slice thickness might have to be modified in some RP processes during model building to compensate for material shrinkage.
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Prototyping Choices
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All of the commercial RP methods depend on computers, but four of them depend on laser beams to cut or fuse each lamination, or provide enough heat to sinter or melt certain kinds of materials. The four processes that make use of lasers are Directed-Light Fabrication (DLF), Laminated-Object Manufacturing (LOM), Selective Laser Sintering (SLS), and Stereolithography (SL); the five processes that do not require lasers are Ballistic Particle Manufacturing (BPM), Direct-Shell Production Casting (DSPC), Fused-Deposition Modeling (FDM), SolidGround Curing (SGC), and 3D Printing (3DP).
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Stereolithography (SL)
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The stereolithographic (SL) process is performed on the equipment shown in Figure 1. The movable platform on which the 3D model is formed is initially immersed in a vat of liquid photopolymer resin to a level just below its surface so that a thin layer of the resin covers it. The SL equipment is located in a sealed chamber to prevent the escape of fumes from the resin vat. The resin changes from a liquid to a solid when exposed to the ultraviolet (UV) light from a low-power, highly focused laser. The UV laser beam is focused on an X-Y mirror in a computer-controlled beam-shaping and scanning system so that it draws the outline of the lowest crosssection layer of the object being built on the film of photopolymer resin. After the first layer is completely traced, the laser is then directed to scan the traced areas of resin to solidify the model s first cross section. The laser beam can harden the layer down to a depth of 0.0025 to 0.0300 in. (0.06 to 0.8 mm). The laser beam scans at speeds up to 350 in./s (890 cm/s). The photopolymer not scanned by the laser beam remains a liquid. In general, the thinner the resin film (slice thickness), the higher the resolution or more refined the finish of the completed model. When model surface finish is important, layer thicknesses are set for 0.0050 in. (0.13 mm) or less. The table is then submerged under computer control to the specified depth so that the next layer of liquid polymer flows over the first hardened layer. The tracing, hardening, and recoating steps are repeated, layer-by-layer, until the complete 3D model is built on the platform within the resin vat.
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Figure 1 Stereolithography (SL): A computer-controlled neon helium ultraviolet light (UV) emitting laser outlines each layer of a 3D model in a thin liquid film of UV-curable photopolymer on a platform submerged a vat of the resin. The laser then scans the outlined area to solidify the layer, or slice. The platform is then lowered into the liquid to a depth equal to layer thickness, and the process is repeated for each layer until the 3D model is complete. Photopolymer not exposed to UV remains liquid. The model is them removed for finishing.
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