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Figure 5 Fused Deposition Modeling (FDM): Filaments of thermoplastic are unwound from a spool, passed through a heated extrusion nozzle mounted on a computercontrolled X-Y table, and deposited on the fixtureless platform. The 3D model is formed as the nozzle extruding the heated filament is moved over the platform. The hot filament bonds to the layer below it and hardens. This laserless process can be used to form thinwalled, contoured objects for use as concept models or molds for investment casting. The completed object is removed and smoothed to improve its finish.
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elastomer. These materials melt at temperatures between 180 and 220 F (82 and 104 C). FDM is a proprietary process developed by Stratasys, Eden Prairie, Minnesota. The company offers four different systems. Its Genisys benchtop 3D printer has a build volume as large as 8 8 8 in. (20 20 20 cm), and it prints models from square polyester wafers that are stacked in cassettes. The material is heated and extruded through a 0.01in. (0.25-mm) diameter hole at a controlled rate. The models are built on a metallic substrate that rests on a table. Stratasys also offers four systems that use spooled material. The FDM2000, another benchtop system, builds parts up to 10 in3 (164 cm3) while the FDM3000, a floorstanding system, builds parts up to 10 10 16 in. (26 26 41 cm). Two other floor-standing systems are the FDM 8000, which builds models up to 18 18 24 in. (46 46 61 cm), and the FDM Quantum system, which builds models up to 24 20 24 in. (61 51 61 cm). All of these systems can be used in an office environment. Stratasys offers two options for forming and removing supports: a breakaway support system and a water-soluble support system. The
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water-soluble supports are formed by a separate extrusion head, and they can be washed away after the model is complete.
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The Three-Dimensional Printing (3DP) or inkjet printing process, diagrammed in Figure 6, is similar to Selective Laser Sintering (SLS) except that a multichannel inkjet head and liquid adhesive supply replaces the laser. The powder supply cylinder is filled with starch and cellulose powder, which is delivered to the work platform by elevating a delivery piston. A roller rolls a single layer of powder from the powder cylinder to the upper surface of a piston within a build cylinder. A multichannel inkjet head sprays a water-based liquid adhesive onto the surface of the powder to bond it in the shape of a horizontal layer of the model. In successive steps, the build piston is lowered a distance equal to the thickness of one layer while the powder delivery piston pushes up fresh powder, which the roller spreads over the previous layer on the build pis-
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Figure 6 Three-Dimensional Printing (3DP): Plastic powder from a reservoir is spread across a work surface by roller onto a piston of the build cylinder recessed below a table to a depth equal to one layer thickness in the 3DP process. Liquid adhesive is then sprayed on the powder to form the contours of the layer. The piston is lowered again, another layer of powder is applied, and more adhesive is sprayed, bonding that layer to the previous one. This procedure is repeated until the 3D model is complete. It is then removed and finished.
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ton. This process is repeated until the 3D model is complete. Any loose excess powder is brushed away, and wax is coated on the inner and outer surfaces of the model to improve its strength. The 3DP process was developed at the Three-Dimensional Printing Laboratory at the Massachusetts Institute of Technology, and it has been licensed to several companies. One of those firms, the Z Corporation of Somerville, Massachusetts, uses the original MIT process to form 3D models. It also offers the Z402 3D modeler. Soligen Technologies has modified the 3DP process to make ceramic molds for investment casting. Other companies are using the process to manufacture implantable drugs, make metal tools, and manufacture ceramic filters.
Direct-Shell Production Casting (DSPC)
The Direct Shell Production Casting (DSPC) process, diagrammed in Figure 7, is similar to the 3DP process except that it is focused on forming molds or shells rather than 3D models. Consequently, the actual 3D model or prototype must be produced by a later casting process. As in the 3DP process, DSPC begins with a CAD file of the desired prototype.
Figure 7 Direct Shell Production Casting (DSPC): Ceramic molds rather than 3D models are made by DSPC in a layering process similar to other RP methods. Ceramic powder is spread by roller over the surface of a movable piston that is recessed to the depth of a single layer. Then a binder is sprayed on the ceramic powder under computer control. The next layer is bonded to the first by the binder. When all of the layers are complete, the bonded ceramic shell is removed and fired to form a durable mold suitable for use in metal casting. The mold can be used to cast a prototype. The DSPC process is considered to be an RP method because it can make molds faster and cheaper than conventional methods.
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