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Because the photopolymer used in the SL process tends to curl or sag as it cures, models with overhangs or unsupported horizontal sections must be reinforced with supporting structures: walls, gussets, or columns. Without support, parts of the model can sag or break off before the polymer has fully set. Provision for forming these supports is included in the digitized fabrication data. Each scan of the laser forms support layers where necessary while forming the layers of the model. When model fabrication is complete, it is raised from the polymer vat and resin is allowed to drain off; any excess can be removed manually from the model s surfaces. The SL process leaves the model only partially polymerized, with only about half of its fully cured strength. The model is then finally cured by exposing it to intense UV light in the enclosed chamber of post-curing apparatus (PCA). The UV completes the hardening or curing of the liquid polymer by linking its molecules in chainlike formations. As a final step, any supports that were required are removed, and the model s surfaces are sanded or polished. Polymers such as urethane acrylate resins can be milled, drilled, bored, and tapped, and their outer surfaces can be polished, painted, or coated with sprayedon metal. The liquid SL photopolymers are similar to the photosensitive UVcurable polymers used to form masks on semiconductor wafers for etching and plating features on integrated circuits. Resins can be formulated to solidify under either UV or visible light. The SL process was the first to gain commercial acceptance, and it still accounts for the largest base of installed RP systems. 3D Systems of Valencia, California, is a company that manufactures stereolithography equipment for its proprietary SLA process. It offers the ThermoJet Solid Object Printer. The SLA process can build a model within a volume measuring 10 7.5 8 in. (25 19 20 cm). It also offers the SLA 7000 system, which can form objects within a volume of 20 20 23.62 in. (51 51 60 cm). Aaroflex, Inc. of Fairfax, Virginia, manufactures the Aacura 22 solid-state SL system and operates AIM, an RP manufacturing service.
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Solid Ground Curing (SGC)
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Solid ground curing (SGC) (or the solider process ) is a multistep inline process that is diagrammed in Figure 2. It begins when a photomask for the first layer of the 3D model is generated by the equipment shown at the far left. An electron gun writes a charge pattern of the photomask on a clear glass plate, and opaque toner is transferred electrostatically to the plate to form the photolithographic pattern in a xerographic process.
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Figure 2 Solid Ground Curing (SGC): First, a photomask is generated on a glass plate by a xerographic process. Liquid photopolymer is applied to the work platform to form a layer, and the platform is moved under the photomask and a strong UV source that defines and hardens the layer. The platform then moves to a station for excess polymer removal before wax is applied over the hardened layer to fill in margins and spaces. After the wax is cooled, excess polymer and wax are milled off to form the first slice. The first photomask is erased, and a second mask is formed on the same glass plate. Masking and layer formation are repeated with the platform being lowered and moved back and forth under the stations until the 3D model is complete. The wax is then removed by heating or immersion in a hot water bath to release the prototype.
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The photomask is then moved to the exposure station, where it is aligned over a work platform and under a collimated UV lamp. Model building begins when the work platform is moved to the right to a resin application station where a thin layer of photopolymer resin is applied to the top surface of the work platform and wiped to the desired thickness. The platform is then moved left to the exposure station, where the UV lamp is then turned on and a shutter is opened for a few seconds to expose the resin layer to the mask pattern. Because the UV light is so intense, the layer is fully cured and no secondary curing is needed. The platform is then moved back to the right to the wiper station, where all of resin that was not exposed to UV is removed and discarded. The platform then moves right again to the wax application station, where melted wax is applied and spread into the cavities left by the removal of the uncured resin. The wax is hardened at the next station by pressing it against a cooling plate. After that, the platform is moved right again to the milling station, where the resin and wax layer are milled to a precise thickness. The platform piece is then returned to the resin application station, where it is lowered a depth equal to the thickness of the next layer and more resin is applied.
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