CHS UCB ME 290P -- October 2002 Rapid Prototyping and its Role in Product Development Carlo H.
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CHS UCB ME 290P -- October 2002 Rapid Prototyping and its Role in Product Development Carlo H. Séquin EECS Computer Science Division University of California, Berkeley CHS UCB Design is an Iterative Process Formal Specifications Detailed Description Clear Concept Experiments, get feedback Vague idea Revision of artifact 1st `hack' Demo Prototype Usable Evaluation Series Marketable Systems Product CHS UCB A Specific Challenge Create as soon as possible a 3D "free-form" part (not a box-like thing that can be built from flat plates) for evaluation in its application context. This includes: visualization tactile feedback function verification simulation of final use. CHS UCB Conceptual Prototyping The Traditional Options: Model from clay Carve from wood Bend wire meshing from styrofoam – perhaps with surface reinforcement Carve Mill from a block of plastic or aluminum (3- or 4-axes machines) CHS UCB New Ways of Rapid Prototyping Based on Layered Manufacturing: Build the part in a layered fashion -- typically from bottom up. Conceptually, like stacking many tailored pieces of cardboard on top of one another. Part geometry needs to be sliced, and the geometry of each slice determined. Computer controlled, fully automated. CHS UCB What SFF exists in COE ? In Etcheverry: A Fused Deposition Modeling Machine A Z-Corp Color/Mono 3D Printer In Cory Hall: Solid Printing / Imaging (3D Systems) Stereolithography (3D Systems) You need to prepare: A “watertight” boundary representation with less than 100’000 triangles In .STL format. CHS UCB SFF: Fused Deposition Modeling Principle: of semi-liquid ABS* plastic get deposited by a head moving in x-y-plane. Beads Supports are built from a separate nozzle. Schematic view ==> Key player: Stratasys: http://www.stratasys.com/ * acrylonitrile-butadine-styrene CHS UCB Fused Deposition Modeling CHS UCB Looking into the FDM Machine CHS UCB Layered Fabrication of Klein Bottle Support material CHS UCB Klein Bottle Skeleton (FDM) CHS UCB Fused Deposition Modeling (FDM) An Informal Evaluation Easy to use Rugged Could and robust have this in your office Good transparent software (Quickslice) with multiple entry points: STL, SSL, SML Inexpensive to operate Slow Think about support removal ! CHS UCB What Can Go Wrong ? Black blobs Toppled supports CHS UCB SFF: Solid Imaging Droplets of a thermoplastic material are sprayed from a moving print head onto a platform surface. Need to build a support structures where there are overhangs / bridges. These supports (of the same material) are given porous, fractal nature. They Key need to be removed (manually). player: 3D Systems: http://www.3dsystems.com/index_nav.asp CHS UCB SFF: Solid Imaging Supports made from same material, but with a fractal structure CHS UCB SFF: Solid Imaging Thermojet Printer (3D Systems) Technology: Multi-Jet Modeling (MJM) Resolution (x,y,z): 300 x 400 x 600 DPI Maximum Model Size: 10 x 7.5 x 8 in (13 lb) Material: neutral, gray, black thermoplastic: ThermoJet 88: smooth surfaces for casting ThermoJet 2000: more durable for handling CHS UCB SFF: Solid Imaging That’s how parts emerge from the Thermojet printer After partial removal of the supporting scaffolding CHS UCB 9-Story Intertwined Double Toroid Bronze investment casting from wax original made on 3D Systems’ “Thermojet” CHS UCB SFF: Solid Imaging An Informal Evaluation Fast Inexpensive Reliable, Good robust for investment casting Support removal takes some care (refrigerate model beforehand) Thermojet 88 parts are fragile CHS UCB Powder-based Approaches Key Properties: Needs no supports that must be removed! Uniform This bed of powder acts as support. powder gets selectively (locally) glued (or fused) together to create the solid portions of the desired part. CHS UCB SFF: 3D Printing -- Principle Selectively deposit binder droplets onto a bed of powder to form locally solid parts. Head Powder Spreading Printing Powder Feeder Build CHS UCB 3D Printing: Some Key Players Z Corporation: http://www.zcorp.com/ Plaster and starch powders for visualization models. Soligen: http://www.zcorp.com/ Metal and ceramic powders for operational prototypes. CHS UCB 3D Printing: Z Corporation The Z402 3D Printer Speed: 1-2 vertical inches per hour Build Volume: 8" x 10" x 8" Thickness: 3 to 10 mils, selectable CHS UCB 3D Printing: Z Corporation CHS UCB 3D Printing: Z Corporation Digging out CHS UCB Optional Curing: 30 min. @ 200ºF Keep some powder in place <-- Tray for transport CHS UCB 3D Printing: Z Corporation Cleaning up in the de-powdering station CHS UCB 3D Printing: Z Corporation The finished part Zcorp, 6” diam., 6hrs. CHS UCB 120 Cell -- Close-up CHS UCB 3D Color Printing: Z-Corporation The Z402C 3D Color Printer Differences compared to mono-color printer: Color print head with: Cyan, Yellow, Magenta, Black, and Neutral. Smaller build area. Specs: Speed: 0.33 - 0.66 vertical inches per hour Build Volume: 6" x 6" x 6" Thickness: 3 to 10 mils, selectable Color depth: 80 mils CHS UCB 3D Color Printing: Z Corporation Use compressed air to blow out central hollow space. CHS UCB 3D Color Printing: Z Corporation Infiltrate Alkyl Cyanoacrylane Ester = “super-glue” to harden parts and to intensify colors. CHS UCB What Can Go Wrong ? Blocked glue lines Crumbling parts CHS UCB Broken Parts CHS UCB 3D Printing: Z Corporation An Informal Evaluation Fast ! Running expenses: moderate, (but overpriced powder) Color print head and tubes need some care in maintenance. Somewhat Lot’s messy cleanup ! of dust everywhere ... CHS UCB SFF: Stereolithography (SLA) UV laser beam solidifies the top layer of a photosensitive liquid. UV Laser Beam Photopolymer Build Stage CHS UCB SFF: Stereolithography (SLA) SLA Machine by 3D Systems Maximum build envelope: 350 x 350 x 400 mm in XYZ Vertical resolution: 0.00177 mm Position repeatability: ±0.005 mm Maximum part weight: 56.8 kg CHS UCB Stereolithography An Informal Evaluation Can do intricate shapes with small holes High precision Moderately Fast Photopolymer Laser is expensive ($700/gallon) is expensive ($10’000), lasts only about 2000 hrs. CHS UCB Séquin’s “Minimal Saddle Trefoil” Stereo- lithography master CHS UCB Séquin’s “Minimal Saddle Trefoil” bronze cast, gold plated CHS UCB Consumer Electronics Prototypes Role of 3D Hardcopy -- Part 1: Modeling and Prototyping Packaging of various electronics components. Custom designed housing for other utility products. The physical frame for an “instrument” … CHS UCB Prototyping Consumer Products “Solarcator” and “Contact-Compact” Two student-designed “products” in ME221 http://kingkong.me.berkeley.edu/html/gallery/Fall1999TradeShow/ CHS UCB Model Prototype Mold Part Injection-Molded Housing for ST TouchChip CHS UCB Artistics Parts, Abstract Sculptures Role of 3D Hardcopy -- Part 3: Maquettes for Visualization All-round inspection, including light and shadows. Parts that could not be made in any other way … Prototyping modular parts, before an injection mold is made. CHS UCB “Viae Globi” Sculptures FDM maquettes of possible bronze sculptures CHS UCB Sculpture Design: “Solar Arch” branches = 4 storeys = 11 height = 1.55 flange = 1.00 thickness = 0.06 rim_bulge = 1.00 warp = 330.00 twist = 247.50 azimuth = 56.25 mesh_tiles = 0 textr_tiles = 1 detail = 8 bounding box: xmax= 6.01, ymax= 1.14, zmax= 5.55, xmin= -7.93, ymin= -1.14, zmin= -8.41 CHS UCB Competition in Breckenridge, CO CHS UCB FDM Maquette of Solar Arch 2nd place CHS UCB Which Process Should You Pick? Do you need a prototype (not just a model)? SLS, FDM (for robustness, strength). Do you need a mold for a small batch? SLA (for smooth, hard surface). Does part need multiple colors? 3D Color-Printing. Does part have convoluted internal spaces? 3D-P, SLS, SLA (easy support removal). CHS UCB Informal Process Ratings Matrix Hollow Hollow 2 Nested, Sphere Sphere with Perforated Drain/Vent Spheres 3D Hilbert Pipe Preassembled Gear Mechanism LOM (F) F F D F SLA (F) D C B D FDM 3D-P (F) (F) F A C A C C D B SLS (F) A A B B