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Prototyping Methods (Subtractive Prototyping (Computer Numerical Control…

- - - - G&M Code (Geometric and Miscellaneous Code)
        
        M-Code (Miscellaneous)
        
        T = Tool Number
        
        T01 = Tool Change
        
        M06 = Automatic Tool Change (ATC)
        
        G-Code (Geometric Code)
        
        N = Movement
        
        R for Radius of the arc
        
        G03 = Circular Interpolation counter clockwise
        
        G02 = Circular interpolation clockwise
        
        G01 = Feed Rate
        
        Z = Depth
        
        Y = Vertical
        
        X = Horizontal
      - A pre-programmed computer software that dictates the movement if the tools/cutters while it removes material from a raw stock /material
    - - Cost Effective
        
        Process is programmable
        
        Cut on hard metallic material
        
        Smooth finishing
    - - Can only cut on the top
        
        All the parts to be clamped
        
        Deciding on how to hold the part (e.g: work piece is held on a rotating part)
        
        Deciding the depth of cut, tool-bit size (Depending on material)
        
        If not optimized, either the cutter will break or a chunk will come flying out of the material
        
        Limitation of tool-bit (cutter diameter) size to produce small details
- - - - Components in SLA Machine:
        
        Elevating Table
        
        Laser System/ Heating System
        
        Electronic Controller (to input files)
        
        Platform
        
        Resin Surface
        
        Photopolymer Resin
        
        Vat
        
        Laser Beam
        
        Laser Source
        
        Support
      - Raw Material Used:
        
        Liquid Photopolymer
      - SLA Process:
        
        3D CAD output data prepared and send to SLA as .STL file
        
        Geometry is sliced into layer.
        
        Generate support (if necessary)
        
        3.Laser start building process. Each pass create one layer. Wiper to fill up liquid polymer for new layer
        
        Resin Support is removed
        
        Cleaned part is put into UV oven to cure
        
        Part is ready for assembly
  - - - Components in SLS machine
        
        Laser
        
        Roller
        
        Scanner System
        
        Powder Bed
        
        Fabrication Piston
        
        Powder Delivery System
        
        -Computer/Control area unit
        
        PC/WINDOWS OS
        
        .STL file
        
        Slices the parts
        
        Monitor and controls the entire building process
        
        -Atmosphere Control unit
        
        Houses the equipment to filter gas recirculated from the process chamber
        
        Maintains a set temperature on the air flowing into the process chamber
        
        Regulates the nitrogen atmosphere used in the unit
        
        Process Chamber
      - SLS Process:
        
        Process begins with the atmosphere in the process chamber heated to the operating temperature and chamber filled with nitrogen
        
        3-D CAD data in the .stl file format is input into the SLS system.The system slices the part into slices (thickness ranging from 0.005 to 0.006 in.)
        
        One powder feed piston rises to distribute a layer of material. At the same time, the part-building cylinder lowers to the desired layer thickness. The other powder feed piston also lowers to accommodate any surplus material, which the leveling roller transfers across the build area.
        
        4.Deposited powder is heated to a temperature just below its melting point. Laser draws one cross section of the desired part to sinter the powder particles. Un-sintered powder remains to support the next layer, which is then distributed, levelled, and sintered
        
        The part-building cylinder then raises to allow the part to be removed after cooling. Excess powder is cleaned off the part by brushing or air-blowing. With the exception of the use of ceramic materials, no post- production curing is required with this system
      - Advantage of SLS
        
        Does not need the use of support, compared to SLA
        
        SLS has more options for raw materials
        
        Excess powder can be reused.
        
        Accuracy is 0.015 in. , depending on material.
        
        Almost any material that softens and decreases in viscosity upon heating can theoretically be selectively
        
        sintered
    - - Components in FDM Machine:
        
        Print Display
        
        Extruder
        
        Filament
        
        Print Bed
        
        Hot End
        
        Cooling Fan
        
        Heated Nozzle
      - Raw Materials used:
        
        Polyactic Acid
        
        ABS
      - Machinery Used
        
        Object Eden 260
        
        Poly Inkjet Printer
        
        Polyject printer combines the technology of FDM with liquid photopolymer.
        
        Is similar to a standard Inkjet printer.
        
        Instead of extruding melted filament, it deposit liquid plastic.
        
        It allows multiple material to be printed at each layer.