Create custom assemblies 24/7: ManifoldBuilder.com
Published

Rapid Prototyping Advances With New Machines & Materials

Bigger parts, tighter accuracy, and new elastomeric materials are some of the latest advances in rapid-prototyping technology. Applications for the new developments range from basic concept modeling to functional testing to the burgeoning field of rapid tooling.

Share

Closer tolerances

A new machine intended for the high-accuracy requirements of rapid tooling has been introduced by Sanders Design International of Wilton, N.H. Called Rapid PatternMaker (RPM), the machine uses four moveable print heads to build models layer by layer through an "ink-jet-style" selective deposition process. One head deposits the thermoplastic material in tiny droplets (75 micron diam.); another lays down a wax for support structures; and two additional heads are available for bulk filling the part's less detailed regions. The machine reportedly deposits material at linear rates of up to 20 in./sec. Resolution in the x and y axes is 0.0002 in., according to company specifications.

The RPM also includes two provisions to achieve uniform layer thickness. It has a milling head that planes each layer to thicknesses between 0.0005 to 0.005 in. Also, the digitally controlled build-table elevator is controllable to 0.000125 in. According to company president Al Hastbacka, these two features allow models to be built with variable slice thicknesses, which result in smoother contours, less "stair-stepping," and a surface finish as smooth as one micron RMS.

The RPM "makes the world's most accurate patterns," Hastbacka claims. As proof, he cites a study in which a standardized part used for benchmarking stereolithography ("SLA User Group Benchmark Test Part") was produced on an RPM and also was CNC machined in aluminum. When compared by a coordinate measuring machine, two RPM parts--one hot off the RPM and another aged four months--achieved accuracies better than 0.05% of feature size, Hastbacka reports. "That's better than CNC machining," he claims.

Maximum build volume for the new RPM machine is a 12-in. cube. The material reservoir holds materials for 72 hr of continuous run time, and the machine controller can be set for unmanned operation.

Stretch your materials

For those who want their prototypes in an elastomeric material, DTM Corp. of Austin, Texas, now has a elastomeric material for use with the company's selective laser sintering (SLS) systems. The material, Somos 201 from DSM Desotech, can be used to make a variety of functional prototypes that demand an elastomer. Automotive hoses, gaskets, and door seals are some examples.

Build bigger parts

The latest "3D printer" or concept modeler from Stratasys Inc. of Eden Prairie, Minn., features a 50% larger build envelope than the company's Genisys unit, which creates models from a polyester material. The new Genisys Xs builds parts up to 12 x 8 x 8 in.

New Extrudable Paste Helps Build Large Models

A new modeling paste from the Adhesives and Tooling Group of Ciba Specialty Chemicals, East Lansing, Mich., is designed to reduce cost and increase accuracy in making large master models for aerospace, automotive, marine, and other transportation industries. RP 4503 R/H paste is a two-component system formulated for fast application using high-output meter/mix equipment. After curing for 24 hr, it is easily machined to a seamless surface without the bond lines seen on models machined from boards.

The paste exhibits low shrinkage (0.002 in./in.) and low coefficient of thermal expansion (32 x 10-6 in./in./°F), enabling it to produce large models that hold close tolerances even when exposed to ambient-temperature extremes, Ciba says. The paste is also said to be virtually odorless and easier to work with than other modeling materials, so it requires less training of personnel who make the rough model build-up.

Insert molding automation
Vacuum conveying powders to extruders compounding
Dri-Air
Plastics Recycling Latam
New 2024 Twin Screw Report
Create custom Smartflow assemblies on-line, 24/7.
Konica Minolta
Gardner Business Media, Inc.
Make Every Pellet Count
Uway LLC
RoyAlloy Stainless Mold Base Steel
structural foam molding chemical foaming agents

Related Content

Elastomers

Non-Fluorosurfactant Peroxide Curable Fluoroelastomers

Solvay launches new high-performance Tecnoflon FKM without use of PFAs used as process aids.

Read More
Testing

Tracing the History of Polymeric Materials -- Part 30: Polyurethane

In the world of polymers, polyurethane chemistry is probably the most versatile. This a resulted in a wide range of products made from these materials and given the industry the flexibility to respond to the progressive march of regulatory concerns.  

Read More
Elastomers

Foster Adds Specialty TPU and TPU Alloy Products to its Arsenal of Healthcare Materials

AdvanSource Biomaterials’ specialty TPU materials are used in application  segments such as cardiology, orthopedics, drug delivery, endoscopy, wound care, urology, and neurology.  

Read More
Elastomers

Tracing the History of Polymeric Materials, Part 25: Silicones

The long road to the development of silicone resulted in a chemistry that is remarkably versatile.  

Read More

Read Next

close up on technology

Processor Turns to AI to Help Keep Machines Humming

At captive processor McConkey, a new generation of artificial intelligence models, highlighted by ChatGPT, is helping it wade through the shortage of skilled labor and keep its production lines churning out good parts.

Read More
Extrusion

Understanding Melting in Single-Screw Extruders

You can better visualize the melting process by “flipping” the observation point so that the barrel appears to be turning clockwise around a stationary screw.

Read More
Extrusion Know How

How Polymer Melts in Single-Screw Extruders

Understanding how polymer melts in a single-screw extruder could help you optimize your screw design to eliminate defect-causing solid polymer fragments.  

Read More
Cranes, Conveyors, Racks, Loaders, Accessories