sla & sls technologies pros & cons - mit opencourseware · pdf fileengineering check...
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Allison Rae
Paramount Industries
Rhode Island School of Design ID 87’
Prototyping Overview
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Prototyping for Mechanical Parts
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Paramount IndustriesStarted as prototyping vendor,
then added:• Industrial Design• Product Engineering• Product verification• Breadboard models• Computer Animations• Graphic Design
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Rapid Prototyping Chart- 3D data required Common uses
Material Description
Cost for Ball Tray
Delivery for Ball Tray Tolerance Layer height
Surface scale 1-4 fine to coarse
SLA Stereo Lithography Apparatus liquid
photopolymer0.002- 0.005
standard appearance models, casting masters
rigid $300 2 days +/-.002 +/-.005
0.005 1
flex resin more durable appearance models
flexible $300 2 days +/-.002 +/-.005
0.005 1
SLS Selective Laser Sintering thermoplastic
powderNylon living hinges, snap fits,
functional modelsnylon,
polyamide$250 2 days +/-.007 0.004 2
Glass Filled Nylon extremely durable 33% glass filled $250 2 days +/-.007 0.004 2Somos, elastomeric soft touch parts like Santoprene $200 2 days +/-.007 0.004 2Castform investment cast
mastersstyrene/wax $300 4 days +/-.007 0.004 2
FDM, Fuse Deposition Modeling modeling
filamentABS replicate ABS thermoplastic $250 2days +/-.005
+/-.0100.005 - 0.016 4
Polycarbonate replicate PolyCarb thermoplastic $250 2 days +/-.005 +/-.010
0.01 4
ZCorp form study models, colors available
starch $150 2 days +/-.005 +/-.010
0.003 - 0.010 3
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Rapid Prototyping- SLS
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Other Prototyping Methods Common uses Benefits Input/ Process Delivery Tolerance
Material characteristics Quantities
Fabricationhand made models form study models, wax
models, breadboard models,
LooksLike/WorksLike models
achieve geometry too complex for
3D CAD, multiple materials
napkin sketch to part drawings
complexity dependant
as needed limitless 1-5
Urethane CastingsSilicone RTV Molds, cast urethane resins
sales samples, LL/WL models,
replicates production, fast,
inexpensive, color
pattern/ cast silicone
1-2 weeks +/- .001- .100 in/in
rigid, flexible, clear, hollow, insert and
co-molding, production like
materials
10 - <50
ThermoformingSheet thermoplastics wall thickness housings,
blister packagingquick, molds and
produce many parts
pattern or mold .5-2 weeks +/-.010- .060 simple geometry, opaque and clear
prototype & production
Investment Castingmetal cast process engineering check models production
materialspattern 2-4 weeks material
dependantmetals, zinc to titanium
prototype & production
CNC MachiningComputer numeric controlled machining
engineering check models, strong parts
production materials
part drawings, 3D data
geometry dependant
limitless all plastic and metals
prototype & production
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Wax Sculpting
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Fabricated Model
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Cast Urethane Samples
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Vacuum Forming
Pattern Part
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Investment Casting
1. Wax Pattern is created (positive)
2. Pattern is dipped in ceramic slurry and then fine sand
3. Assembly is de-waxed by applying heat
4. Molten metal is poured into shell
• Creates metal parts that are difficult or impossible to machine
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CNC Machining
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Prototype Tooling Uses Benefits Input/ Process Delivery ToleranceMaterial
characteristics QuantitiesAluminum test production
materials and part geometry
faster and less expensive than
production tooling
2D, 3D data, Pattern/ CNC
EDM, pantograph
1-10 weeks +/- .002 in/in medium temp thermoplastics
25K- <50k
Pre-Hard Steel (P-20) same as aluminum, longer tool life, more complex tools, wider
range of materials
same as aluminum
2D, 3D data, Pattern/ CNC
EDM, pantograph
1-10 weeks production all thermoplastics w/ glass
100K - <250K
Production Tooling Uses Benefits Input/ Process Delivery ToleranceMaterial
characteristics QuantitiesHardened Steel, Multi Cavity all materials large quantities,
lower part cost2D, 3D data,
Pattern/ CNC, EDM,
pantograph
complexity dependant
production all thermoplastics w/ glass
1M +
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Prototype Tooling
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Prototype ToolingAluminum or Pre-hardened Steel
• Process, machined, EDM• Tool Life: 12 - 250,000• Benefits:
– Low volume production– High accuracy– Most Thermoplastics
• Delivery: 4-6 weeks
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Types of Models
Verification Model SLS
Foam Study Model
Clinical Trial Prototype, Autoclavable GE Ultem: CAM/CNC
• ConceptFunctional, bread boards, form
• Looks like modelPhotography, presentations
• Looks like/ works likeSales samples, market testing
• Tooling patterns• Engineering check models
Confirm geometry, test production materials,prove function
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Concept Models• Purpose; Study scale, develop form, explore
ergonomics• Input; Sketches, verbal description, 3D data• Process and materials;
– Hand build, foam, insulation or urethane, foam core, clay, cannibalize existing products
– Rapid prototyping, Z Corp, SLS, SLA
– Machining, block, tube and sheet stock
• Tolerances; Not important• Quantity; Usually ONE
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Concept Model
Handmade foam model to explore form
Chosen for speed, 3D data not available
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Concept Breadboard Model
Fabricated by hand
Chosen to accommodated many materials19
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Looks Like Model (LL Model)
• Purpose, same as above including functional requirements.– Draft included only as it effects the performance.– Cored for function only.– Materials used to replicate production material performance.– Includes batteries, electronics, springs, LEDs .
• Process and materials.– Rapid prototypes, SLS, SLA.– Castings/ urethane, silicone.– Machining/ stock plastic.
• Tolerances, tight as needed.• Quantity, 1-12.
Looks Like/ Work Like Model (LL/WL)
• Purpose, aesthetic– Shows surface finish; color, clear parts, labels, tactile materials
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Looks Like/ Works Like
SLA master RTV Mold, Cast Urethane
Chosen for production like resins
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LooksLike/WorksLike
Urethane Casting from SLA master and RTV moldsChosen to replication production parts in accuracy, color and texture
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Tooling Pattern
Fabricated by hand
Chosen to accommodate highly complex geometry
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Engineering Models• Purpose, confirm geometry, test production
materials, review function• Input, 3D data, detailed part drawings• Process and materials
– Rapid prototyping/ SLS, FDM, SLA– CNC or machined/ production materials– Prototype molds/ production materials
• Tolerances, critical• Quantity, usually ONE
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Engineering Model
Rapid Prototype, SLA
Chosen for accuracy and speed
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Engineering Model
Rapid Prototype, SLS Glass Filled Nylon
Chosen for durability to withstand testing
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Prototype Molded Parts
Aluminum Prototype Injection Mold
Chosen to prove material adhesion and for market testing
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Qualifying your prototyping needs• What type of model do you need?• What type of input do you have?
– sketches, control drawings, 3D data • Is the production material required?• What are the tolerances?• How many do you need?• When do you need it?• Are you working within a budget?
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PD EfficiencyThe right questions will improve PD efficiency• Identify risk in your project• Formulate questions, that if answered, will
reduce/eliminate risk• Use models/prototypes to get the answers• Target individual questions at first.
Repeat as necessary.Can use other tools to answer questions.
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