Stereolithography Apparatus, or more commonly known as SLA, is a commercially Rapid Prototyping process which is still widely used today to provide better accuracy and finish to a surface than the other rapid prototyping technologies on the market.

The Stereolithography Apparatus (SLA) technique was originally developed by 3D Systems of Valencia, California back in 1986. SLA allows for a rapid prototyping service, turning a 3D CAD drawing into a solid object. Most SLA can be used as master patterns for injection molding core and cavity inserts, thermoforming, blow molding, and various metal casting processes. Rapid prototyping exploits a SLA Pattern, which can be generated using a CAD file. SLA is a pattern used in place of a wax pattern for the lost wax process of investment casting. The result is a casting that can be put into use to prove the process without the heavy investment in permanent tooling.

Some benefits for utilizing a SLA Rapid Prototyping process are that it is:

* Inexpensive
* Does not require much time
* Uses a light-sensitive liquid polymer
* Requires no milling step or masking steps
* Investment casting patterns allow rapid production of metal prototypes

Investment casting companies have created castings for customers using the SLA Patterns across the nation. These investment companies utilize the SLA pattern and process it through the foundry in the same manner as the wax pattern. This has allowed their customers to evaluate the effectiveness of their overall design. Once verified, a decision can be made on investing in permanent tooling with the security of knowing the design functions properly with no additional changes needed.

Hello, my name is Pat Shebby and recently I have been doing a lot of research in the lost wax casting process in the steel industry.

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Origin: Rapid prototyping has taken virtual designs through ‘animation modeling software’ or ‘computer aided design (CAD)’. Thereafter, transformation into virtual, thin, horizontal cross-sections takes place. Each cross-section then gets created in the physical space. This process goes on till the model gets completed. It is better known as WYSIWYG process. Let’s understand this process in detail.

WYSIWYG: WYSIWYG as the abbreviation for ‘What You See Is What You Get’. It is used in ‘computing’ for describing a system wherein content looks similar to final product at the time of editing. It is generally used in word processors. However, this use is in the form of HTML (Web) authoring. The popularization of this phrase was carried out by the comedian ‘Flip Wilson’. His character ‘Geraldine’ used to say this very often to give an excuse against her idiosyncratic behavior.

This expression came to be applied later to computer-based applications as practicality in technology arrived. At times, it is phonetically spelled as ‘Wizzywig’ or ‘Wizywig’. It has also been used as a brand name for a ‘lighting design tool’ utilized in theatre industry to pre-visualize the shows and 3D CAD.

The process further : The additional fabrication causes the machine to read data from CAD drawing. After that, consecutive layers of powder, sheet material, or liquid are laid down. Likewise, a model gets built-up from a chain of cross-sections. Such layers, corresponding to CAD model’s virtual cross section, are then fused automatically or joined together for creating the ultimate shape. The basic advantage of additive fabrication goes to state that any geometric feature or shape can be created through this.

The CAD software and machines are interfaced by the ’standard data interface’ in the ‘STL file format’. The function of STL file is approximating the shape of an assembly or a part by making use of triangular facets. Surfaces of higher quality are produced by smaller facets.

The word ‘rapid’ can be used relatively. The construction of models using present-day methods could take time ranging from a few hours to a few days. This depends on the technique used, along with the complexity and size of the model. The additive systems take less time. They can produce models within some hours. Some techniques such as ’solid freedom fabrication’ make use of two materials for construction of parts. The 1st material is known as ‘part material’ and the 2nd one as ’support material’. The removal of support material takes place by heat. It might also be dissolved with water or any other solvent. When it comes to manufacture of plastic products, that too in large quantities, injection molding proves to be a cheaper alternative.

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Rapid prototyping allows more flexibility than machining because the even complex model designs does not suffer any limitations during its production. Rapid prototyping enables engineers and product designers to generate three dimensional models quickly and accurately.

Different rapid prototyping systems make use of a variety of materials to create different three dimensional objects. A common material used is prototyping wax. This material is usually ideal when engineers and designers require small quantities of casting parts to create intricate patterns without the use of tooling.

Prototyping wax can also be used together with other types of prototyping materials in order to make the resulting prototype work better with different casting methods that make use of metals as well as non-metals. Combining prototyping wax with other materials to create the models will also be ideal for low-temperature furnaces and vacuum plaster casting methods.

A rapid prototyping modeling process utilizing prototyping wax to create a wax pattern can be advantageous in some ways. Forming and de-waxing a shell mold made from prototyping wax can be done quite rapidly using normal casting procedures. Using this type material simplifies in a way the model-making process that helps you to get your products to be developed and be released in the market faster.

Aside from prototyping waxes, there are also other materials being used for a number of rapid prototyping processes. One such material is thermoplastics. If product engineers are looking forward in creating durable prototype parts that might require aggressive functional testing, thermoplastics can be the ideal material to use for rapid prototyping. Thermoplastic materials have effective heat and chemical resisting properties that make them the best choice for models that undergo aggressive product testing procedures.

Not only that, thermoplastics also provide excellent surface finish to prototype models. They are also machinable and weldable when required. Thermoplastics can also be joined mechanically or with the use of special adhesives. Other prototyping material choices available include powdered metals for injection molding, and for directly creating metal prototype parts, Polycarbonate and polyphenylsulfone materials for forming durable, high-strength, and functional prototypes that are to be used for testing and final design verification.

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CNC rapid prototyping solutions include: stereolithography (SLA), selective laser sintering (SLS), RTV tooling, hybrid tooling, injection molding, and direct metal laser sintering (DMLS). Between these options, basically any part, mold, etc can be developed. Top quality engineers can help to make a dream a reality with the CNC rapid prototyping process.

However, the need for speed can become a loss in other categories. The need to develop parts in a short period of time comes as a trade off. Producing with speed causes less layers of resin on certain parts; therefore, the detail of these parts will be less. The trade off for speed is in the detailing. You just have to decide which one you would rather prefer.

Through the sintering process, parts can be created that are able to be directly used as they come out of the machine. No longer will customers have to build the parts, now all they have to do is to build assemblies. This can save a lot of time and money for many companies who utilize this type of technology.

Stereolithography uses a laser (UV) to cure resins. The laser builds the product by layers. The end product is usually yellow to white in color and can finished with a variety of different finishes.

Selective laser sintering (SLS) is similar to SLA (stereolithography) but instead of resin a powdered is infused or sintered by a laser. The powder is spread onto a table that is heated and the laser provides even more heat to help build the shape of the desired end product. Once again, this is a layering process. Nylon among other things can be used in this process. The end product can be finished off with a variety of colors and finishes.

Direct metal laser sintering (DMLS) also uses a layering process to build the final product. Metallic powder is used in this process which is then spread over a plate and sintered by a laser beam to the specifications that the software file specifies.

As you can see, CNC rapid prototyping really incorporates some high technology and this type of technology can be beneficial to many different industries in today’s society. Not just anyone can operate these machines. It takes high skilled and well trained individuals, usually with an engineering background to produce these products through the use of these machines.

Computer numerical controlled technology and robotic technology combined with high tech software programs can pretty much create anything that anyone can dream of. If you have any questions about CNC rapid prototyping, ask any dealer who deals in these types of machines. They will be able to answer any questions that you may have.

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Manufacturing technologies have advanced geometrically over the past twenty years. And rapid prototyping techniques have grown even faster. In all most every process that is used to make components, a complimentary process has been developed to make prototypes and short production runs.

Aluminum die casting has been the process of choice for the majority of high volume applications for decades. Volumes need to exceed 50,000 pieces per year. So what if you have a new product that you want to launch with 5,000 units and it involves several aluminum castings per product?

Is there a way to produce these components on a limited tooling budget?

Fortunately there are numerous processes for producing prototype and low volume precision castings.
Several of the processes are:

1) Plaster Mold Casting

2) Graphite Mold Casting

3) V-Process Casting

What are the advantages of these processes? Precision castings that simulate the die casting method can be produced for a fraction of the upfront(tooling) costs required for die casting. Plus these methods have high volume production capabilities. All of the processes are capable of producing 100 units and then with the same tooling, can be ramped up to higher volume of 2,000 to 5,000 piece production runs.

These methods are also fast. Castings can be produced in 1-2 weeks if necessary.

These precision casting methods can produce components with .100 – .125 ” wall thicknesses, with a surface finish of 125 rms. They then can be machined to your required dimensions and tolerancing.

For more information about aluminum castings, plastic injection molding, forging technologies, machining and other production methods visit www.manufacturingtips.com

About The Author

For those involved in product development, engineering, and other form-giving applications, rapid prototyping (RP) technology can offer an excellent deliverable for various applications. Prototyping can be used for concept generation, ergonomic testing, test fitting, functional testing and even small-batch production.

There are various rapid prototyping technologies available for use including Fused Deposition Modeling (FDM), Stereolithography (STL), Selective Laser Sintering (SLS), and 3D Printing. Each of these technologies has advantages and disadvantages.

Fused Deposition Modeling technology is marketed commercially by Stratasys, which also holds a trademark on the term. Like most other RP processes FDM works on an “additive” principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which can turn on and off the flow. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided design software package. In a similar manner to stereolithography, the model is built up from layers as the material hardens immediately after extrusion from the nozzle.

Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable photopolymer “resin” and a UV laser to build parts a layer at a time. On each layer, the laser beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the pattern traced on the resin and adheres it to the layer below.

Selective laser sintering is an additive rapid manufacturing technique that uses a high power laser to fuse small particles of plastic, metal, ceramic, or glass powders into a mass representing a desired 3D object. The laser selectively fuses powdered material by scanning cross-sections generated from a 3D digital description of the part on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed.

3D printing is a unique form of prototype creation that is rooted in traditional rapid printing technology. A three dimensional object is created by layering and connecting successive cross sections of material. 3D printers are generally faster, more affordable and easier to use than other additive fabrication technologies. While prototyping dominates current uses, 3D printing offers tremendous potential for retail consumer uses, especially because the cost of production is less than other methods, and the part build time is minimal. In the latest incarnations, 3D color printing is also available. This means that a part can be printed to represent the colors of the finished product, to show label concepts or requirements, or to indicate the results of stress analysis or other failure mode effects (FME) analysis.

For the most part, all rapid prototype systems require a 3D computer model to start the process. In most cases a significant amount of file preparation must be undertaken to get a file to generate a correct rapid prototype model.

As part of the innovation process, some companies may employ one or several rapid prototyping technologies in-house. However, being a new “cutting-edge” technology, many firms can make use of service bureaus to provide their rapid prototyping as the need becomes evident. Most service bureaus have detailed websites to market and serve their customers.

A handful of service bureaus are fairly large companies with numerous employees and locations. Many provide related services and technologies, such as tooling, industrial design, molding and production. However, service bureaus are typically small companies, and while they may be small, many of them are vertically integrated and can provide services from concept models to finished functional parts.

Service bureaus tend to specialize in one or more areas such injection molding, casting, etc. Examine a company’s portfolio or case histories on their web pages, or discuss previous projects with the company to try to better understand areas of particular expertise. Sculptors have also used the technology to produce complex shapes for fine arts exhibitions.

In the near future, rapid prototype technology will become more widespread and pervade even to the home. For now though, for timely and expert delivery, the use of a service bureau is the best way for most innovative companies, individuals and organizations.

About The Author

Geoffrey Brennan

Rapid prototyping denotes that automatic generation of objects by use of solid free form fabrication. The inception of the concept in 1980s saw the production of various forms of models as well prototype parts. The rapid prototyping concept has spread across various domains and features in numerous applications. Rapid prototyping is also commonly used in the manufacturing domains where the concept is used for production quality parts in relatively low figures. In arts also, the concepts are used for instance by sculptors to generate complex design and shapes that are meant for fine art exhibitions.

Rapid Prototyping is based on virtual designs taken from computerized designs or computer Aided design (CAD) closely related to the animation modeling software. The concepts of rapid prototyping would then transform the virtual designs into thin horizontal cross sections, which then lead to the creation of cross sections in physical locations. These are created in succession until a point where the whole model is complete.

In rapid prototyping, additive fabrication facilitates the reading of data from a CAD drawing by the machine. The machine will then get into a layering process where either, powder, sheet or liquid material in layered in succession. This is how a model in actually generated from a series of cross section representations. The feasibility of the methodology is that the layers which are done in correspondence with the virtual cross section from the CAD model are brought together and blended automatically to generate the final shape. One remarkable aspects of additive technology is its dynamism, which can be used to generate any shape or geometric feature.

In rapid prototyping the term ‘rapid’ is used relatively. The reality is that the generation of the desired model with available methods and procedures can talk many hours or even stretch to a number of days in tandem with the method adopted as well as the size and the complexity of the desired model. The term ‘rapid’ is thus used in a relative sense considering that the additive technologies can in some instance be produced desired models in hours but again it will depend on the type of a machine being used, the size of model in focus as well as the number of models to be generated simultaneously in cases of multiple model production.

Convectional injection molding is known to be more cost effective especially in manufacturing polymer products in large volumes. On the other end additive technology is also known to be speedy and cost effective in the cases where there is a production of relatively small quantities of parts. The remarkable merit of rapid prototyping is that it has enabled designers as well theme or concept modeling teams to generate components or parts as well concepts representations by use of convenient and portable desktop size printers. Printing and design technologies abound in the market yet rapid prototyping cashes in on the merits of cost effectiveness and speedy print out put and premium quality, which give designers and concept developers the real sense, and representation of their design models.

With today’s advancements in technology, CNC rapid prototyping can be done faster than ever. CNC machines can create three dimensional prototypes within days compared to the former technology of the past. With the software programs that run these machines, any design or specifications from one of your drawings can be created to the specifications that are required.

CNC rapid prototyping solutions include: stereolithography (SLA), selective laser sintering (SLS), RTV tooling, hybrid tooling, injection molding, and direct metal laser sintering (DMLS). Between these options, basically any part, mold, etc can be developed. Top quality engineers can help to make a dream a reality with the CNC rapid prototyping process.

However, the need for speed can become a loss in other categories. The need to develop parts in a short period of time comes as a trade off. Producing with speed causes less layers of resin on certain parts; therefore, the detail of these parts will be less. The trade off for speed is in the detailing. You just have to decide which one you would rather prefer.

Through the sintering process, parts can be created that are able to be directly used as they come out of the machine. No longer will customers have to build the parts, now all they have to do is to build assemblies. This can save a lot of time and money for many companies who utilize this type of technology.

Stereolithography uses a laser (UV) to cure resins. The laser builds the product by layers. The end product is usually yellow to white in color and can finished with a variety of different finishes.

Selective laser sintering (SLS) is similar to SLA (stereolithography) but instead of resin a powdered is infused or sintered by a laser. The powder is spread onto a table that is heated and the laser provides even more heat to help build the shape of the desired end product. Once again, this is a layering process. Nylon among other things can be used in this process. The end product can be finished off with a variety of colors and finishes.

Direct metal laser sintering (DMLS) also uses a layering process to build the final product. Metallic powder is used in this process which is then spread over a plate and sintered by a laser beam to the specifications that the software file specifies.

As you can see, CNC rapid prototyping really incorporates some high technology and this type of technology can be beneficial to many different industries in today’s society. Not just anyone can operate these machines. It takes high skilled and well trained individuals, usually with an engineering background to produce these products through the use of these machines.

Computer numerical controlled technology and robotic technology combined with high tech software programs can pretty much create anything that anyone can dream of. If you have any questions about CNC rapid prototyping, ask any dealer who deals in these types of machines. They will be able to answer any questions that you may have.