Selective Laser Sintering machine is a modern invention. This system was invented by Carl Deckard, Texas in 1989. Selective Laser Sintering machines utilize a system with a laser ray to mix selectively powdered matters, like plastics, metals or any matter, such as natural or synthetic rubber, that is capable to renew its primary shape when a straining force is eliminated, into a single firm object. Particles are superstructed over a horizontal surface placed just under the outer in a receptacle of the powder. The laser goes after the sample in the primary layer, and then frits them together. The horizontal surface goes down through the elevation of the succeeding layer and then powder is applied again. The process goes on until it is finished. Leftover powder in each layer helps to keep the consolidated part in the endurance of the object.

The Selective Laser Sintering appliances are created in Texas. The system of these appliances utilizes carbon dioxide laser. This laser has the main objective to flux a range of a synthetic plastic or resin in addition to metal powder matters to attain three dimensional materials by layers originated from three dimensional computer files. Since this process is additive, very much complicated geometries can be created without any problems and since the powder keeps the particles, there is no requirement to use support structure. The fast manufacturing of permanent and functional matters devoted for broad range of objectives is the main advantage offered by Selective Laser Sintering machines.

Selective Laser Sintering machines’ end objects can be colored in different ways so it is possible to make the positive presentation for better visual perception of the model. Video representation can be performed also if needed by clients. System uses a range of substances: solid in addition to supple natural or synthetic rubber, entirely solid metal, rubber elastomers and casting-amicable outlines. Working parts mix perfectly with other details to get a great finished look.

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Additive manufacturing is a new and efficient method. It is a common name for a range of producing approaches that are potent to be detached from the traditional machine technique. One of these approaches is known as fused deposition modelling. The fused deposition modelling machine is utilized most generally in creation of prototypes, model creation or making applications. This is one of those technologies that can be possibly named as a contemporary approach. Dissimilar from the majority of the other approaches of identical kind, this approach has been represented to the world very newly. The fused deposition modelling technology was created in the late eighties of the twentieth century. The inventor of this technology is Scott Crump. Despite the fact it was created as a new technology, it was used as a modelling technique only in nineties.

Since then this technology has been one of the most fortunate and one of the most frequently applied approaches in different parts of the globe. Recently this technology has faced a lot of fame and has got attention of many professionals who are involved in the field of manufacturing. How does this technology operate? Fused deposition modelling operates on an additive approach that is general to the range of additive production methods. Its workflow is in common identical to that of other appliances. Nevertheless, the technology itself takes the workflow forward in dissimilar steps.

The workflow operates by die forming cast plastic fibers through the heated nozzles in a specific sample of layers. When one layer is finished, the platform goes lower by a layer thickness and the workflow is going on. A permanent part with constant surface treatment and indulgence is made. It can be related to as a perfect alternative for three dimensional prototypes that want to densely represent the output product that is strong and tough. The opportunity of utilizing this technology is the comparative ease of the workflow. It uses binders but not a laser system and that is why it is less costly.

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Three-dimensional printing is one way of rapid prototyping. Now there are dozens of tools for rapid prototyping. All of them differ from each other, but their principle is in layered imposition of a composite material and allows shortening significantly the terms of models for visualization, fit, tooling and other applications that provide:

Reduce the development cycle;
Improvement of design;
Improving the quality;
Reduction of product price and production;
Accelerating change in the design.

The main advantage is the ability to create products with only the geometric model.

This product is created at once, and there is no need for planning succession of processes. However, in comparison with CNC machines, it is very limited choice of material for the product.

The technology of formation products through the gradual build-up of the material appeared in early 1980. There are 3 stages at the basis of the process: the formation of cross-section, layer overlay of sections and combining layers. That is, for creation a product you need to know only the cross-section. It solves some of the challenges of creating a product:

No need for topological design and construction elements in the transformation of the elements of manufacturing. Cross-sections are generated only on the basis of the model.

Manufacturing of parts at once allow minimizing the amount of equipment.

No need to define the geometry of empty space, because it is adding, but not delete the material.

No need to design the construction of mounting clips.

The process is without using instruments, hence no need for additional equipment.

There are several ways to create and combine layers of cross-sections:

Three-dimensional printing.

It was developed at the Massachusetts Institute of Technology and received its name because of its similarity print of usual printer. The process is following: the layer of ceramic powder is applied on the platform. Print head inflicts a special binder, through which the particles are sticking to each other and form the desired cross-section. The platform is lowered on one layer thickness and the material is put on it. The binder on a new layer is delivered and it is bonded with the first layer. The required number of repetitions is performed. Then it is done additional heat treatment during which the piece hardens completely.

SGC-Solid Ground Curing.

Each layer is cured by exposing the ultraviolet lamp. In this case, all points of the layer are hardened simultaneously and do not require a final cure. The process consists of the following steps:

The set of cross sections is calculated for a given geometric model and the desired thickness;

It is manufactured optical mask in the form of cross-section for each layer;

The platform is covered with liquid photopolymer;

A mask is placed corresponding to the cross-section above the layer of polymer and the plastic is exposed to ultraviolet light;

Removal of the remaining liquid;

Filling voids with liquid wax. After its solidification layer is stitched to the required thickness of the grinding disc;

The product is covered by a layer of liquid polymer and the process is repeated until you receive a finished product;

Frozen wax is melted and removed from the product.

The advantage of this method is the absence of need for additional support, since all voids are filled with wax. Due to uniform irradiation with ultraviolet it is achieved greater uniformity of product and additional curing is not required.

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Mask stereo lithography. Faster version of this technology was developed by Cubital Inc. It is called “mask stereo lithography” (Solid Ground Curing or SGC). As the working material it is used the same photopolymer only it is lighted its entire surface with ultraviolet light through the artwork.

Photo mask for each layer is printed on the glass. For this it is used the technology, reminiscent of laser printing. Obviously, this method provides significant gains of performance at the expense of illumination at the same time of the polymer layer instead of the point wise scanning. For instance, the company Envisiontec Prefactory offers installation, which takes only 0.3 m 2, so it can be accommodated even in a small office. Material is lighted by the method of Digital Light Processing, or DLP, similar to that is used in digital projection systems. The size for a single working layer (cross section) is of 1280×1024 pixels with a physical pixel size of 150 or 90 microns. Thickness varies from 150 to 90 microns. Prefactory can create prototypes of up to 190x152x230 mm at speeds up to 15 mm (height) per hour. The control is performed with a computer operating system Linux, link with the outside – through a local network.

Selective laser sintering. An alternative method of stereo lithography is Selective Laser Sintering (or SLS). This process was developed in the 80′s of last century in the University of Texas at Austin and patented in 1989 by a graduate of the University Karl Dekard.

Selective laser sintering begins when a very thin layer of fusible during heating of the powder is placed into the cooking chamber of a cylindrical shape. It is used a laser for baking powder, resolved within the boundary of the contour of the working chamber. The laser increases the temperature of the powder to the melting point; there is a partial sintering material and forming it into a solid mass. The intensity of the beam is changed in such a way in order to smelt powder only in areas bounded by the geometry of the future construction. As soon as the laser processes the entire layer of powder in this section, immediately a new thin layer is poured and the process repeats. The component is removed from the processing zones and free powder is shaked. SLS-details can be obtained from powders with different grain sizes depending on the future use of parts.

Laser sintering provides a high quality of finished products, although the surface of the model is obtained porous. Advantage – is sufficient for small series production strength of parts. However, SLS-device is expensive, and the playback speed of a digital model is only a few centimeters per hour, plus a few hours on the heating and cooling of the device. In addition to good accuracy and high strength of derived objects, SLS has also such a dignity as an opportunity to receive details of moving parts, such as moving loop connections.

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This rapid prototyping methodology is a strong tool nowadays. Use it to study products, their weak and strong points. Also keep in mind that modern Internet technologies offer you a unique chance to try and to find anything you might require. Should you want to keep track of the latest publications on the subject.

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