We provide complete modelling from cad generated STL files to produce a model in almost a variety of materials. The current facilties that are available include SLS, SLS and FDM services.

Visualization, verification and design optimization.

Communication tool for simultaneous engineering.

Form-fit-function tests .

Marketing studies of consumer preferences.

Metal prototypes fabricated from polymer parts.

Tooling fabricated from polymer parts.

List of commercial technolgies used:

Stereolithography (SLA)

           Laminated Object Manufacturing (LOM)

           Selective Laser Sintering (SLS)

        Fused Deposition Modeling (FDM) 

        Electron Bean Melting(EBM) 

           3D Plotting/Printing(3DP)

3D SCANNING

3D scanner is used to scan models and transfer the data into the computer for re-work or further modifications.Point cloud data.

To map the object a mesh is used or a sticker is stuck on the object for the as a guide for the laser beam.

Laser Scanning is a non-contact technology that digitally captures the shape of physical objects using laser light. A laser probe projects a line of laser light onto a surface while cameras continuously triangulate the changing distance and shape of the laser line as it sweeps along, digitizing the object in three dimensions .

Laser triangulation is an active stereoscopic measurement technique that computes the distance of an object with a directional light source and a video camera. A laser beam is deflected from a mirror onto a scanning object.  The object scatters the light, which is then collected by a video camera located at a known triangulation distance from the laser so that the 3D spatial coordinates of a surface point or line are calculated. 

Rapid prototyping steps in when the scanned output data is saved as a stereolithography file solid CAD file.  This file can then be created into a physical 3D model for analysis via use of rapid prototype 3D printing technology.

STEREO LITHOGRAPHY -SLA

Builds a part in layers by exposing liquid photosensitive polymers to ultraviolet (UV) light that solidifies the liquid. The platform is then lowered the depth of one layer, the solidified layer is re-coated with the liquid, and the laser traces the next layer of the part. The new layer adheres to the previous layer as solidification occurs The part is then removed from the liquid and any excess liquid is rinsed. Any supports are then broken off of the part and the part is cured in an UV oven called a Post-Curing Apparatus (PCA).

Liquids used for this technique are liquid epoxy and acrylate resin.

SLA parts tend to have very good feature detail.

A part constructed using this technology is not considered to be strong enough to replace production plastic parts, but can be used in a number of functional test.

LAMINATED OBJECT MANUFACTURING -LOM

Builds a part in layers by placing melted plastic unto a platform. A plastic filament or pellets are fed into a nozzle that heats the plastic to just above the solidification state. The nozzle places the melted plastic onto the platform in such a manner that the first two-dimensional slice of the part is formed when the plastic solidifies.

Parts constructed with this technology must be sealed and finished with paint or varnish to prevent moisture damage.

In addition to paper some additional materials available for this technology are plastic, water-repellent paper, and ceramic and metal powder tapes.

SELECTIVE LASER SINTERING- SLS

Builds a part in layers by sintering a heat-fusible powder with a laser beam. The part is built upon a platform that is placed just below the surface of the powder. The laser beam sinters the powder by heating the powder just above the melting point which cools to a solid once the laser beam passes.

Some powders that can be used for this technology include polymers (nylon and polystyrene), metals (steel, titanium, alloy mixtures, and composites) and green sand.

Parts built using this technology are porous and depending on the application may require some finishing consisting of filling any voids with another material and/or applying a painted finish.

The strength, details, and quality of these parts tend to be very good although some fine details and sharp edges can loose some definition.

FUSED DEPOSITION MODELLING- FDM

       Builds a part in layers by placing melted plastic unto a platform. A plastic filament or pellets are fed into a nozzle that heats the plastic to just above the solidification state. The nozzle places the melted plastic onto the platform in such a manner that the first two-dimensional slice of the part is formed when the plastic solidifies.

Acrylonitrile Butadiene Styrene (ABS) and medical grade ABSi, elastomer E20 for flexible parts, polycarbonate, polycaprolactone, polyphenolsulfone, and investment casting wax as well as some water-soluable materials.

ELECTRON BEAM MELTING- EBM

Builds a part in layers by melting metal powder with an electron beam in a vacum. A layer of powder is scraped onto a surface. A computer controlled electron beam melts the powder together to create the geometry for a layer of the part .This beam bombards the layers with high speed electrons .5-.8 times the speed of light generating heat and melting the surface of the part causing the material to locally vaporize. The surface is then lowered the thickness of the layer of powder before the next layer is scraped onto the surface.

Materials that can be used for parts built using this technology include metals, non-metals, ceramics and composites. Titanium alloys are widely used with this technology which makes it a candidate for the medical implant market as well as other highly demanding mechanical applications.

3D PRINTING

Builds a three-dimensional model upon a platform layer by layer until the model is built. There are variations of this technology including inkjet printing and 3D microfabrication.

This technique is ideal for features under 100 nm as well as complex structures. 3DP's are generally faster, more affordable,and easier to use than other additive fabrication technologies. Build layers as thin as .0005”.

MATERIAL CHOICES AND PROCESSES

SLA

DPT can produce SLA parts in five different materials

DSM 9120 to simulate flexible thermoplastics like polypropylene

DSM 11122XC for waterclear parts and rapid tooling patterns

DSM 12120 for high heat applications (can operate up to 259° F)

DSM 18420 for functional assemblies with ABS production part appearance

DMX-SL 100 for high impact strength and production plastic appearance

SLS

GF Nylon for mechanical properties that support functional testing in most applications. The large percentage of SLS applications are met using GF Nylon.

FDM (Fused Deposition Modeling)

DPT can produce FDM parts in two different materials

FDM ABS

We can also offer a SS- bronze alloy FDM out put from green part by investment of the FDM part.

RAPID TOOLING AND MANUFACTURE:

JAGS DRC provides rapid injection molded parts using SLA patterns with epoxy tooling and machined aluminum molds. An epoxy injection mold is formed much like an RTV Rubber Mold using a StereoLithography prototype as the pattern. The epoxy tool is then used to cast parts out of standard injection moldable materials. This process eliminates the need for metal tooling therefore dramatically reducing lead-time and tooling costs. The epoxy tool is great for short production runs and preliminary production runs. The epoxy tool can also provide parts for functional testing of the production material and for evaluating the producibility of the design for rapid injection molding.

INVESTMENT CASTING AND LOST WAX TECHNIQUES

Wax pattern build from multi-jet droplet technique.

Pattern used in investment casting to fabricate metal products

Allows for design modifications and quick turnaround of metal objects

Creation of real undercut difficult to mold parts created from wax injected patterns.

Can be suitable for a wide range of materials including copper, brass, bronze alloys etc.

LINKS

SEE MORE RAPID PROTOTYPING CASE STUDIES

RAPID PROTOTYPING MATERIALS SUPPLY

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