fused deposition modelling systems

8/8/2019 Fused Deposition Modelling Systems

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CH4 FUSED DEPOSITIONCH4 FUSED DEPOSITION

MODELLING SYSTEMSMODELLING SYSTEMS


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The FDM process was developed in 1988 by S.Crump whofounded Stratasys the following year. Since then the

company has produced more than 1000 systems. The firstproduct ,the 3D MODELER, was introduced by thecompany in 1922.

The FDM process works by extruding a thermoplasticmaterial and depositing it layer-by-layer fusing it to the layerbeneath it, to form a 3D model. FDM creates functional

prototypes using a variety of engineering materials like ABS,and polycarbonate.


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PROCESSPROCESS

Step 1 : The PreparationStep 1 : The Preparation

FDM begins with a 3D CAD file that is oriented in theFDM begins with a 3D CAD file that is oriented in theappropriate orientation for building the part. The data is thenappropriate orientation for building the part. The data is thenmathematically sliced into 2D crossmathematically sliced into 2D cross--sections (layers) along the Zsections (layers) along the Z--

axis.axis.Step 2 : The BuildStep 2 : The Build

The nozzle is heated to melt the plastic filament and is mountedThe nozzle is heated to melt the plastic filament and is mountedto a mechanical stage which can be moved in both horizontalto a mechanical stage which can be moved in both horizontaland vertical directions. As the nozzle is moved over the table inand vertical directions. As the nozzle is moved over the table in

the required geometry, it deposits a thin bead of extruded plasticthe required geometry, it deposits a thin bead of extruded plasticto form each layer and create a twoto form each layer and create a two--dimensional cross section ofdimensional cross section ofthe model.the model.


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PROCESSPROCESS

The plastic hardens immediately after being squirted from theThe plastic hardens immediately after being squirted from thenozzle and bonds to the layer below. The platform then descendsnozzle and bonds to the layer below. The platform then descends

where the next layer is extruded upon the previous. Thiswhere the next layer is extruded upon the previous. This

continues until the model is completed. The entire system iscontinues until the model is completed. The entire system iscontained within a chamber which is held at a temperature justcontained within a chamber which is held at a temperature justbelow the melting point of the plastic.below the melting point of the plastic.

Step 3 : The CompletionStep 3 : The Completion

Once all the layers are drawn and the model is complete, theOnce all the layers are drawn and the model is complete, themodel is then removed from the platform, and the supportmodel is then removed from the platform, and the supportstructures are removed from the part.structures are removed from the part.


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PROCESS PARAMETERSPROCESS PARAMETERS

FDM 2000FDM 2000 FDM 3000FDM 3000 FDM 8000FDM 8000 QuantumQuantum

Build sizeBuild sizemmmm

254 x 254 x 254254 x 254 x 254 254 x 254 x 406254 x 254 x 406 457 x 457 x 609457 x 457 x 609 600 x 500 x 600600 x 500 x 600

AccuracyAccuracymmmm

+/+/-- 0.1270.127 +/+/-- 0.1270.127 +/+/-- 0.1270.127--0.2540.254 +/+/-- 0.1270.127

Size mmSize mm 660x 914 x660x 914 x10671067

660 x 1067 x660 x 1067 x914914

1486 x 1905 x1486 x 1905 x10031003

2235 x 1981 x2235 x 1981 x11181118


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PROCESS PARAMETERSPROCESS PARAMETERSWeightWeight

KgKg

160160 160160 392392 11341134

PowerPowerrequirementsrequirements

220220--240 VAC240 VAC

50/60 Hz50/60 Hz10A single10A single

phasephase

208208--240 VAC240 VAC


phasephase

220220--240 VAC240 VAC


phasephase

208208--240 VAC240 VAC


phasephase

MaterialsMaterials ABS (white)ABS (white)

InvestmentInvestmentcasting waxcasting wax

ElastomerElastomer

ABS (white)ABS (white)

InvestmentInvestmentcasting waxcasting wax

ElastomerElastomer

ABSABS ABSABS

Layer widthLayer width 0.254 to 2.540.254 to 2.54mmmm

0.254 to 2.540.254 to 2.54mmmm

0.254 to 2.540.254 to 2.54mmmm

0.38 to 0.510.38 to 0.51

LayerLayerthicknessthickness

0.05 to 0.7620.05 to 0.762mmmm

0.05 to 0.7620.05 to 0.762mmmm

0.05 to 0.7620.05 to 0.762mmmm

0.18 to 0.250.18 to 0.25mmmm


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ADVANTAGESADVANTAGES

True desktop manufacturing system that can be run in officeTrue desktop manufacturing system that can be run in officeenvironment. There is no worry of exposure to toxic fume andenvironment. There is no worry of exposure to toxic fume andchemicals.chemicals.

The process is clean, simple, easy to operate and produces noThe process is clean, simple, easy to operate and produces no

wastewaste Fast building for bottle like structure or hollow partsFast building for bottle like structure or hollow parts Material is supplied in spool form which is easy to handle andMaterial is supplied in spool form which is easy to handle and

can be changed in minutecan be changed in minute

Materials used are very cost effective, typical parts cost underMaterials used are very cost effective, typical parts cost under

US$20US$20 A good variety of material is available including colour ABS andA good variety of material is available including colour ABS and

Medical ABS, investment casting wax and elastomerMedical ABS, investment casting wax and elastomer

Mid range performance/cost RP system and is the best sellingMid range performance/cost RP system and is the best sellingRP system in 1995RP system in 1995


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DISADVANTAGESDISADVANTAGES

Accuracy is relatively low and is difficult to buildAccuracy is relatively low and is difficult to build

parts with complicated detailsparts with complicated details

Poor strength in vertical directionPoor strength in vertical direction Slow for building a mass partSlow for building a mass part


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APPLICATIONSAPPLICATIONS

It does not need laser systems, uses relativelyIt does not need laser systems, uses relativelyinexpensive binders, and is easy to changeinexpensive binders, and is easy to changematerials.materials.

The main difficulties are in controllingThe main difficulties are in controllingtemperature within the growing part, the need totemperature within the growing part, the need toprovide support structures for the growingprovide support structures for the growing

modelmodelThe accuracy which is limited to the nozzleThe accuracy which is limited to the nozzle

diameter.diameter.


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APPLICATIONSAPPLICATIONS

Limited number of prototypes needed (1Limited number of prototypes needed (1--10)10) Concept ModelsConcept Models Functional testingFunctional testing

Si3N4 components with good mechanical properties andSi3N4 components with good mechanical properties andmicrostructure were produced with a filament containing 55 volmicrostructure were produced with a filament containing 55 vol% of the ceramic.% of the ceramic. After FDM, green parts were densified by hotAfter FDM, green parts were densified by hotpressing and gave four point bend strengths similar to that of hotpressing and gave four point bend strengths similar to that of hotisostatic pressed parts.isostatic pressed parts.

A fine scaled piezoelectric composite structure can be madeA fine scaled piezoelectric composite structure can be made

consisting of PZT and polymer.consisting of PZT and polymer. The piezoelectric properties ofThe piezoelectric properties ofthe composite are similar or superior to conventionallythe composite are similar or superior to conventionallyprocessed PZT composites.processed PZT composites.

Composites with controlled composition distribution and aComposites with controlled composition distribution and avariety of microstructures can be made by combining filamentsvariety of microstructures can be made by combining filamentsof different compositions.of different compositions.


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Rapid Manufacturing Jigs and Fixtures with FDMRapid prototyping has become a standard practice in product

development. At the BMW

AG plant in Regensburg, Germany, FDM(fused deposition modeling) continues to be an important component invehicle design prototyping. But moving beyond prototyping, BMW is

extending the application of FDM to other areas and functions,including rapid manufacturing.

Rapid Manufacturing at

BMW

BMWhas determined that the FDM process can be an alternative to

the conventional metal-cutting manufacturing methods like milling,turning, and boring.


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Landing Gear Prepared for FlightLanding Gear Prepared for Flight

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