Investigation of detail resolution on basic shapes and development of design rules Dominik Sippel Diploma student 15.04.2008
Investigation of detail resolution on basic shapes and development of design rules
Dominik Sippel Diploma student
15.04.2008
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 2
— General test condition
3
— Test geometries
4
— Tests and results•Font
5•Walls
11•Pins
15•Gaps
18•Holes
23
Content Page
Investigation of detail resolution on basic shapes and development of design rules
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 3
Test conditions and test geometries describe the general test frame
— Maschine
/ Layer thickness•
P390 / 0.15mm
— Material•
PA2200
— Exposure Type•
Mechanic standard
— PSW3.3
— Material dependent scaling•
X: 3.2%•
Y: 3.2%•
Z (0): 2.2%•
Z (600): 1.6%
— Beam
offset•
0.33mm
Test conditions
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 4
Test conditions and test geometries describe the general test frame
— Font
— Shapes•Walls•Pins
— Cutouts•Gaps •Holes
Test geometries
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 5
Please see test parts to judge the labeling
quality
— Font type•Arial
— Small font size•8pt to 14pt
— Letter height outside & inside •0.2mm to 1.2mm
— Orientation•Vertical•Horizontal UpSkin•Horizontal DownSkin
— Test results
subjective
Font test specifications
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 6
VerticalSkin
orientation offers very detailed labeling quality
Source: EOS GmbH
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14
VS inside [mm]
fon
t si
ze [
pt]
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14
VS outside [mm]
fon
t si
ze [
pt]
Design Chart - VerticalSkin
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 7
Font in UpSkin
orientation shows rather low labeling
quality
Source: EOS GmbH
Design Chart - upskin
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14
inside [mm]
fon
t si
ze [
pt]
US
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14fon
t si
ze [
pt]
US outside [mm]
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 8
Font in DownSkin
orientation shows good labeling
quality
Source: EOS GmbH
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14
DS inside [mm]
fon
t si
ze [
pt]
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6
689
10111214
>14
outside [mm]
fon
t si
ze [
pt]
DS
Design Chart - Downskin
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 9
Source: EOS GmbH
Overview of inside & outside font in all basic orientations
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6
6 68 89 9
10 1011 1112 1214 14
>14 >14
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6
6 68 89 9
10 1011 1112 1214 14
>14 >14
>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6
6 68 89 9
10 1011 1112 1214 14
>14 >14
inside [mm]
fon
t si
ze [
pt]
US
VS outside [mm]
fon
t si
ze [
pt]
US outside [mm]
outside [mm]
fon
t si
ze [
pt]
VS inside [mm]
fon
t si
ze [
pt]
fon
t si
ze [
pt]
DS inside [mm]
fon
t si
ze [
pt]
DS
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 10
Summary Fonts
— Higher detail resolution on VerticalSkin
and DownSkin
— Design chart is a suggestion how required information for designers can look like
— Are you interested in the test geometry ?
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 11
The analysis of basic shapes creates fundamental design information
— Wall thickness•0.50mm to 2.00mm•in 0.05mm steps
— Orientation•Vertical
— Position•X-direction•Y-direction•30°
to X-direction
Wall test specifications
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 12
The investigated test parts showed a max. deviation of ±0.06mm
Source: EOS GmbH
0,60
0,80
1,00
1,20
1,40
1,60
1,80
2,00
1 3 5 7 9 11 13 15 17 19 21 23 25 27
measurement points
wa
ll t
hic
kn
ess [
mm
]
nominal size
actual averagesize
deviation value:-0.06mm
deviation value:+0.06mm
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 13
Switch
from edge to contour exposure increase deviation up to 0.1mm
Source: EOS GmbH
Wall thickness:
0.65mm
0.70mm
Exposure type:
Edge
Contour
Nominal geometry
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 14
Summary walls
— Reliable minimum value: ≥0.80mm
— Maximum deviation
±
0.06mm
— Keep in mind that switch from edge to contour can cause higher deviation
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 15
The analysis of basic shapes creates fundamental design information
— Pin diameter•0.80mm to 2.00mm•In 0.05mm steps
— Orientation•Vertical
Pins test specifications
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 16
The investigated pins showed an average deviation of -0.2mm
Source: EOS GmbH
0,50
0,70
0,90
1,10
1,30
1,50
1,70
1,90
2,10
1 3 5 7 9 11 13 15 17 19 21 23 25
measurement points
pin
dia
me
ter
[mm
] nominal size
actual average size
deviation averagevalue: -0.2mm
maximum tolerancevalue: -0.3mm
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 17
— Reliable minimum diameter:
≥0.8mm
— Average deviation:
-0.2mm
— Maximum deviation value:
-0.3mm
— Smaller diameters can produce unexpected results
Source: EOS GmbH
Summary pins
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 18
The analysis of basic shapes creates fundamental design information
— Gap size•
Length: 10mm•
Width:0.50mm to 2.00mm•
in 0.1mm steps
— Wall thickness•
0.30mm to 6.00mm
— Orientation•
Horizontal
— Position•
X-direction•
Y-direction•
30°
to X-direction
Gap test specifications
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 19
The gap deviation rises with increasing wall thickness
Source: EOS GmbH
0,00
0,50
1,00
1,50
2,00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
measurement points
ga
p w
idth
[m
m]
nominal size
wall thickness0.30mmwall thickness3.00mmwall thickness6.00mmdeviation average3.00mm: -0.1mmdeviation average6.00mm: -0.2mm
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 20
The gap deviation rises with increasing wall thickness
Source: EOS GmbH
0.5
0.6
0.7
0.8
0.30mm 3.00mm 6.00mm
Gap width
[mm]:
Wall thickness:
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 21
The design chart shows the usable area in the relation gap size/ wall thickness
Source: EOS GmbH
0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 4,8 5,1 5,4 5,7 6,00,50,60,70,80,91,01,11,21,31,41,51,61,71,81,92,0
gap
wid
th [m
m]
Wall thickness [mm]
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 22
Summary gaps
— reduce wall thickness for higher detail resolution
— Gap quality is a function of gap size/ wall thickness
— Design chart shows performance of gap in order to remove loose powder
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 23
The analysis of basic shapes creates fundamental design information
— Hole diameter•0.50mm to 2.00mm•in 0.1mm steps
— Wall thickness•0.30mm to 6.00mm•in 0.3mm steps
— Orientation•Horizontal
Hole test specifications
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 24
The hole accuracy depends heavily on the wall thickness
Source: EOS GmbH
0,00
0,50
1,00
1,50
2,00
2,50
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
measurement points
ho
le d
iam
ete
r [m
m]
nominal size
wall thickness 0.30mm
wall thickness 0.60mm
wall thickness 2.70mm
wall thickness 3.00mm
wall thickness 5.70mm
wall thickness 6.00mm
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 25
The hole accuracy depends heavily on the wall thickness
Source: EOS GmbH
Hole diameter:
0.5mm
0.6mm
0.7mm
0.8mm
Wall thickness:
0.30mm
0.60mm
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 26
The design chart shows the usable area in the relation wall thickness / hole size
0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 4,8 5,1 5,4 5,7 6,00,50,60,70,80,91,01,11,21,31,41,51,61,71,81,92,0
Wall thickness [mm]
diam
eter
[mm
]
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 27
Summary holes
— For higher detail resolution reduce wall thickness or rather increase hole diameter
— Be aware of close relationship between hole diameter and wall thickness
— More investigation to express this function as an aspect ratio summarize in one number
Source: EOS GmbH
EOS 2008 · Thesis: Detail Resolution · Dominik Sippel Page 28
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