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Group 2 | SLS 3D Printer Background

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

http://www.arptech.com.au/slshelp.htm

Additive Manufacturing- Rapid CAD to 3D Object- Made of successive 2D layers- Prototyping benefits to many industries

Methods- Stereolithography (SLA) >$5000- Fused Deposition Moulding (FDM) >$500- Selective Laser Sintering (SLS) >$10000

Selective Laser Sintering

https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/

Group 2 | SLS 3D Printer Project Problem


There Exists a Need for an Economic SLS 3D Printer for:

- Additive manufacturing research- Material scientists- Education institutions- Small businesses- Hobbyists

Develop an SLS 3D printer with comparable cost and performance to small-business FDM 3D printers currently on the market

Problem Statement:

Design Criteria:- Completely safe- Most basic/simply functional design- Under $600 (supplied funds)- Sold for a cost equal to current small-business 3D printer- Prints large variety of sinter-able powder - Thermoplastics, metals, ceramics, organics

(chocolate)- Robust and reliable hardware and software- Professional and attractive appearance

Patents:US Patent #8172562:- SLS Printer with translating powder box

US Patent #8187522:- Describes the SLS process1) Lay a layer of powder2) Irradiate the powder to solidify at required areas3) Repeat steps 1 and 2 to create a 3D object

SLS Literature:- Pan/Tilt- CO2 Laser- Heated Powder Beds

- No support during print- Improved chemical resistance over SLA- Increased density and strength over FDM


Group 2 | SLS 3D Printer Project Planning

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Problem Formulation Select Solution

Preliminary Design Gantry Design

Powder Applicator Design Frame Design

Software Design Melting Properties Test

Aquire Materials Final Design Presentation

Final Design Reports Assemble Frame

Test Arduino IO Gantry Install

Electrical Wiring Applicator Install

Test Hardware Integrate Software

Safety Verification Test Basic Full Integration Test

Optimization

Potential ContactsProfessor Toyserkani, The University of Waterloo

- 3D printing related research- Potential supplies - Bulk chocolate powder

Coherent- Laser company- Borrow high-power laser for increased printing time

Component Design

Testing

Deliverables

or


Group 2 | SLS 3D Printer Morphological Chart

StationaryLaser

TranslatingPowder Box

XY Gantry

Aluminum Plastic Wood

CO2 Laser Laser Diode

Pan/Tilt Mirror

Optical Lens Adjustment

VerticalAdjustment

Cylindrical Roller

Wedge Slider

RadialDispensing

Subtractions SolutionsSolutionsSolutions

Frame MaterialSafety Enclosure Fully Enclosed Laser-safe Plexiglass

Laser Type

Laser Positioning

Powder Transferring

Laser Diameter Adjustment

Temperature Control Thermo Electric Cooler (TEC) Fan

StationaryLaser

TranslatingPowder Box

XY Gantry

CO2 Laser Laser Diode

Pan/Tilt Mirror

Optical Lens Adjustment

VerticalAdjustment

Cylindrical Roller

Wedge Slider

RadialDispensing

Group 2 | SLS 3D Printer Alternative Designs


Criteria Safety Ease of Construction Cost Accuracy Speed Weight Total Rank

Safety 1 1 1 1 1 5 1

Ease of Construction 0 1 1 1 1 4 2

Cost 0 0 1 1 1 3 3

Accuracy 0 0 0 1 1 2 4

Speed 0 0 0 0 1 1 5

Weight 0 0 0 0 0 0 6

Criteria Safety Ease Cost Acc. Speed Weight Total

Weighting Factor 100 90 70 60 50 40

Design 1 4x100 = 400

5x90 = 450

5x70 = 350

5x60 = 300

8x50 = 400

4x40 = 160 2060

Design 2 6x100 = 600

7x90 = 630

6x70 = 420

6x70 = 420

7x50 = 350

6x40 = 240 2660

Design 3 9x100 = 900

8x90 = 720

8x90 = 720

8x60 = 480

6x50 = 300

7x40 = 280 3240

Design 1 Design 2 Design 3WoodFull EnclosureLaser DiodePan & TiltCylindrical RollerTEC

PlasticPlexiglass EnclosureLaser DiodeXY GantryWedge SliderTEC

AluminumFull EnclosureLaser DiodeXY GantryWedge SliderTEC

Note: Laser Diameter Adjustment was removed from design due to difficulty and time constraint

Criteria Priority Table Decision Matrix


Group 2 | SLS 3D Printer References3D Printer Choices for $20,000 or Less, Worldwide Guide to Rapid Prototyping http://www.additive3d.com/

3dpr_cht.htm, Oct 5th, 2012

Rapid Prototyping, Excalibur Engineering Services, http://www.excalibur-engineering-services.com/rapidprototyping.htm, Oct 13th, 2012

Solid Concepts, Stereolithography (SLA) Gallery, https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/, Oct 13th, 2012

ARPTECH - Rapid Prototyping Services, http://www.arptech.com.au/slshelp.htm, Oct 13th, 2012

United States Patent and Trademark Office, #8172562, http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,172,562&OS=8,172,562&RS=8,172,562, Oct 13th, 2012

United States Patent and Trademark Office, #8187522, http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,187,522&OS=8,187,522&RS=8,187,522, Oct 13th, 2012

3D Printing - From CAD file to Complex Metal Part, Layer by Layer - Direct Metal Laser Sintering, http://www.youtube.com/watch?v=28B8NvBFU0E, Oct 13th, 2012

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