Rapid Manufacturing Processes: Gear

39-245Spring 2000

Carnegie Mellon University

Brian Oosterman

Eric Egenolf

Niti Yongvanich

Characteristics of Gears: 2.5D: a geometry that can be described

without any overhangs. High yield strength and hardness Simple, uniform section Smoothness Ductility Fatigue

Impossible Process: Stereolithography(SLA)

Brittle (photosensitive polymer)

Cool, Unnecessary Features Enhance the geometric visualization of a

product Easily modified (any last minute changes) Fast, a prototype can be made in a matter of

dayshttp://www.stereolithography.com/slainfo.htm

Preferable Process:JP Systems Low material cost (using paper) Suited for education Not likely to get a perfect prototype the

first time No particular level of accuracy is

guaranteed.

http://www.schroff.com/jpsystem5/index.htm

Other Possible Processes:

Fused Deposition Manufacturing (FDM) Accurate to the size of the thread (0.07

inches) Shape Deposition Manufacturing (SDM)

Retains a 3-D representation LaserCamm

2-dimensional cutterhttp://www.cs.cmu.edu/~rapidproto/students.99/jburnett/project2

Other Possible Processes: CyberCut

Dimensional Tolerance ~ 0.001” to 0.01” CNC Machining

Mills both 2 and 3 dimensional parts for models

Create different degrees of rotation, allowing for more flexible designs

Molding Quick and inexpensive