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

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

SLS Literature: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

- Pan/Tilt- CO2 Laser- Heated Powder Beds

QuickTime™ and a decompressor

are needed to see this picture.

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

http://www.youtube.com/watch?v=28B8NvBFU0E

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

Group 2 | SLS 3D Printer Project Planning

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

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

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 Solutions

Frame Material

Safety 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

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

Criteria SafetyEase of

Construction

Cost Accuracy Speed Weight Total Rank

Safety 1 1 1 1 1 5 1

Ease of Constructi

on0 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

CriteriaSafet

yEase Cost Acc.

Speed

Weight

Total

Weighting

Factor100 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 3

WoodFull 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

Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

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