ADDITIVE MANUFACTURING

UNIT – I

Definition of a Prototype
An approximation of a product (or system) or
its components in some form for a definite purpose
in its implementation.
Prototype is an important and vital part of the product development
process. In any design practice, the word “prototype” is often not far from
the things that the designers will be involved in. In most dictionaries, it is
defined as a noun, e.g. the Oxford Advanced Learner’s Dictionary of
Current English
A prototype is the first or original example of something that has been or
will be copied or developed; it is a model or preliminary version;
e.g.: A prototype supersonic aircraft.

Types of Prototypes

The general definition of the prototype contains three aspects of

interests:

(1) The implementation of the prototype; from the entire product (or
system) itself to its sub-assemblies and components,
(2) The form of the prototype; from a virtual prototype to a physical
prototype, and
(3) The degree of the approximation of the prototype; from a very rough
representation to an exact replication of the product.

The implementation aspect of the prototype covers the range of

prototyping the complete product (or system) to prototyping part of, or a
sub-assembly or a component of the product. The complete prototype, as
its name suggests, models most, if not all, the characteristics of the product.
It is usually implemented full-scale as well as being fully functional. One
example of such prototype is one that is given to a group of carefully
selected people with special interest, often called a focus group, to examine
and identify outstanding problems before the product is committed to its
final design. On the other hand, there are prototypes that are needed to study
or investigate special problems associated with one component, sub-
assemblies or simply a particular concept of the product that requires close
attention. An example of such a prototype is a test platform that is used to
find the comfortable rest angles of an office chair that will reduce the risk
of spinal injuries after prolonged sitting on such a chair. Most of the time,
sub-assemblies and components are tested in conjunction with some kind
of test rigs or experimental platform.

Roles of the Prototypes

The roles that prototypes play in the product development process

are several. They include the following:
(1) Experimentation and learning
(2) Testing and proofing
(3) Communication and interaction
(4) Synthesis and integration
(5) Scheduling and markers

To the product development team, prototypes can be used to help

the thinking, planning, experimenting and learning processes whilst
designing the product. Questions and doubts regarding certain issues of the
design can be addressed by building and studying the prototype. For
example, in designing the appropriate elbow-support of an office chair,
several physical prototypes of such elbow supports can be built to learn
about the “feel” of the elbow support when performing typical tasks on the
office chair.
Prototypes can also be used for testing and proofing of ideas and
concepts relating to the development of the product. For example, in the
early design of folding reading glasses for the elderly, concepts and ideas
of folding mechanism can be tested by building rough physical prototypes
to test and prove these ideas to see if they work as intended.

ADVANTAGES OF RAPID PROTOTYPING

Today’s automated, toolless, patternless RP systems can directly

produce functional parts in small production quantities. Parts produced in
this way usually have an accuracy and surface finish inferior to those made
by machining. However, some advanced systems are able to produce near
tooling quality parts that are close to or are the final shape. The parts
produced, with appropriate post processing, will have material qualities and
properties close to the final product. More fundamentally, the time to
produce any part — once the design data are available — will be fast, and
can be in a matter of hours.
The benefits of RP systems are immense and can be categorized into direct
and indirect benefits.

CLASSIFICATION OF RAPID PROTOTYPING SYSTEMS

While there are many ways in which one can classify the numerous
RP systems in the market, one of the better ways is to classify RP systems
broadly by the initial form of its material, i.e. the material that the prototype
or part is built with. In this manner, all RP systems can be easily categorized
into
(1) liquid-based
(2) solid-based and
(3) powderbased.

Liquid-Based
Liquid-based RP systems have the initial form of its material in liquid state.
Through a process commonly known as curing, the liquid is converted into
the solid state. The following RP systems fall into this category:
(1) 3D Systems’ Stereolithography Apparatus (SLA)
(2) Cubital’s Solid Ground Curing (SGC)
(3) Sony’s Solid Creation System (SCS)
(4) CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)
(5) Autostrade’s E-Darts
(6) Teijin Seiki’s Soliform System

Solid-Based
Except for powder, solid-based RP systems are meant to encompass all
forms of material in the solid state. In this context, the solid form can
include the shape in the form of a wire, a roll, laminates and pellets.
The following RP systems fall into this definition:
(1) Cubic Technologies’ Laminated Object Manufacturing (LOM)
(2) Stratasys’ Fused Deposition Modeling (FDM)
(3) Kira Corporation’s Paper Lamination Technology (PLT)
(4) 3D Systems’ Multi-Jet Modeling System (MJM)
(5) Solidscape’s ModelMaker and PatternMaster

Powder-Based
In a strict sense, powder is by-and-large in the solid state. However,
it is intentionally created as a category outside the solid-based RP systems
to mean powder in grain-like form. The following RP systems fall into this
definition:

(1) 3D Systems’s Selective Laser Sintering (SLS)

(2) EOS’s EOSINT Systems
(3) Z Corporation’s Three-Dimensional Printing (3DP)
(4) Optomec’s Laser Engineered Net Shaping (LENS)
(5) Soligen’s Direct Shell Production Casting (DSPC)
(6) Fraunhofer’s Multiphase Jet Solidification (MJS)
(7) Acram’s Electron Beam Melting (EBM)
(8) Aeromet Corporation’s Lasform Technology
(9) Precision Optical Manufacturing’s Direct Metal Deposition (DMDTM)
(10) Generis’ RP Systems (GS)
(11) Therics Inc.’s Theriform Technology
(12) Extrude Hone’s PrometalTM 3D Printing Process

LIQUID-BASED RAPID PROTOTYPING SYSTEMS

Most liquid-based rapid prototyping systems build parts in a vat of

photo-curable liquid resin, an organic resin that cures or solidifies under the
effect of exposure to laser radiation, usually in the UV range. The laser
cures the resin near the surface, forming a hardened layer. When a layer of
the part is formed, it is lowered by an elevation control system to allow the
next layer of resin to be similarly formed over it. This continues until the
entire part is completed. The vat can then be drained and the part removed
for further processing, if necessary. There are variations to this technique
by the various vendors and they are dependent on the type of light or laser,
method of scanning or exposure, type of liquid resin, type of elevation and
optical system used.

STEREOLITHOGRAPHY APPARATUS (SLA)

Models and Specifications

3D Systems produces a wide range of machines to cater to various part sizes

and throughput. There are several models available, including those in the
series of SLA 250/30A, SLA 250/50, SLA-250/50HR, SLA 3500, SLA
5000, SLA 7000 and Viper si2. The SLA 250/30A is an economical and
versatile SLA starter system that uses a Helium Cadmium (He–Cd) laser.
The SLA 250/50 is a supercharged system with a higher powered laser,
interchangeable vats and Zephyr recoater system, whereas the SLA
250/50HR adds a special feature of a small spot laser for high-resolution
application. All SLA 250 type systems have a maximum build envelope of
–Cd laser. For bigger build
envelopes, the SLA 3500, SLA 5000 and SLA 7000 are available. These
three machines use a different laser from the SLA 250 (solid-state
Nd:YVO4 ). The SLA 7000 (see Figure 3.1) is the top of the series. It can
build parts up to four times faster than the SLA 5000 with the capacity of
building thinner layers (minimum layer thickness 0.025 mm) for finer
surface finish. Its faster speed is largely due to its dual spot laser’sability.
This means that a smaller beam spot is used for the border for accuracy,
whereas the bigger beam spot is used for internal crosshatching for speed.
3D Systems’ new Viper si2 SLA system is their first solid imaging system
to combine standard and high-resolution part building in the same system.
The Viper si2 system lets you choose between standard resolution, for the
best balance of build speed and part resolution, and high resolution (HR
mode) for ultra-detailed small parts and features. All these are made
possible by a carefully integrated digital signal processor (DSP) controlled
high speed scanning system with a single, solid-state laser that delivers a
constant 100 mW of available power throughout its 7500-hour warranty
life. The Viper si2 system builds parts with a smooth surface finish,
excellent optical clarity, high accuracy, and thin, straight vertical walls. It
is ideal for a myriad of solid imaging applications, from rapid modeling and
prototyping to injection molding and investment casting. Specifications of
these machines are summarized in Tables

Table: Summary specifications of SLA-250 machines (Source from 3D Systems)

Table 3.1(a): (Continued )

 Model SLA 250/30A SLA 250/50 SLA 250/50HR

FEA
TUR
ES

Interchangeab
le Vat Available Option Yes Yes

SmartSweep No No No

er
pt
ha
C
Auto Resin
Refill No No No

SOF
TW
ARE

:
3
With Build-station With Build-station
3D Lghtyear / 3.8.4 3.8.4 With Build-station 3.8.4

Windows NT

d
i
u
q
i
L
-
Buildstation
O/S MS DOS MS DOS MS DOS

R
d
e
s
a
B
E
S
I
N
S

General
Purpose SL 5149, SL 5170, SL 5149, SL 5170, SL 5149, SL 5170,
Durable N/A N/A N/A

SL 5220 SL 5220 SL 5220

d
i
p
a
R

High
Temperature SL 5210 SL 5210 SL 5210
g
n
i
p
y
t
o
t
o
r
P
s
m
e
t
s
y
S

WA
RRA
NTY

1 yr from 1 yr from installation 1 yr from installation

installation date date date
 Table 3.1(b): Summary specifications of the rest of the SLA machines (Source from

Model SLA 3500 SLA 5000 SLA 7000

SYSTEM CHARACTERISTICS

A mid-sized system up to A large-frame system A supercharged large-frame

2.5 times faster than SLA with three times the build system two times faster than

250 with productivity volume of SLA 3500. SLA 5000 with the capability

enhancements like auto building thinner layers for fin

resin refill and surface finish.

SmartSweep.

VAT CAPACITY
3 3 3

Maximum Build 350 × 350 × 400 mm 508 × 508 × 584 mm 508 × 508 × 600 mm
3 3 3

Envelope 13.8 × 13.8 × 15.7 in 20 × 20 × 23 in 20 × 20 × 23.6 in

VOLUME

L (U.S. gal) 99.3 (25.6 ) 253.6 (67)

LASER

Type Solid-State (Nd:YVO4)

Wavelength 354.7 nm

Power at Vat @ 5000/hrs @ 5000/hrs @ 5000/hrs

@ hrs 160 mW 216 mW 800 mW

Warranty 5000 hrs

OPTICAL & SCANNING

Dual Spot No Ye

Beam Diameter; 0.25 +/− 0.025 mm

2
Border @ l/e (0.010 +/− 0.001 in)

Beam Diameter; 0.25 +/− 0.025 mm 0.7615 +/− 0.0765 mm

2

Hatch @ l/e (0.010 +/− 0.001 in) (0.03 +/− 0.003 in)

RECOATING SYSTEM

Zephyr

Table 3.1(b): (Continued )

Model SLA 3500 SLA 5000 SLA 7000

FEATURES

Interchangeable Vat Yes

SmartSweep Yes

Auto Resin Refill Yes

SOFTWARE

3D Lghtyear / Buildstation 5.1

Windows NT

Buildstation O/S Windows NT 3.5.1

 RESINS

General Purpose SL 5190, SL 5510 SL 5195, SL 5510 SL 7510

Durable SL 5520

High Temperature SL 5530 HT

WARRANTY

1 yr from installation date

Principle

The SLA process is based fundamentally on the following principles [3]:

Parts are built from a photo-curable liquid resin that cures when
exposed to a laser beam (basically, undergoing the photo-polymerization
process) which scans across the surface of the resin. The building is done
layer by layer, each layer being scanned by the optical scanning system and
controlled by an elevation mechanism which lowers at the completion of
each layer.
These two principles will be briefly discussed in this section to lay the
foundation to the understanding of RP processes. They are mostly
applicable to the liquid-based RP systems described in this chapter. This
first principle deals mostly with photo-curable liquid resins, which are
essentially photopolymers and the photo-polymerization process. The
second principle deals mainly with CAD data, the laser, and the control of
the optical scanning system as well as the elevation mechanism

Process
3D Systems’ stereolithography process creates three-dimensional plastic
objects directly from CAD data. The process begins with the vat filled with
the photo-curable liquid resin and the elevator table set just below the
surface of the liquid resin (see Figure 3.2). The operator loads a three-
dimensional CAD solid model file into the system. Supports are designed
to stabilize the part during building. The translator converts the CAD data
into a STL file. The control unit slices the model and support into a series
of cross sections from 0.025 to 0.5 mm (0.001 to 0.020 in) thick

Laser

Wiper Elevator

Vat
Platform

Resin
 The computer-controlled optical scanning system then directs and
focuses the laser beam so that it solidifies a two-dimensional cross-section
corresponding to the slice on the surface of the photo-curable liquid resin
to a depth greater than one layer thickness. The elevator table then drops
enough to cover the solid polymer with another layer of the liquid resin. A
leveling wiper or vacuum blade (for ZephyrTM recoating system) moves
across the surfaces to recoat the next layer of resin on the surface. The laser
then draws the next layer. This process continues building the part from
bottom up, until the system completes the part. The part is then raised out
of the vat and cleaned of excess polymer.

The main components of the SLA system are a control computer,

a control panel, a laser, an optical system and a process chamber. The
workstation software used by the SLA system, known as 3D Lightyear
exploits the full power of the Windows NT operating system, and delivers
far richer functionality than the UNIX-based Maestro software. Maestro
includes the following software modules

3dverifyTM Module: This module can be accessed to confirm the

integrity and/or provide limited repair to stereolithography (STL) files
before part building without having to return to the original CAD software.
Gaps between triangles, overlapping or redundant triangles and incorrect
normal directions are some examples of the flaws that can be identified and
corrected

ViewTM Module. This module can display the STL files and slice file
(SLI) in graphical form. The viewing function is used for visual
inspection and for the orientation of these files so as to achieve optimal
building.

MERGE Module. By using MERGE, several SLI files can be merged

into a group which can be used together in future process.

VistaTM Module. This module is a powerful software tool that

automatically generates support structures for the part files. Support
structures are an integral part to successful part building, as they help
to anchor parts to the platform when the part is free floating or there is
an overhang.

Part ManagerTM Module. This software module is the first stage of

preparing a part for building. It utilizes a spreadsheet format into which
 the STL file is loaded and set-up with the appropriate build and recoat
style parameters.

SliceTM Module. This is the second stage of preparing a part for

building. It converts the spreadsheet information from the Part
ManagerTM module to a model of three-dimensional cross sections or
layers.

ConvergeTM Module. This is the third and last stage of preparing a part for
building. This is the module which creates the final build files used by the
SLA.

Advantages
The main advantages of using SLA are:
Round the clock operation. The SLA can be used continuously and
unattended round the clock.

Good user support. The computerized process serves as a good user

support.

Build volumes. The different SLA machines have built volumes ranging
from small to large to suit the needs of different users.

Good accuracy. The SLA has good accuracy and can thus be used for many
application areas.

Surface finish. The SLA can obtain one of the best surface finishes
amongst RP technologies.

Wide range of materials. There is a wide range of materials, from general-

purpose materials to specialty materials for specific applications.
Disadvantages
The main disadvantages of using SLA are:
Requires support structures. Structures that have overhangs and
undercuts must have supports that are designed and fabricated together
with the main structure.

Requires post-processing. Post-processing includes removal of

supports and other unwanted materials, which is tedious, time-
consuming and can damage the model.

Requires post-curing. Post-curing may be needed to cure the object

completely and ensure the integrity of the structure.

Applications
The SLA technology provides manufacturers with cost justifiable methods
for reducing time to market, lowering product development costs, gaining
greater control of their design process and improving product design. The
range of applications include:

Models for conceptualization, packaging and presentation.

Prototypes for design, analysis, verification and functional testing.

Parts for prototype tooling and low volume production tooling.

Patterns for investment casting, sand casting and molding.

Tools for fixture and tooling design, and production tooling.

Photopolymers

There are many types of liquid photopolymers that can be solidified by

exposure to electro-magnetic radiation, including wavelengths in the
gamma rays, X-rays, UV and visible range, or electron-beam (EB) [4, 5].
The vast majority of photopolymers used in the commercial RP systems,
including 3D Systems’ SLA machines are curable in the UV range. UV-
curable photopolymers are resins which are formulated from
photoinitiators and reactive liquid monomers. There are a large variety of
them and some may contain fillers and other chemical modifiers to meet
specified chemical and mechanical requirements [6]. The process through
which photopolymers are cured is referred to as the photo-polymerization
process.

Photopolymerization
Loosely defined, polymerization is the process of linking small mole-cules
(known as monomers) into chain-like larger molecules (known as
polymers). When the chain-like polymers are linked further to one another,
a cross-linked polymer is said to be formed. Photopolymeri-zation is
polymerization initiated by a photochemical process whereby the starting
point is usually the induction of energy from the radiation source [7].

Polymerization of photopolymers is normally an energetically favorable or

exothermic reaction. However, in most cases, the formu-lation of a
photopolymer can be stabilized to remain unreacted at ambient
temperature. A catalyst is required for polymerization to take place at a
reasonable rate. This catalyst is usually a free radical which may be
generated either thermally or photochemically. The source of a
photochemically generated radical is a photoinitiator, which reacts with an
actinic photon to produce the radicals that catalyze the poly-merization
process.
The free-radical photopolymerization process is schematically
presented in Figure 3.3 [8]. Photoinitiator molecules, Pi , which are mixed
with the monomers, M, are exposed to a UV source of actinic photons, with
energy of hν. The photoinitiators absorb some of the photons and are in an
excited state. Some of these are converted into reactive initiator molecules,
P•, after undergoing several complex chemical energy transformation steps.
These molecules then react with a monomer molecule to form a
polymerization initiating molecule, PM•. This is the chain initiation step.
Once activated, additional monomer molecules go on to react in the chain
propagation step, forming longer molecules, PMMM• until a chain
inhibition process terminates the polymerization reaction. The longer the
reaction is sustained, the higher will be the molecular weight of the
resulting polymer. Also, if the monomer molecules have three or more
reactive chemical groups, the resulting polymer will be cross-linked, and
this will generate an insoluble continuous network of molecules.

During polymerization, it is important that the polymers are sufficiently

cross-linked so that the polymerized molecules do not re-dissolve back into
the liquid monomers. The photopolymerized molecules must also possess
sufficient strength to remain structurally sound while the cured resin is
subjected to various forces during recoating.

While free-radical photopolymerization is well-established and yields

polymers that are acrylate-based, there is another newer “chemistry” known
as cationic photopolymerization [9]. It relies on cationic initiators, usually
iodinium or sulfonium salts, to start polymerization. Commercially
available cationic monomers include epoxies, the most versatile of
cationally polymerizable monomers, and vinylethers. Cationic resins are
attractive as prototype materials as they have better physical and
mechanical properties. However the process may require higher exposure
time or a higher power laser.
Layering Technology, Laser and Laser Scanning

Almost all RP systems use layering technology in the creation of prototype

parts (see Chapter 2). The basic principle is the availability of
computer software to slice a CAD model into layers and reproduce it in an
“output” device like a laser scanning system. The layer thickness is
controlled by a precision elevation mechanism. It will correspond directly
to the slice thickness of the computer model and the cured thickness of the
resin. The limiting aspect of the RP system tends to be the curing thickness
rather than the resolution of the elevation mechanism.

The important component of the building process is the laser and its
optical scanning system. The key to the strength of the SLA is its ability to
rapidly direct focused radiation of appropriate power and wavelength onto
the surface of the liquid photopolymer resin, forming patterns of solidified
photopolymer according to the cross-sectional data generated by the
computer [10]. In the SLA, a laser beam with a speci-fied power and
wavelength is sent through a beam expanding telescope to fill the optical
aperture of a pair of cross axis, galvanometer driven, beam scanning
mirrors. These form the optical scanning system of the SLA. The beam
comes to a focus on the surface of a liquid photopoly-mer, curing a
predetermined depth of the resin after a controlled time of exposure
(inversely proportional to the laser scanning speed).

The solidification of the liquid resin depends on the energy per unit area
(or “exposure”) deposited during the motion of the focused spot on the
surface of the photopolymer. There is a threshold exposure that must be
exceeded for the photopolymer to solidify.

To maintain accuracy and consistency during part building using the

SLA, the cure depth and the cured line width must be controlled. As such,
accurate exposure and focused spot size become essential.

Parameters which influence performance and functionality of the parts are

the physical and chemical properties of the resin, the speed and resolution
of the optical scanning system, the power, wavelength and type of the laser
used, the spot size of the laser, the recoating system, and the post-curing
process
CUBITAL’S SOLID GROUND CURING (SGC)
Models and Specifications
Cubital’s products include the Solider 4600 and Solider 5600. The
Solider 4600 is Cubital’s entry level three-dimensional model making
system based on Solid Ground Curing. The Solider 5600, Cubital’s
sophisticated high-end system, provides a wider range and options for the
varied modeling demands of Solid Ground Curing. Table 3.2 summarizes
the specifications of the two machines. Cubital’s system uses several kinds
of resins, including liquid resin and cured resin as materials to create parts,
water soluble wax as support material and ionographic solid toner for
creating an erasable image of the cross-section on a glass mask.

Model Solider 4600 Solider 5600

Irradiation medium High power UV lamp

XY resolution (mm) Better than 0.1

Surface definition
(mm) 0.15 0.15

Elevator vertical
resolution 0.15 0.1–0.2
(mm)

0.4 (horizontal, X–
Minimum feature size 0.4 (horizontal, X–Y) Y)
(mm)
0.15 (vertical, Z) 0.15 (vertical, Z)

Work volume, 350 × 350 × 350 500 × 350 × 500

XYZ (mm × mm ×
mm)
 Production rate
(cm3/hr) 550 1311
Minimum layer
thickness 0.06 0.06
(mm)

Dimensional accuracy 0.1% 0.1%

Size of unit, 1.8 × 4.2 × 2.9 1.8 × 4.2 × 2.9

XYZ (m × m × m)

Data control unit Data Front End (DFE) workstation

380 –415 VAC , 3 380 –415 VAC , 3

Power supply phase, phase,
50 kW 50 kW

Principle
Cubital’s RP technology creates highly physical models directly from
computerized three-dimensional data files. Parts of any geometric
complexity can be produced without tools, dies or molds by Cubital’s RP
technology.

The process is based on the following principles:

Parts are built, layer by layer, from a liquid photopolymer resin that
solidifies when exposed to UV light. The photopolymerization process
is similar to that described in Section 3.1.4, except that the irradiation
source is a high power collimated UV lamp and the image of the layer
is generated by masked illumination instead of optical scanning of a
laser beam. The mask is created from the CAD data input and “printed”
on a transparent substrate (the mask plate) by an nonimpact
ionographic printing process, a process similar to the Xerography
process used in photocopiers and laser printers [15]. The image is
formed by depositing black powder, a toner which adheres to the
substrate electrostatically. This is used to mask the uniform
 illumination of the UV lamp. After exposure, the electrostatic toner is
removed from the substrate for reuse and the pattern for the next layer
is similarly “printed” on the substrate.

Multiple parts may be processed and built in parallel by grouping them

into batches (runs) using Cubital’s proprietary software.

Each layer of a multiple layer run contains cross-sectional slices of one

or many parts. Therefore, all slices in one layer are created
simultaneously. Layers are created thicker than desired. This is to
allow the layer to be milled precisely to its exact thickness, thus giving
overall control of the vertical accuracy. This step also produces a
roughened surface of cured photopolymer, assisting adhesion of the
next layer to it. The next layer is then built immediately on the top of
the created layer.

The process is self-supporting and does not require the addition of external
support structures to emerging parts since continuous structural support for
the parts is provided by the use of wax, acting as a solid support material.

Process
The Cubital’s Solid Ground Curing process includes three main steps:
1. Data preparation,
2. Mask generation and
3. Model making
Data Preparation:
In this first step, the CAD model of the job to be prototyped is
prepared and the cross-sections are generated digitally and transferred to
the mask generator. The software used, Cubital’s Solider DFE (Data Front
End) software, is a motif-based special-purpose CAD application pack-age
that processes solid model CAD files prior to sending them to Cubital
Solider system. DFE can search and correct flaws in the CAD files and
render files on-screen for visualization purposes. Solider DFE accepts CAD
files in the STL format and other widely used formats exported by most
commercial CAD systems.
Mask Generation
After data are received, the mask plate is charged through an “image-wise”
ionographic process (see item 1, Figure). The charged image is then
developed with electrostatic toner

Model Making
In this step, a thin layer of photopolymer resin is spread on the work surface
(see item 2, Figure 3.6). The photo mask from the mask generator is placed
in close proximity above the workpiece, and aligned under a collimated UV
lamp (item 3). The UV light is turned on for a few seconds (item 4). The
part of the resin layer which is exposed to the UV light through the photo
mask is hardened. Note that the layers laid down for exposure to the lamp
are actually thicker than the desired thickness. This is to allow for the final
milling process. The un-solidified resin is then collected from the
workpiece (item 5). This is done by vacuum suction. Following that, melted
wax is spread into the cavities created after collecting the liquid resin (item
6). Consequently, the wax in the cavities is cooled to produce a wholly
solid layer. Finally, the layer is milled to its exact thickness, producing a
flat solid surface ready to receive the next layer (item 7).

In the SGC 5600, an additional step (item 8) is provided for final curing
of the layer whereby the workpiece travels under a powerful longitudinal
UV lamp. The cycle repeats itself until the final layer is completed.

The main components of the Solider system are (see Figure 3.7):

Data Front End (DFE) workstation.

Model Production Machine (MPM). It includes:

Process engine,

Operator’s console,
Vacuum generator.
Automatic Dewaxing Machine (optional).
Advantages and Disadvantages
The Solider system has the following advantages:

Parallel processing. The process is based on instant, simultaneous curing of a whole cross-
sectional layer area (rather than point-by-point curing). It has a high speed throughput that is
about eight times faster than its competitors. Its production costs can be 25% to 50% lower. It
is a time and cost saving process.
 Self-supporting. It is user-friendly, fast, and simple to use. It has a solid modeling environment
with unlimited geometry. The solid wax supports the part in all dimensions and therefore a
support structure is not required.

Fault tolerance. It has good fault tolerances. Removable trays allow job changing during a run
and layers are erasable.
Unique part properties. The part that the Solider system produces is reliable, accurate, sturdy,
machinable, and can be mechanically finished.

CAD to RP software. Cubital’s RP software, Data Front End (DFE), processes solid model
CAD files before they are transferred to the Cubital’s machines. The DFE is an interactive and
user-friendly software.
Minimum shrinkage effect. This is due to the full curing of every layer.
High structural strength and stability. This is due to the curing process that minimizes the
development of internal stresses in the structure. As a result, they are much less brittle.

No hazardous odors are generated. The resin stays in a liquid state for a very short time, and the
uncured liquid is wiped off immediately. Thus safety is considerably higher.
Disadvantages
The Solider system has the following disadvantages:

Requires large physical space. The size of the system is much larger than other systems with a similar
build volume size.

Wax gets stuck in corners and crevices. It is difficult to remove wax from parts with intricate geometry.
Thus, some wax may be left behind.

Waste material produced. The milling process creates shavings, which have to be cleaned from the
machine.

Noisy. The Solider system generates a high level of noise as compared to other systems.

Applications
The applications of Cubital’s system can be divided into four areas:

General applications. Conceptual design presentation, design proofing, engineering testing, integration
and fitting, functional analysis, exhibitions and pre-production sales, market research, and inter-
professional communication.

Tooling and casting applications. Investment casting, sand casting, and rapid, tool-free manufacturing
of plastic parts.
Mold and tooling. Silicon rubber tooling, epoxy tooling, spray metal tooling, acrylic tooling, and
plaster mold casting.

Medical imaging. Diagnostic, surgical, operation and reconstruc-tion planning and custom prosthesis
design.