Design Improvement On Support System For Resin Based 3D Printer.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN IMPROVEMENT ON SUPPORT SYSTEM FOR RESIN
BASED 3D PRINTER
This report submitted accordance with requirement of the Universiti Teknikal Malaysia
Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Manufacturing
Design) with Honours.
by
CHE ROZAIDA BT CHE MOD
FACULTY OF MANUFACTURING ENGINEERING
MAY 2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
JUDUL: Design Improvement on Support System for Resin Based 3D Printer
SESI PENGAJIAN: 2008/2009 Semester 2
Saya : CHE ROZAIDA BT CHE MOD
mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
**Sila tandakan (√)
SULIT
TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
(TANDATANGAN PENULIS)
(TANDATANGAN PENYELIA)
Alamat Tetap:
Lot.501, Kg. Cherang Melintang,
16210 Tumpat,
Kelantan.
Cop Rasmi:
Tarikh: _______________________
Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan
menyatakan sekali sebab dan tempoh Laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
ABSTRACT
Stereolitography is one of the rapid prototyping systems that can produce a part with
high accuracy and good surface finish. Stereolitography is a three-dimensional building
process and can produce a solid plastic model. The device that is called Stereolitography
Apparatus (SLA) is used to produce the part using stereolitography system.
Nevertheless, SLA has its own disadvantages. This apparatus needs support structures.
Other than that, there is a problem occurred on the support system. This project
presented the research on the support system for resin based 3D printer and E-Darts
machine is used for this purpose. Overall system for this machine understands first
including support system. Then, the specimen is design using CAD software and
produces it using E-Darts machine while the ultraviolet (UV) laser traces twodimensional cross-sections on the surface of a liquid resin(photosensitive liquid plastic) .
Problem occurred on the support system can be examined. Suggestion for designs
improvement can be create. The better design is chosen to make an improvement. Thus,
the problem occurred on the support system can be reduce.
ABSTRAK
Streolitografi merupakan salah satu sistem rapid prototyping yang boleh menghasilkan
sesuatu bahagian (objek) dengan ketepatan yang tinggi dan permukaan yang baik.
Stereolitografi merupakan proses pembentukan tiga dimensi dan dapat menghasilkan
model pepejal plastik. Peralatan yang dikenali sebagai Aparatus Stereolitografi (SLA)
digunakan untuk menghasilkan sesuatu bahagian (objek) meggunakan sistem
stereolitografi. Walaubagaimanapun, Aparatus Stereolitografi (SLA) mempunyai
keburukan yang tersendiri. Apparatus ini memerlukan struktur sokongan. Selain
daripada itu, terdapat juga masalah yang berlaku pada sistem sokongan. Projek ini
dijalankan untuk menunjukkan kajian terhadap sistem sokongan bagi pencetak resin tiga
dimensi dan mesin E-Darts digunakan bagi tujuan ini. Keseluruhan sistem bagi mesin
ini difahamkan terlebih dahulu termasuklah sistem sokongan. Kemudian, spesimen
direka bentuk menggunakan software Reka bentuk Terbantu Komputer (CAD) dan
seterusnya dihasilkan menggunakan mesin E-Darts di mana laser ultra-ungu mengesan
keratan rentas pada permukaan cecair resin (cecair plastik fotosensitif). Masalah yang
berlaku pada sistem sokongan dapat dikaji. Cadangan bagi pembaikan rekabentuk sistem
sokongan dapat diberikan. Reka bentuk yang terbaik akan dipilih untuk dibuat
pembaikan. Dengan itu, masalah yang berlaku pada sistem sokongan dapat dikurangkan.
DEDICATION
To my beloved family.
ACKNOWLEDGEMENT
First of all, I would like to express special appreciation to my supervisor, En Wahyono
Sapto Widodo for his great patience guiding me, give an advice, opinion, help and also
support me in the process to finish this project. Thank you so much for your good
support, various suggestion and comments.
I also would like to express gratitude to Puan Ruzy Haryati Bt Hambali as my supervisor
for PSM 1 with her guidance start from the title selection.
Then, I want to express my special appreciation to my parent, brother and sisters for
their encouragement and support during doing this project. Also to En. Mohd Fairus B.
Ninggal, thanks for your advice and suggestion. Finally, thank you to all of the lectures
and staff of Faculty of Manufacturing Engineering UTeM that give me full cooperation
to carry out this project.
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Contents
v
List of Tables
ix
List of Figures
x
List of Abbreviations
xiv
1. INTRODUCTION
1
1.1 Background
1
1.2 Problem Statement
2
1.3 Objective
3
1.4 Scope
3
2. LITERATURE REVIEW
4
2.1 Rapid Prototyping
4
2.1.1 What is the Rapid Prototyping?
4
2.1.2 Classification of the Rapid Prototyping Processes
5
2.1.3 Characteristic of Additive Rapid-Prototyping
7
2.2 Liquid-Base Rapid Prototyping System
9
2.2.1 Additive Processes
9
2.3 Stereolitography
10
2.3.1 Process of Stereolitography
10
2.3.2 Principle of SLA
12
2.3.3 Advantages and Disadvantages of SLA
13
2.4 Photopolymers
13
2.4.1 Photopolymerization
14
2.5 Supports System
16
2.5.1 Supports
16
2.5.2 Support System for Stereolitography
18
2.6 Support System for another Rapid Prototyping System
20
2.6.2 Support System for Fused Deposition Modeling System
24
3. METHODOLOGY
25
3.1 Flow Chart
25
3.2 Details of Methodology
29
3.2.1 Get the Title for PSM
29
3.2.2 Understand About the Title
29
3.2.3 Identify Requirement of the Title
29
3.2.4 Search the Information about Rapid Prototyping, Types and Process
29
3.2.5 Search Journals about Support Structure for Resin Based 3D Printer
29
3.2.6 Review the Journals
29
3.2.7 Gather the Information
30
3.2.8 Design the Specimen Using Software
30
3.2.9 Produce the Specimen Using Resin Based 3D Printer
30
3.2.10 Study the Support Structure
30
3.2.11 Investigate the Problem Occurred On Support System
30
3.2.12 Suggestion Improvement for the Support System
30
3.2.13 Validation
30
3.2.14 Design Improvement
30
3.2.15 Documentation for Final Project
31
4. PROJECT DESIGN
32
4.0 Project Background
32
4.1 Details of the Project
33
4.1.1 Apparatus
34
4.1.2 Components inside E-Darts Printer
35
4.1.3 Materials
36
4.1.4 Procedures
37
4.1.4.1 Stage 1: Design the Specimen
37
4.1.4.2 Stage 2: Preparation for the Construction
38
4.1.4.3 Stage 3: Setting for the Construction Conditions
41
4.1.4.4 Stage 4: Construction
43
4.1.4.5 Stage 5: Study the Support Structure
47
4.1.4.6 Stage 6: Design an Improvement for the Support Structure
48
4.1.4.7 Stage 7: Produce the Prototype
60
4.1.4.8 Stage 8: Analyze the Design
64
5. RESULT
65
5.1 Designs with Screw
66
5.2 New Design with Screw
67
5.3 Prototype Produce by Using FDM Machine
68
5.4 Construction Base Holder and Support Base after Hole Making
69
5.5 Result from the Design Analysis Using CosmosXpress
70
5.5.1 Analysis for the Construction Base Holder
70
5.5.2 Analysis for the Support Base
74
5.5.3 Analysis for the Screw
78
6. DISCUSSION
82
6.1 Current Design
83
6.2 New Design (After Improvement)
85
6.3 Result Obtained from Stress Analysis Using CosmosXpress
88
7. CONCLUSION AND RECOMMENDATION
89
7.1 Conclusion
89
7.2 Recommendation
90
REFERENCES
91
APPENDICES
A Gantt chart for PSM 1
B Gantt chart for PSM 2
C Design with Screw (1) Before Improvement
D Design with Screw (2) After Improvement
E Design with Clip
F Design with Glue Gun
G Current Design
LIST OF TABLES
2.1: Characteristic of Additive Rapid-Prototyping Technologies
A 1 Gantt chart for PSM 1
A 2 Gantt chart for PSM 2
7
LIST OF FIGURES
2.1
The Computational Steps in Producing a Stereolitography File
5
2.2
Schematic Illustration of the Stereolitography Process
11
2.3
The Principle of Stereolitography
11
2.4
Schematic Diagram of the Stereolitography (SLA) System
12
2.5
Schematic for A Simplified Free-Radical Photopolymerization
15
2.6
Transformation of Solid Model to Hatched Base Support
18
2.7
Support for Stereolitography System
19
2.8
E-Darts Process
20
2.9
Regions to Be Supported
22
2.10
Example of Self-Supporting Region
22
2.11
Region That Cannot Be Supported By Adjacent Sheet
23
2.12
Deflection of Sheet
24
2.13
Fused Deposition Modelling
24
3.1
Flow Charts for PSM
26
4.1
Computer
34
4.2
E-Darts Printer
34
4.3
Support Base (large size)
34
4.4
Support Base (small size)
34
4.5
Leveler
34
4.6
Syringe
34
4.7
Weighing Scale
35
4.8
Gloves
35
4.9
Inside E-Darts Printer
35
4.10
Support Base
35
4.11
Construction Base Holder
36
4.12
Side View of Construction Base Holder and Support Base
36
4.13
Liquid Resin Bath
36
4.14
Resin (KAYARD NAF-20)
36
4.15
Hardener
36
4.16
Specimen Design
37
4.17
Preparation for Construction
38
4.18
Preparation for Construction
38
4.19
Preparation for Construction
39
4.20
Preparation for Construction
39
4.21
Preparation for Construction
39
4.22
Preparation for Construction
40
4.23
Construction Base Holder and Construction Base
40
4.24
Windows E-Darts Controller
41
4.25
Parameter List Window
43
4.26
Start Support Construction
44
4.27
X, Y and Z Control Panel
45
4.28
Special Parameter Dialog Box
46
4.29
Holder Base and Resin Bath Condition
47
4.30
Support Base and Construction Base Holder
47
4.31
Current Design
48
4.32
Exploded View Drawing
49
4.33
Construction Base Holder Part
49
4.34
Construction Base Part
50
4.35
Support Base Part
50
4.36
Screw
51
4.37
Design with Screw
52
4.38
Exploded View
52
4.39
Exploded View Drawing
53
4.40
Design with Screw
54
4.41
Exploded View
54
4.42
Clip
55
4.43
Design with Clip
55
4.44
Exploded View
56
4.45
Exploded View Drawing
56
4.46
Glue Gun
57
4.47
Design with Glue Gun
58
4.48
Exploded View
58
4.49
Exploded View Drawing
59
4.50
FDM Machine (FDM 400mc)
60
4.51
Dimension for the Construction Base Holder Part
61
4.52
Drawing for the Construction Base Part
62
4.53
Material for New Support Base (acrylic)
63
4.54
Jigsaw
63
4.55
File
63
4.56
Hand Drill with Tool Size 2.5mm
63
4.57
Tap Wrench
64
4.58
Center Punch
64
5.1
Assemble Drawing for Design with Screw
66
5.2
Exploded View
67
5.3
Holder Part
68
5.4
Base Part
68
5.5
Construction Base Holder and Construction Base Part
68
5.6
Construction Base Holder
68
5.7
Support Base with New Size
69
5.8
New Design
69
5.9
Stress Result for Construction Base Holder
71
5.10
Deformation Result for Construction Base Holder
72
5.11
Design Check Result for Construction Base Holder
73
5.12
Stress Result for Support Base
75
5.13
Deformation Result for Support Base
76
5.14
Design Check Result for Support Base
77
5.15
Stress Result for Screw
79
5.16
Deformation Result
80
5.17
Design Check Result for Screw
81
6.1
Current Design
82
6.2
New Design
82
6.3
Construction Base with Constructions Base Holder
83
6.4
Support Base
83
6.5
Current Design
83
6.6
Construction Base Holder
85
6.7
Support Base
85
6.8
Screw (M3 x 8)
85
6.9
New Design
85
6.10
Current Size for Support Base
87
6.11
New Size for Support Base with Hole
87
LIST OF ABBREVIATIONS
ABS – Acrylo-nitrile Butadiene Styrene
CAD – Computer Aided Design
CPU – Central Processing Unit
DSPC - Direct Shell Production Casting
EB - Electron-Beam
FDM - Fused Deposition Modeling
PCA - Post-Cure Apparatus
RP – Rapid Prototyping
RP & M – Rapid Prototyping and Manufacturing
SLA - Stereolithography
SLS - Selective Laser Sintering
UV – Ultra-Violet
2D – Two Dimensional
3D – Three Dimensional
i
CHAPTER 1
INTRODUCTION
The purpose of this project is to make a design improvement on support system for resin
based 3D printer. The basic concept of rapid prototyping must be understand first. Then,
support system for resin based 3D printer was studied. By using 3D printer, 3D object
can be created by layering a material (plaster, cornstarch, resins) and it consist of an
inkjet layering printing system. 3D object can be created with a short time compared to
the other method. To examine the problem on support system, the main cause was
investigated and step to avoid this problem from occurred again will be done by doing a
design improvement on the machine. Some improvement on the support system for resin
based 3D machine is needed to make sure that this machine can perform it task with
efficient and perfectly. By doing this research this problem can be solved.
1.1 Background
Rapid prototyping (RP) is a terms which embraces a range of new technologies for
producing accurate parts directly from CAD models in a few hours, with little need for
human (Pham, D.T. and Gault, R.S. (1998)). This means that designers have the freedom
to produce physical models of their drawings more frequently, allowing them to check
the assembly and function of the design. RP technologies may be divided into the
addition material and removal material. The most popular among currently available RP
technologies is perhaps stereolitography.
1
Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable
photopolymer "resin" and a UV laser to build parts a layer at a time ( Kalpakjian,S. and
Schmid, S. (2000)). On each layer, the laser beam traces a part cross-section pattern on
the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the
pattern traced on the resin and adheres it to the layer below. Stereolithography requires
the use of support structures to attach the part to the elevator platform and to prevent
certain geometry from not only deflecting due to gravity, but to also accurately hold the
2-D cross sections in place such that they resist lateral pressure from the re-coater blade.
Supports are generated automatically during the preparation of 3-D CAD models for use
on the stereolithography machine, although they may be manipulated manually.
Supports must be removed from the finished product manually; this is not true for all
rapid prototyping technologies.
1.2 Problem Statement
Rapid prototyping is a most popular method to produce a product with a short time, low
cost and easy to use. There are many types of rapid prototyping system for example
stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling
(FDM), direct shell production casting (DSPC), 3D printers and direct fabrication
processes. Stereolitography is a type of rapid prototyping system. This is a method and
apparatus to produce solid objects by successively "printing" thin layers of the curable
material and inkjet printing system will be used. The apparatus that is used to produce a
part using this system is E-Darts machine. This machine not always can be function
perfectly and requires support structures. Structures that have overhangs and undercuts
must have supports that are designed and fabricated together with the main structure.
The problem may be occurred on this machine for example on the support system. This
project will be performing to examine the problem and design an improvement for this
support system.
2
1.3 Objective
Objective of this project are:
a) To understand the basic concept for rapid prototyping system.
b) To understand about the operation of resin based 3D printer
c) To examine the problem occurred on the support system for resin based 3D
printer.
d) To design an improvement on the support system for resin based 3D printer.
e) To examine the improvement of the resin based 3D machine.
1.4 Scope
This project will be concentrate on resin based 3D printer which can produce prototype
with faster compared to the other method. The machine that will be used is E-darts
machine. This machine will be operating to produce the specimen. Problem on this
machine will be examined. By examine the cause of this problem the solution can be
make and improvement on this machine also can be done by crate new design of the
support system.
3
CHAPTER 2
LITERATURE REVIEW
2.1 Rapid Prototyping
2.1.1 What Is The Rapid Prototyping?
In the development of a new product, there is invariably a need to produce a single
example or prototype of a designed part or system before the allocation of large amounts
of capital to new production facilities or assembly lines ( Kalpakjian,S. and Schmid, S.
(2000)). The main reasons for this need are that the capital cost is very high and
production tooling takes considerable time to prepare. Consequently, a working
prototype is needed for design evaluation and troubleshooting before a complex product
or system is ready to be produced and marketed.
Rapid prototyping systems have become commercially available; they can offer a
significant reduction in the product development life cycle (LIU, S. and WANG, Z.
(1998)). Currently, most of the basic research work on rapid prototyping is focused on
the development of new materials or techniques for deposition. New application-based
research is critically needed to make the rapid prototyping technology more costeffective, efficient and versatile, particularly during the part design, process planning
and support design stages.
4
2.1.2 Classification of the Rapid Prototyping Processes
Rapid Prototyping is a technology that also can be called as solid free from fabrication.
Rapid prototyping process can be divided into three different groups: subtractive,
additive and virtual processes. Subtractive process will remove the material from a
workpiece. The workpiece is larger than the final part. While the additive process will
build up a part by adding the material to produce the final part. Virtual process will use
an advanced computer-based visualization technologies. According to Kalpakjian, S.
and Schmid, S the computational steps in producing a stereolitography file is shown in
figure below.
Figure 2.1: The computational steps in producing a stereolitography file.
5
(a) Three-dimensional description part.
(b) The part is divided into slices (only one in 10 is shown).
(c) Support material is planned.
(d) A set of tool directions is determined to manufacture each slice. Also shown is the
extruder path at section A-A from (c) for a fused-deposition-modeling operation.
6
DESIGN IMPROVEMENT ON SUPPORT SYSTEM FOR RESIN
BASED 3D PRINTER
This report submitted accordance with requirement of the Universiti Teknikal Malaysia
Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Manufacturing
Design) with Honours.
by
CHE ROZAIDA BT CHE MOD
FACULTY OF MANUFACTURING ENGINEERING
MAY 2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
JUDUL: Design Improvement on Support System for Resin Based 3D Printer
SESI PENGAJIAN: 2008/2009 Semester 2
Saya : CHE ROZAIDA BT CHE MOD
mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
**Sila tandakan (√)
SULIT
TERHAD
(Mengandungi maklumat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
TIDAK TERHAD
Disahkan oleh:
(TANDATANGAN PENULIS)
(TANDATANGAN PENYELIA)
Alamat Tetap:
Lot.501, Kg. Cherang Melintang,
16210 Tumpat,
Kelantan.
Cop Rasmi:
Tarikh: _______________________
Tarikh: _______________________
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan
menyatakan sekali sebab dan tempoh Laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
ABSTRACT
Stereolitography is one of the rapid prototyping systems that can produce a part with
high accuracy and good surface finish. Stereolitography is a three-dimensional building
process and can produce a solid plastic model. The device that is called Stereolitography
Apparatus (SLA) is used to produce the part using stereolitography system.
Nevertheless, SLA has its own disadvantages. This apparatus needs support structures.
Other than that, there is a problem occurred on the support system. This project
presented the research on the support system for resin based 3D printer and E-Darts
machine is used for this purpose. Overall system for this machine understands first
including support system. Then, the specimen is design using CAD software and
produces it using E-Darts machine while the ultraviolet (UV) laser traces twodimensional cross-sections on the surface of a liquid resin(photosensitive liquid plastic) .
Problem occurred on the support system can be examined. Suggestion for designs
improvement can be create. The better design is chosen to make an improvement. Thus,
the problem occurred on the support system can be reduce.
ABSTRAK
Streolitografi merupakan salah satu sistem rapid prototyping yang boleh menghasilkan
sesuatu bahagian (objek) dengan ketepatan yang tinggi dan permukaan yang baik.
Stereolitografi merupakan proses pembentukan tiga dimensi dan dapat menghasilkan
model pepejal plastik. Peralatan yang dikenali sebagai Aparatus Stereolitografi (SLA)
digunakan untuk menghasilkan sesuatu bahagian (objek) meggunakan sistem
stereolitografi. Walaubagaimanapun, Aparatus Stereolitografi (SLA) mempunyai
keburukan yang tersendiri. Apparatus ini memerlukan struktur sokongan. Selain
daripada itu, terdapat juga masalah yang berlaku pada sistem sokongan. Projek ini
dijalankan untuk menunjukkan kajian terhadap sistem sokongan bagi pencetak resin tiga
dimensi dan mesin E-Darts digunakan bagi tujuan ini. Keseluruhan sistem bagi mesin
ini difahamkan terlebih dahulu termasuklah sistem sokongan. Kemudian, spesimen
direka bentuk menggunakan software Reka bentuk Terbantu Komputer (CAD) dan
seterusnya dihasilkan menggunakan mesin E-Darts di mana laser ultra-ungu mengesan
keratan rentas pada permukaan cecair resin (cecair plastik fotosensitif). Masalah yang
berlaku pada sistem sokongan dapat dikaji. Cadangan bagi pembaikan rekabentuk sistem
sokongan dapat diberikan. Reka bentuk yang terbaik akan dipilih untuk dibuat
pembaikan. Dengan itu, masalah yang berlaku pada sistem sokongan dapat dikurangkan.
DEDICATION
To my beloved family.
ACKNOWLEDGEMENT
First of all, I would like to express special appreciation to my supervisor, En Wahyono
Sapto Widodo for his great patience guiding me, give an advice, opinion, help and also
support me in the process to finish this project. Thank you so much for your good
support, various suggestion and comments.
I also would like to express gratitude to Puan Ruzy Haryati Bt Hambali as my supervisor
for PSM 1 with her guidance start from the title selection.
Then, I want to express my special appreciation to my parent, brother and sisters for
their encouragement and support during doing this project. Also to En. Mohd Fairus B.
Ninggal, thanks for your advice and suggestion. Finally, thank you to all of the lectures
and staff of Faculty of Manufacturing Engineering UTeM that give me full cooperation
to carry out this project.
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Contents
v
List of Tables
ix
List of Figures
x
List of Abbreviations
xiv
1. INTRODUCTION
1
1.1 Background
1
1.2 Problem Statement
2
1.3 Objective
3
1.4 Scope
3
2. LITERATURE REVIEW
4
2.1 Rapid Prototyping
4
2.1.1 What is the Rapid Prototyping?
4
2.1.2 Classification of the Rapid Prototyping Processes
5
2.1.3 Characteristic of Additive Rapid-Prototyping
7
2.2 Liquid-Base Rapid Prototyping System
9
2.2.1 Additive Processes
9
2.3 Stereolitography
10
2.3.1 Process of Stereolitography
10
2.3.2 Principle of SLA
12
2.3.3 Advantages and Disadvantages of SLA
13
2.4 Photopolymers
13
2.4.1 Photopolymerization
14
2.5 Supports System
16
2.5.1 Supports
16
2.5.2 Support System for Stereolitography
18
2.6 Support System for another Rapid Prototyping System
20
2.6.2 Support System for Fused Deposition Modeling System
24
3. METHODOLOGY
25
3.1 Flow Chart
25
3.2 Details of Methodology
29
3.2.1 Get the Title for PSM
29
3.2.2 Understand About the Title
29
3.2.3 Identify Requirement of the Title
29
3.2.4 Search the Information about Rapid Prototyping, Types and Process
29
3.2.5 Search Journals about Support Structure for Resin Based 3D Printer
29
3.2.6 Review the Journals
29
3.2.7 Gather the Information
30
3.2.8 Design the Specimen Using Software
30
3.2.9 Produce the Specimen Using Resin Based 3D Printer
30
3.2.10 Study the Support Structure
30
3.2.11 Investigate the Problem Occurred On Support System
30
3.2.12 Suggestion Improvement for the Support System
30
3.2.13 Validation
30
3.2.14 Design Improvement
30
3.2.15 Documentation for Final Project
31
4. PROJECT DESIGN
32
4.0 Project Background
32
4.1 Details of the Project
33
4.1.1 Apparatus
34
4.1.2 Components inside E-Darts Printer
35
4.1.3 Materials
36
4.1.4 Procedures
37
4.1.4.1 Stage 1: Design the Specimen
37
4.1.4.2 Stage 2: Preparation for the Construction
38
4.1.4.3 Stage 3: Setting for the Construction Conditions
41
4.1.4.4 Stage 4: Construction
43
4.1.4.5 Stage 5: Study the Support Structure
47
4.1.4.6 Stage 6: Design an Improvement for the Support Structure
48
4.1.4.7 Stage 7: Produce the Prototype
60
4.1.4.8 Stage 8: Analyze the Design
64
5. RESULT
65
5.1 Designs with Screw
66
5.2 New Design with Screw
67
5.3 Prototype Produce by Using FDM Machine
68
5.4 Construction Base Holder and Support Base after Hole Making
69
5.5 Result from the Design Analysis Using CosmosXpress
70
5.5.1 Analysis for the Construction Base Holder
70
5.5.2 Analysis for the Support Base
74
5.5.3 Analysis for the Screw
78
6. DISCUSSION
82
6.1 Current Design
83
6.2 New Design (After Improvement)
85
6.3 Result Obtained from Stress Analysis Using CosmosXpress
88
7. CONCLUSION AND RECOMMENDATION
89
7.1 Conclusion
89
7.2 Recommendation
90
REFERENCES
91
APPENDICES
A Gantt chart for PSM 1
B Gantt chart for PSM 2
C Design with Screw (1) Before Improvement
D Design with Screw (2) After Improvement
E Design with Clip
F Design with Glue Gun
G Current Design
LIST OF TABLES
2.1: Characteristic of Additive Rapid-Prototyping Technologies
A 1 Gantt chart for PSM 1
A 2 Gantt chart for PSM 2
7
LIST OF FIGURES
2.1
The Computational Steps in Producing a Stereolitography File
5
2.2
Schematic Illustration of the Stereolitography Process
11
2.3
The Principle of Stereolitography
11
2.4
Schematic Diagram of the Stereolitography (SLA) System
12
2.5
Schematic for A Simplified Free-Radical Photopolymerization
15
2.6
Transformation of Solid Model to Hatched Base Support
18
2.7
Support for Stereolitography System
19
2.8
E-Darts Process
20
2.9
Regions to Be Supported
22
2.10
Example of Self-Supporting Region
22
2.11
Region That Cannot Be Supported By Adjacent Sheet
23
2.12
Deflection of Sheet
24
2.13
Fused Deposition Modelling
24
3.1
Flow Charts for PSM
26
4.1
Computer
34
4.2
E-Darts Printer
34
4.3
Support Base (large size)
34
4.4
Support Base (small size)
34
4.5
Leveler
34
4.6
Syringe
34
4.7
Weighing Scale
35
4.8
Gloves
35
4.9
Inside E-Darts Printer
35
4.10
Support Base
35
4.11
Construction Base Holder
36
4.12
Side View of Construction Base Holder and Support Base
36
4.13
Liquid Resin Bath
36
4.14
Resin (KAYARD NAF-20)
36
4.15
Hardener
36
4.16
Specimen Design
37
4.17
Preparation for Construction
38
4.18
Preparation for Construction
38
4.19
Preparation for Construction
39
4.20
Preparation for Construction
39
4.21
Preparation for Construction
39
4.22
Preparation for Construction
40
4.23
Construction Base Holder and Construction Base
40
4.24
Windows E-Darts Controller
41
4.25
Parameter List Window
43
4.26
Start Support Construction
44
4.27
X, Y and Z Control Panel
45
4.28
Special Parameter Dialog Box
46
4.29
Holder Base and Resin Bath Condition
47
4.30
Support Base and Construction Base Holder
47
4.31
Current Design
48
4.32
Exploded View Drawing
49
4.33
Construction Base Holder Part
49
4.34
Construction Base Part
50
4.35
Support Base Part
50
4.36
Screw
51
4.37
Design with Screw
52
4.38
Exploded View
52
4.39
Exploded View Drawing
53
4.40
Design with Screw
54
4.41
Exploded View
54
4.42
Clip
55
4.43
Design with Clip
55
4.44
Exploded View
56
4.45
Exploded View Drawing
56
4.46
Glue Gun
57
4.47
Design with Glue Gun
58
4.48
Exploded View
58
4.49
Exploded View Drawing
59
4.50
FDM Machine (FDM 400mc)
60
4.51
Dimension for the Construction Base Holder Part
61
4.52
Drawing for the Construction Base Part
62
4.53
Material for New Support Base (acrylic)
63
4.54
Jigsaw
63
4.55
File
63
4.56
Hand Drill with Tool Size 2.5mm
63
4.57
Tap Wrench
64
4.58
Center Punch
64
5.1
Assemble Drawing for Design with Screw
66
5.2
Exploded View
67
5.3
Holder Part
68
5.4
Base Part
68
5.5
Construction Base Holder and Construction Base Part
68
5.6
Construction Base Holder
68
5.7
Support Base with New Size
69
5.8
New Design
69
5.9
Stress Result for Construction Base Holder
71
5.10
Deformation Result for Construction Base Holder
72
5.11
Design Check Result for Construction Base Holder
73
5.12
Stress Result for Support Base
75
5.13
Deformation Result for Support Base
76
5.14
Design Check Result for Support Base
77
5.15
Stress Result for Screw
79
5.16
Deformation Result
80
5.17
Design Check Result for Screw
81
6.1
Current Design
82
6.2
New Design
82
6.3
Construction Base with Constructions Base Holder
83
6.4
Support Base
83
6.5
Current Design
83
6.6
Construction Base Holder
85
6.7
Support Base
85
6.8
Screw (M3 x 8)
85
6.9
New Design
85
6.10
Current Size for Support Base
87
6.11
New Size for Support Base with Hole
87
LIST OF ABBREVIATIONS
ABS – Acrylo-nitrile Butadiene Styrene
CAD – Computer Aided Design
CPU – Central Processing Unit
DSPC - Direct Shell Production Casting
EB - Electron-Beam
FDM - Fused Deposition Modeling
PCA - Post-Cure Apparatus
RP – Rapid Prototyping
RP & M – Rapid Prototyping and Manufacturing
SLA - Stereolithography
SLS - Selective Laser Sintering
UV – Ultra-Violet
2D – Two Dimensional
3D – Three Dimensional
i
CHAPTER 1
INTRODUCTION
The purpose of this project is to make a design improvement on support system for resin
based 3D printer. The basic concept of rapid prototyping must be understand first. Then,
support system for resin based 3D printer was studied. By using 3D printer, 3D object
can be created by layering a material (plaster, cornstarch, resins) and it consist of an
inkjet layering printing system. 3D object can be created with a short time compared to
the other method. To examine the problem on support system, the main cause was
investigated and step to avoid this problem from occurred again will be done by doing a
design improvement on the machine. Some improvement on the support system for resin
based 3D machine is needed to make sure that this machine can perform it task with
efficient and perfectly. By doing this research this problem can be solved.
1.1 Background
Rapid prototyping (RP) is a terms which embraces a range of new technologies for
producing accurate parts directly from CAD models in a few hours, with little need for
human (Pham, D.T. and Gault, R.S. (1998)). This means that designers have the freedom
to produce physical models of their drawings more frequently, allowing them to check
the assembly and function of the design. RP technologies may be divided into the
addition material and removal material. The most popular among currently available RP
technologies is perhaps stereolitography.
1
Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable
photopolymer "resin" and a UV laser to build parts a layer at a time ( Kalpakjian,S. and
Schmid, S. (2000)). On each layer, the laser beam traces a part cross-section pattern on
the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the
pattern traced on the resin and adheres it to the layer below. Stereolithography requires
the use of support structures to attach the part to the elevator platform and to prevent
certain geometry from not only deflecting due to gravity, but to also accurately hold the
2-D cross sections in place such that they resist lateral pressure from the re-coater blade.
Supports are generated automatically during the preparation of 3-D CAD models for use
on the stereolithography machine, although they may be manipulated manually.
Supports must be removed from the finished product manually; this is not true for all
rapid prototyping technologies.
1.2 Problem Statement
Rapid prototyping is a most popular method to produce a product with a short time, low
cost and easy to use. There are many types of rapid prototyping system for example
stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling
(FDM), direct shell production casting (DSPC), 3D printers and direct fabrication
processes. Stereolitography is a type of rapid prototyping system. This is a method and
apparatus to produce solid objects by successively "printing" thin layers of the curable
material and inkjet printing system will be used. The apparatus that is used to produce a
part using this system is E-Darts machine. This machine not always can be function
perfectly and requires support structures. Structures that have overhangs and undercuts
must have supports that are designed and fabricated together with the main structure.
The problem may be occurred on this machine for example on the support system. This
project will be performing to examine the problem and design an improvement for this
support system.
2
1.3 Objective
Objective of this project are:
a) To understand the basic concept for rapid prototyping system.
b) To understand about the operation of resin based 3D printer
c) To examine the problem occurred on the support system for resin based 3D
printer.
d) To design an improvement on the support system for resin based 3D printer.
e) To examine the improvement of the resin based 3D machine.
1.4 Scope
This project will be concentrate on resin based 3D printer which can produce prototype
with faster compared to the other method. The machine that will be used is E-darts
machine. This machine will be operating to produce the specimen. Problem on this
machine will be examined. By examine the cause of this problem the solution can be
make and improvement on this machine also can be done by crate new design of the
support system.
3
CHAPTER 2
LITERATURE REVIEW
2.1 Rapid Prototyping
2.1.1 What Is The Rapid Prototyping?
In the development of a new product, there is invariably a need to produce a single
example or prototype of a designed part or system before the allocation of large amounts
of capital to new production facilities or assembly lines ( Kalpakjian,S. and Schmid, S.
(2000)). The main reasons for this need are that the capital cost is very high and
production tooling takes considerable time to prepare. Consequently, a working
prototype is needed for design evaluation and troubleshooting before a complex product
or system is ready to be produced and marketed.
Rapid prototyping systems have become commercially available; they can offer a
significant reduction in the product development life cycle (LIU, S. and WANG, Z.
(1998)). Currently, most of the basic research work on rapid prototyping is focused on
the development of new materials or techniques for deposition. New application-based
research is critically needed to make the rapid prototyping technology more costeffective, efficient and versatile, particularly during the part design, process planning
and support design stages.
4
2.1.2 Classification of the Rapid Prototyping Processes
Rapid Prototyping is a technology that also can be called as solid free from fabrication.
Rapid prototyping process can be divided into three different groups: subtractive,
additive and virtual processes. Subtractive process will remove the material from a
workpiece. The workpiece is larger than the final part. While the additive process will
build up a part by adding the material to produce the final part. Virtual process will use
an advanced computer-based visualization technologies. According to Kalpakjian, S.
and Schmid, S the computational steps in producing a stereolitography file is shown in
figure below.
Figure 2.1: The computational steps in producing a stereolitography file.
5
(a) Three-dimensional description part.
(b) The part is divided into slices (only one in 10 is shown).
(c) Support material is planned.
(d) A set of tool directions is determined to manufacture each slice. Also shown is the
extruder path at section A-A from (c) for a fused-deposition-modeling operation.
6