LIQUID BASED SYSTEM

STEREOLITHOGRAPHY APPARATUS (SLA)

Models and Specifications
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 250 × 250 × 250 mm and use a He–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 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.
Process
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. 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 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.
Working Principle
The SLA process is based fundamentally on the following principles
(1) Parts are built from a photo-curable liquid resin that cures when exposed to a laser
beam (basically, undergoing the photopolymerization process) which scans across the surface
of the resin.
(2) 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.
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). 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. The process through
which photopolymers are cured is referred to as the photopolymerization process.
Photopolymerization
Loosely defined, polymerization is the process of linking small molecules (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.

Advantages of SLA
The main advantages of using SLA are:
1. Round the clock operation. The SLA can be used continuously and unattended
round the clock.
2. Good user support. The computerized process serves as a good user support.
3. Build volumes. The different SLA machines have build volumes ranging from small
to large to suit the needs of different users.
4. Good accuracy. The SLA has good accuracy and can thus be used for many
application areas.
 5. Good Surface finish. The SLA can obtain one of the best surface finishes amongst
RP technologies.
Disadvantages of SLA:
1. Requires support structures. Structures that have overhangs and undercuts must
have supports that are designed and fabricated together with the main structure.
2. Requires post-processing. Post-processing includes removal of supports and other
unwanted materials, which is tedious, time consuming and can damage the model.
3. Requires post-curing. Post-curing may be needed to cure the object completely and
ensure the integrity of the structure.
Applications
1. Prototypes for design, analysis, verification and functional testing.
2. Parts for prototype tooling and low volume production tooling.
3. Patterns for investment casting, sand casting and molding.
4. Tools for fixture and tooling design, and production tooling.
LIQUID BASED SYSTEM
Material Jetting (PolyJet) 3D Printing:

· It’s very similar to standard inkjet printing, just with each printed layer stacking up to
make a 3D part. It’s also one of the only technologies that allows for full color 3D
printing, and can also print multiple materials at the same time.

· Both PolyJet and Material Jetting are the same technology. PolyJet is the name patented
by Objet Geometries back in the late 1990s, whereas Material Jetting is the technical
name for the process.

· As with all technologies, you need a 3D printer file. Usually an STL file, you will then
need to send this file to 3D slicer program such as Cura. These programs will then work
out how to print your part based on the layer sizes and print settings.

· PolyJet is one of the most accurate 3D printing technologies, with accuracy of up to 16

microns as well as the ability to create extremely smooth finishes. Two aspects of
Material Jetting heavily influence part quality: jet droplet size (similar to laser spot size in
SLA); and layer height.
· Material Jetting is compatible with a great variety of materials and colors. With PolyJet,
you can create multi-colored or even full color 3D printer parts using Material Jetting,
and even have print parts with multiple different materials in different areas of the part!
PolyJet printers can print a near infinite range of colors since they’re compatible with
Pantone color ranges, much like a high quality 2D inkjet printer.

· PolyJet uses the same liquid polymer resins as Stereolithography, which are jetted and
then cured by being exposed to a UV light. This is somewhat similar to 2D inkjet
printing, just with printing layers on top of each other to create a solid part rather than
printing on paper.

· Since PolyJet uses photopolymers like SLA, so it could be said that the two processes
are similar.

· The process is similar to inkjet printing, just instead of jetting drops of ink onto paper,
PolyJet uses small nozzles to deposit droplets of liquid photopolymers onto the build tray.
As it is being jetted, the material is simultaneously cured by a UV light. The polymers are
heated to between 30-60°C to control their viscosity as they are jetted and printed.

· Parts created using this process require supports to protect the part from deforming or
warping, and are printed concurrently with the part. Supports are usually made from a
different material which is designed to separate from the part when dissolved in water.

· Since no extreme heating is used there is very little warping or shrinkage of parts
during the printing process. This helps reinforce PolyJet as one of the accurate and best
surface finishes of all the 3D printing technologies.

· Though PolyJet offers the best surface finishes of all additive manufacturing
technologies, there are still a number of post-processing techniques available. These
include sanding the part if the part is to be coated afterwards. Also, parts can be dyed and
painted to change color. However, with the ability to print in full color anyway, this isn’t
always necessary.

· There are a huge range of materials available to be used with PolyJet, literally
thousands. These range in color and chemical properties, from rigid, to flexible, to
castable. To be considered a suitable material for printing, the material needs to have low
viscosity and be able to be jetted in droplet form.

PolyJet / Material Jetting Advantages

● Accurate: the most dimensionally accurate 3D printing technology, up to 16 microns.
● Smooth surface finish: comparable to injection molding, hence Material Jetting has
applications in injection molding prototypes.
● Fast and scalable: PolyJet can print multiple parts simultaneously without loss of
speed unlike FDM or SLS 3D printers.
 ● Full color: not many technologies can produce full color prints — just Binder Jetting,
PolyJet and some Multi Jet Fusion printers. Add in the fact that multiple materials can
be printed in the same part, and Material Jetting really stands out. Moreover, the fact
that nearly infinite shades of color can be used make this extremely versatile for color
printing.

PolyJet / Material Jetting Disadvantages

● Poor mechanical properties: parts often have worse mechanical properties than parts
creating with technologies such as FDM or SLS. Like SLA 3D printed parts they are
vulnerable to heat and sunlight, and can lose strength over time.
● Very expensive: they are industrial 3D printers and materials can cost
$300-$1,000/kg, with industrial Material Jetting printers sometimes costing
$100,000+.

PolyJet / Material Jetting Applications

1. Realistic models for education: another common use of Material Jetting 3D printing
is to create realistic models, such as accurate anatomical models of human organs.
These models can then be used to help teach students how to perform medical
procedures so they have more experience before performing real surgeries. This
shortening of the learning curve is key in reducing fatality rates during surgeries
2. Full color prototypes: since full-color and smooth surfaces can be achieved, PolyJet
is the perfect method for detailed visual prototypes. This enables designers and
engineers to see how their product looks up close, and assess the details and
functionality.
3. creating patterns: It’s often used in creating patterns for molds to be used in other
processes such as injection molding. The original prototype is created using PolyJet,
and is then used to create many more injection molded products.
CASE STUDIES
Ford Uses Stereolithography to Cast Prototype
Tooling
With a single project triumph, Ford has begun a new era of “rapid manufacturing” —
applying QuickCast technology to the development of both prototype and, ultimately,
production tooling. Such innovation demonstrates the potential to save manufacturing
industries millions in tooling costs.
Ingenuity was Ford’s most critical ingredient. When production units of a rear wiper
motor cover for the 1994 Explorer were needed for testing, several tooling alternatives were
explored. Traditional methods would have provided the tool in three months. Ford used
QuickCast in its first application of rapid tooling by investment casting stereolithography
mold halves to create the hard tool.
They first built a SL model of the cover, fit it over the wiper motor to verify design
integrity, and found a clearance problem. The plastic part was modified by hand, the fit was
re-verified, and the CAD model was adjusted.
The SLA 250-generated QuickCast patterns resulted in a core and cavity pair
investment cast in A2 steel. Knowledge of the cast metal’s characteristics facilitated changes
in a second set of production tooling, e.g., inclusion of ejector holes and addition of cooling
lines. The turnaround time for the second set of tooling was only four weeks, and the cost for
“QuickCast Tooling” was only $5000 per tool set, compared to the $33 000 quoted for
machining a single tool. Ford was able to start durability and water flow testing 18 months
ahead of schedule, with costs reduced by 45% and time savings of more than 40% achieved.

Black & Decker Saves a Year by Using

Stereolithography to Prototype their Improved
Shearer/Shrub Trimmer Power Tool
Designers at Black & Decker had only 100 days to transform an idea for an improved
shearer/shrub trimmer power tool into an attractive functioning prototype that could be
introduced at an important trade show. The new power tool, which would expand the
company’s VersaPak outdoor power tool product line, had to undergo design, proofing,
building, assembly and testing of at least 30 copies of the product in that time frame. Failing
to deliver functioning prototypes would put Black & Decker back one year in introducing the
product to the market place. The new concept would offer a more ergonomically designed
shearer/shrub trimmer. This model would also be more streamlined in appearance. The new
design was also to incorporate, in the single body of the trimmer, an easy-access battery pop-
out.
Bose Saves Five Weeks Using Stereolithography
Over Traditional Hard Tooling
Bose Corporation, world leader in audio components and systems located in Framingham,
Massachusetts, needed appearance parts for two different car speaker grills, one being 101
mm (4 in) in diameter and the other 76 mm (3 in) in diameter, for actual road testing on an
Oldsmobile Aurora. Needing more than an SL prototype, Bose approached Drew Santin,
owner of Santin Engineering, and requested a short run of production parts in end-use
material which included uniform texture and multiple colors to match the car interior color
options. The catch? Parts needed to be delivered in exactly four weeks. Santin determined
that traditional hard tooling would take nine weeks to complete due to each part’s contoured
design, compound curvature parting line, and complex detail. Because of its ability to
produce a textured surface finish, its greater temperature control of the tool, and its durability
to guarantee a run of at least 500 parts, Santin turned to the Shaw process of rapid tooling for
successful delivery of these timesensitive parts.

Layering Technology, Laser and Laser Scanning

Almost all RP systems use layering technology in the creation of prototype parts. 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. In the SLA, a laser beam with a specified power and wavelength
is sent through a beam expanding telescope to fill the optical aperture of a pair of cross axis,
galvanometer driven, and beam scanning mirrors. These form the optical scanning system of
the SLA. The beam comes to a focus on the surface of a liquid photopolymer, 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.

Lasers are the most effective energy source in Additive Manufacturing since the laser beam
can transfer a large amount of energy into micro scale focal region instantaneously to solidify
or cure materials in air.
Therefore enabling high precision, high through put manufacturing for a wide range of
materials.
Laser scanners are non contact devices that capture millions of discrete data points to
measure an object or space using laser infra red technology that produces the detailed 3D
images in minutes.

CUBITAL’S SOLID GROUND CURING (SGC)

The Solid Ground Curing (SGC) System is produced by Cubital Ltd. and its address is
Cubital Ltd., 13 Hasadna St., P.O.B. 2375, Industrial Zone North Raanana, 43650 Israel.
Outside Israel, Cubital America Inc. is located at 1307F Allen Drive Troy, MI 48083, USA
and Cubital GmbH, at Ringstrasse 132 55543
Bad-Kreuznach, Germany. Cubital Ltd.’s operations began in 1987 as a spin-off from Scitex
Corporation and commercial sales began in 1991.

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 below 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.
SGC Process:-
The Cubital’s Solid Ground Curing process includes three main steps: data preparation, mask
generation and 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
package 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. The charged image is then developed with electrostatic toner.

Fig: Solid Ground curing process

Model Making

In this step, a thin layer of photopolymer resin is spread on the work surface (item 2). 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 unsolidified
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

Data Front End (DFE) workstation.
Model Production Machine (MPM). It includes:
Process engine,
1. Operator’s console,
2. Vacuum generator.( Automatic De waxing Machine (optional).)

Fig: Solider system block diagram SGC 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. 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.

1.Multiple parts may be processed and built in parallel by grouping them into batches (runs)
using Cubital’s proprietary software.
2.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.
3.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.

Applications
The applications of Cubital’s system can be divided into four areas:
1. 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.
2. Tooling and casting applications. Investment casting, sand casting, and
rapid, tool-free manufacturing of plastic parts.
3. Mold and tooling. Silicon rubber tooling, epoxy tooling, spray metal tooling, acrylic
tooling, and plaster mold casting.
4. Medical imaging. Diagnostic, surgical, operation and reconstruction
planning and custom prosthesis design.

Advantages and Disadvantages

The Solider system has the following advantages:
(1) 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.
(2) 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.
(3) Fault tolerance. It has good fault tolerances. Removable trays allow job changing
during a run and layers are erasable.
(4) Unique part properties. The part that the Solider system produces is reliable, accurate,
sturdy, machinable, and can be mechanically finished.
(5) 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.
(6) Minimum shrinkage effect. This is due to the full curing of every layer.
(7) 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.
(8) 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.

The Solider system has the following disadvantages:

(1) Requires large physical space. The size of the system is much larger than other systems
with a similar build volume size.
(2) 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.
(3) Waste material produced. The milling process creates shavings, which have to be cleaned
from the machine.
(4) Noisy. The Solider system generates a high level of noise as compared to other
systems.