쾌속조형 (Rapid Prototyping, RP) 기술의이해와응용

Transcription

1 캐드앤그래픽스 C&G TV 지식방송 / 이슈 쾌속조형 (Rapid Prototyping, RP) 기술의이해와응용 안성훈교수 서울대학교기계항공공학부

2 Outline Introduction Processes Applications Nano Composite Deposition System (NCDS) Summary

3 Introduction

4 NASA: Printing in Space Emergency case in 2008 summer FDM1600 test at zero gravity Johnson Space Center & Marshall Space Flight Center 2000

5 From 2D to 3D printing 2D sheet 2.5D Prismatic plate 3D structure

6 Rapid Prototyping --Verification of of product design --Function test -- Prototype --Biomedical implants -- Simulation of of surgery

7 Introduction to RP Other names of RP - Layered Manufacturing - Rapid Prototyping and Manufacturing - Solid Freeform Fabrication (SFF) - 3D printing Group of related technologies that are used to fabricate physical objects directly from CAD data Add and bond materials in layered form to create 3D objects

8 Advantages of RP No need to define a blank geometry No need to define set-ups and material handling No need to consider jigs, fixtures, and clamping No need to design mold and die

9 General System Configuration of RP

10 Stereo Lithography Process Geometry Input : STL file format - Developed for STereo Lithography - De facto standard for RP data - Most CAD systems support STL format

11 Typical Errors in STL file

12 Stair-Step Effect Surface roughness vs. build time

13 Support Structures

14 Processes

15 1. Stereo Lithography Apparatus (SLA) Developed by 3D Systems, Inc. Laser beam will scan the surface following the contours of the slice SLA-3500

16 Micro SLA Parts Gear Turbine Horse Dog S. Kawata et al, 2001

17 SLA Parts Collins' Hyperbolic Heptagon Carlo H. Séquin, UC Berkeley

18 2. Selective Laser Sintering (SLS) Developed by The University of Texas at Austin Powders are spread over a platform by a roller A laser sinters selected areas causing the particles to melt and then solidify

19 SLS Process Sintering laser beam polymer coating laser beam metal bonded powders powders bonded powders powders

20 3. Laminated Object Modeling (LOM) Developed by Helysis The undersurface of the foil has a binder that when pressed and heated by the roller causes it to glue to the previous foil. The foil is cut by a laser following the contour of the slice Helisys 2030E LOM machine Part envelope size 32"x22"x20"

21 LOM-based Technique Paper Lamination Technology (PLT) System Cutting knife < Kira Solid Center > -Type: PLT-A4 - Model Material: Exclusive use sheet paper ( m) - Paper Thickness: 0.08mm, 0.15mm -Resolution: ±0.05mm (X, Y), ±0.1mm (Z) - Accuracy: ±0.2mm

22 4. Fused Deposition Modeling (FDM)

23 Stratasys 1650 FDM Machine

24 FDM Parts 3D Yin-Yang shapes 3D Hilbert curves Carlo H. Séquin, UC Berkeley

25 FDM Parts (cont.) GPS module for PDA

26 5. 3D Printers Developed at MIT Parts are built upon a platform situated in a bin full of powder material. Carlo H. Séquin, UC Berkeley 3-D printing method developed by Sachs and colleagues (2000)

27 3D Printer Parts Z- corp (3D Printer) Carlo H. Séquin, UC Berkeley

28 3D Printer Parts (cont.) Z- corp (3D Printer) Carlo H. Séquin, UC Berkeley

29 6. Digital Light Processor (DLP) Light sensitive Acrylic resin solidifies when it is exposed to the light source Array of one million tiny mirrors Build in mm Mirror module Envisiontec Perfactory system

30 7. Shape Deposition Manufacturing (SDM) Developed by Stanford University/CMU Uses deposition and milling Provides good surface finish

31 RP Processes and Materials Rapid Prototyping Powder Liquid Solid 1 component 1 component + binder 2 component Melting (excess of material) Gluing (sheets) Polymerization Selective Laser Sintering 3D Printing Interference Melting Laminated Object Mfg. Foil Polymerization Melting + Solidification Liquid Polymerization Shape Melting Fused Deposition Mfg. Ballistic Particle Mfg. Light single frequency Light two frequencies Heat Lamps Laser beam Holography Beam Interference Solid Thermal Polymerization Streolithography Streolithography Holographic Interference Solid J.P. Kruth, Material Incress Manufacturing by Rapid Prototyping Techniques, Annals of the CIRP 40 (2) (1991), pp

32 Issues in RP Materials Rapid Fabrication of functional parts - Structural - Optical - Surface Roughness - Electrical - Thermal - Color -

33 FDM Software Three Levels STL file Tessellated Stereolithography file export from solid modeling package SSL file Sliced Layer File, Support Calculation Proper part orientation can drastically affect build time, support requirements, and part strength SML file Raster, Build Parameters, time estimation

34 Case study: FDM 1. Tessellated (Triangulated) format 4. Road Generation 2. Vertically Sliced File 5. SML firle 3. Support Calculation

35 Micro Structure of FDM

36 Resin Infiltration Raw FDM ABSi During Infiltration After Infiltration Transmissivity(%) Wave length(nm) Transmissivity(%) Raw material Infiltration Infiltration+Sanding Air Gap(inch) Ahn, S. H., Lee, C. S., and Jung, W. B., 2004, "Development Translucent FDM Parts by Post-processing," Rapid Prototyping Journal, Vol. 10, No. 4, pp

37 Tensile Strength Definition of build direction in the NCDS and FDM specimens Each specimen consisted of 6 layers with various raster orientations - Axial [0 ] - Criss-cross [45 /-45 ] - Cross [0 /90 ] - Transverse [90 ] Definition of build direction in the 3DP specimens [0 ] [45 ] [90 ] Loading Direction Each specimen with various raster orientations - Axial [0 ] - Diagonal [45 ] - Transverse [90 ] Ahn, S. H., Baek, C., Lee, C. S., and Ahn, I. S., 2003, "Anisotropic Tensile Failure Model of Rapid Prototyping Parts -Fused Deposition Modeling (FDM), International Journal of Modern Physics B, Vol. 17, No. 4, pp

38 Tensile Strength Result of Tensile Strength Test - Build direction caused the anisotropic behavior of RP parts - Tensile strength of human bone is 60~160MPa Ahn, S. H., Baek, C., Lee, C. S., and Ahn, I. S., 2003, "Anisotropic Tensile Failure Model of Rapid Prototyping Parts -Fused Deposition Modeling (FDM), International Journal of Modern Physics B, Vol. 17, No. 4, pp

39 Applications

40 Flash Memory Reader CATIA modeling: 5 hours FDM process: 10 hours Post-process : 24 hours Total prototyping time : 39 hours

41 Architectures A machine mounted on rails might be used to build multiple houses Ian et al., Rapid prototyping for architectural models, 2002 Rotunda model (SLS nylon)

42 Materialization of arts Materialise group Lifting the kouros out of the Mammoth The original Volomandra Kouros and the SLA replica

43 MRP (Medical rapid prototyping) Magnetic Resonance Imaging (MRI) 1 neck of Sung-Hoon Ahn 3 8

44 3D model creation process 3D Digital image Data transfer process Evaluation of design :Using CAD program RP medical model validation RP medical model production University College London (UCL)

45 Knee Joint Xian Jiaotong University

46 Implanted joint Xian Jiaotong University

47 Organ Printing Medical University of South Carolina, USA Deposition of cell and gell layers to construct 3-dimensional structure Perfusion of bioreactor Schematic picture of bio-printer Methods of dispensing cells

48 Tissue Engineering Vacanti, et al Yan, et al CAD modeling RP part Rehabilitated ear

49 Robot Micro component Micro robot by Sandia Lab

50 Mold Making Rapid Tooling (RT) Core and cavity sets produced by RapidTool DTM's RapidTool process for rapid mold making

51 Nano Composite Deposition System (NCDS)

52 NCDS Hardware Z axis control Deposition; Rapid Prototyping Cutting; Milling High speed spindle Hybrid; Both Dispenser UV lamp Microscope Micro needle Micro endmill SPECIFICATIONS Micro needle Micro endmill Granite Base X and Y axis control 3 Axes-stage Dispenser Micro needle Micro tool High speed spindle UV curing system Controller 1μm resolution 15 ~ 700 kpa φ 140 μm ~ φ 800 μm φ 100 μm ~ φ 1000 μm Max. 46,000rpm 0 ~ 400 W, λ = 365 nm PMAC (Multi-tasking board)

53 NCDS (cont.) Hybrid process: depositing + machining Air cylinder High speed spindle Micrometer Barrel I Barrel II Micro needle Micro tool Conceptual process of NCDS

54 NCDS (cont.) Process planning 3D MODEL Deposition Machining SLICING PROCESS PLANNING Part material Support material CONVENTIONAL DEPOSITON SYSTEM NO DEPOSITION CURING LAST LAYER? YES POST-PROCESS DEPOSITION CURING MACHINING LAST LAYER? YES NO HYBRID SYSTEM Deposition and Machining Support Machining Part Deposition Machining Molding / Casting 3D PART Heat Hemisphere, PLGA (85:15) Demolding

55 Example of stapes Stapes - The smallest bone in human body - Part size: width 2.5mm / height 3.5mm - 40wt% Hydroxyapatite + Acrylic resin - Mold (using wax) machining part deposition surface machining demolding 3.4mm 3.0mm Geometry of stapes

56 Scaffold for Bone Growth Bio-degradable polymer PLGA 85/15 PLGA 85/ wt% HA Size: Φ 5mm 10mm

57 Drug Delivery System (DDS) Specimen for zero-order release test Scaffold type DDS (controlled pore size) (a) (b) (c) (d) Fabricated drug delivery device of scaffold shape (15 layers, [0 8/90 7], 5mm 5mm) 2mm 2mm size of DDS for implantation 5-FU(10wt%)/PLGA(85:15)(85wt%)/HA(5wt%)

58 DDS (cont.) In vivo test with Sprague-dawley Rat Sprague-dawley Rat Anesthetize mouse Remove hairs Incise back skin Prepare scaffold DDS Insert the scaffold Suture the skin

59 DDS (cont.) Collecting implanted DDS form Sprague-dawley rat (a) (b) 40 Cylinder (c) Cumulative amount of released drug (%) Scaffold Time (days) (a) Resection of back skin of the rat, (b) DDS in the back of the rat, and (c) DDS in resected skin

60 Summary

61 Summary Basic mechanism of Rapid Prototyping was introduced. Various RP processes and their materials were introduced: - SLA, SLS, LOM, FDM, 3DP, DLP, SDM, etc. - Polymer, paper, metal, composite, etc. Various applications were reviewed - Product development - Architecture, medical domain, tissue engineering, robot, and mold making. Using RP technology, 3D parts with specific functionality can be fabricated.

62 Thank you for your attention!! Innovative Design and Integrated Manufacturing Lab. Director & Professor Sung-Hoon Ahn Credit for assistant: Hyung-Jung Kim, Won-Shik Chu, Min-Saeng Kim