1. Group 2 | SLS 3D Printer Background
Additive Manufacturing Selective Laser Sintering
- Rapid CAD to 3D Object
- Made of successive 2D layers
- Prototyping benefits to many industries
https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/
Methods
- Stereolithography (SLA) >$5000 http://www.arptech.com.au/slshelp.htm
- Fused Deposition Moulding (FDM) >$500
- Selective Laser Sintering (SLS) >$10000
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

2. Group 2 | SLS 3D Printer Project Problem
Problem Statement:
Develop an SLS 3D printer with comparable cost and performance to small-business FDM 3D printers
currently on the market
There Exists a Need for an Economic
SLS 3D Printer for: SLS Literature:
- Additive manufacturing research - No support during print - Pan/Tilt
- Material scientists - Improved chemical resistance over SLA - CO2 Laser
- Education institutions - Increased density and strength over FDM - Heated Powder Beds
- Small businesses
- Hobbyists
Patents:
Design Criteria: US Patent #8172562:
- Completely safe - SLS Printer with translating powder
- Most basic/simply functional design box
- Under $600 (supplied funds)
- Sold for a cost equal to current small-business 3D US Patent #8187522:
printer - Describes the SLS process
1) Lay a layer of powder
- Prints large variety of sinter-able powder 2) Irradiate the powder to solidify at required areas
- Thermoplastics, metals, ceramics, organics 3) Repeat steps 1 and 2 to create a 3D object
(chocolate)
- Robust and reliable hardware and software
- Professional and attractive appearance
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

3. Group 2 | SLS 3D Printer Project Planning
05-Nov
12-Nov
19-Nov
26-Nov
10-Sep
17-Sep
24-Sep
03-Dec
10-Dec
17-Dec
24-Dec
31-Dec
04-Mar
11-Mar
18-Mar
25-Mar
04-Feb
11-Feb
18-Feb
25-Feb
01-Oct
08-Oct
15-Oct
22-Oct
29-Oct
07-Jan
14-Jan
21-Jan
28-Jan
01-Apr
Component
Design
Problem Formulation
Testing
Select Solution
Preliminary Design Deliverables
Gantry Design
Powder Applicator Design
Frame Design
Software Design
Melting Properties Test
Aquire Materials
Final Design Presentation
Final Design Reports
Assemble Frame
Test Arduino IO
Gantry Install
Electrical Wiring
Applicator Install
Test Hardware
Integrate Software
Safety Verification Test
Basic Full Integration Test
Optimization
Potential Contacts
Professor Toyserkani, The University of Waterloo or Coherent
- 3D printing related research - Laser company
- Bulk chocolate powder
- Potential supplies - Borrow high-power laser
for increased printing time
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

4. Group 2 | SLS 3D Printer Morphological Chart
Subtractions Solutions
Frame Material Aluminum Plastic Wood
Safety Enclosure Fully Enclosed Laser-safe Plexiglass
Laser Type CO2 Laser Laser Diode
Stationary
Laser
Laser Positioning XY Gantry Pan/Tilt Mirror
Translating
Powder Box
Cylindrical Wedge Radial
Powder Transferring Roller Slider Dispensing
Optical Lens Vertical
Adjustment Adjustment
Laser Diameter
Adjustment
Temperature Control Thermo Electric Cooler (TEC) Fan
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

5. Group 2 | SLS 3D Printer Alternative Designs
Design 1 Design 2 Design 3
Wood Plastic Aluminum
Full Enclosure Plexiglass Enclosure Full Enclosure
Laser Diode Laser Diode Laser Diode
Pan & Tilt XY Gantry XY Gantry
Cylindrical Roller Wedge Slider Wedge Slider
TEC TEC TEC
Note: Laser Diameter Adjustment was removed from design due to difficulty and time constraint
Criteria Priority Table Decision Matrix
Ease of Criteria Safety Ease Cost Acc. Speed Weight Total
Criteria Safety Cost Accuracy Speed Weight Total Rank
Construction
Weighting
Safety 1 1 1 1 1 5 1 100 90 70 60 50 40
Factor
Ease of
0 1 1 1 1 4 2
Construction
4x100 5x90 5x70 5x60 8x50 4x40
Design 1 2060
= 400 = 450 = 350 = 300 = 400 = 160
Cost 0 0 1 1 1 3 3
Accuracy 0 0 0 1 1 2 4 6x100 7x90 6x70 6x70 7x50 6x40
Design 2 2660
= 600 = 630 = 420 = 420 = 350 = 240
Speed 0 0 0 0 1 1 5
9x100 8x90 8x90 8x60 6x50 7x40
Design 3 3240
= 900 = 720 = 720 = 480 = 300 = 280
Weight 0 0 0 0 0 0 6
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

6. Group 2 | SLS 3D Printer References
3D Printer Choices for $20,000 or Less, Worldwide Guide to Rapid Prototyping http://www.additive3d.com/
3dpr_cht.htm, Oct 5th, 2012
Rapid Prototyping, Excalibur Engineering Services, http://www.excalibur-engineering-services.com/rapidprototyping.htm,
Oct 13th, 2012
Solid Concepts, Stereolithography (SLA) Gallery, https://www.solidconcepts.com/resources/galleries/stereolithography-
sla-gallery/, Oct 13th, 2012
ARPTECH - Rapid Prototyping Services, http://www.arptech.com.au/slshelp.htm, Oct 13th, 2012
United States Patent and Trademark Office, #8172562, http://patft.uspto.gov/netacgi/nph-Parser?
Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-
bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,172,562&OS=8,172,562&RS=8,172,562, Oct 13th, 2012
United States Patent and Trademark Office, #8187522, http://patft.uspto.gov/netacgi/nph-Parser?
Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-
bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,187,522&OS=8,187,522&RS=8,187,522, Oct 13th, 2012
3D Printing - From CAD file to Complex Metal Part, Layer by Layer - Direct Metal Laser Sintering, http://
www.youtube.com/watch?v=28B8NvBFU0E, Oct 13th, 2012
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar