Solid based RP systems FDM

1. UNIT 2
SOLID BASED
RAPID PROTOTYPING
SYSTEMS

2. INTRODUCTION
 Solid Based Additive Manufacturing systems utilise
solids as the primary medium to create the part or
prototype.

3. FUSED DEPOSITION
MODELLING(FDM)

4. COMPANY
 Stratasys Ltd developed AM systems based on
Fused Deposition Modelling technology.
 The technology was first developed by Scott Crump
in 1988
 Patent was awarded in USA in 1992.
 Stratasys introduced first FDM AM machine in
1992.
 Its headquarters is in USA.

5. PRODUCTS/MODELS
 Stratasys manufactures 3D printing equipment and
materials that create physical objects directly from
digital data.
 Its system range from affordable desktop 3D printers to
large and advanced 3D production systems making 3D
printing more accessible than ever.

6. IDEA SERIES 3D PRINTERS

7. IDEA SERIES 3D PRINTERS
 Stratasys' Idea Series 3D printers are compact, light
and affordable desktop 3D printers that enhance
users' design capability at the push of a
button.
 With FDM technology, they liberate customers
creativity and accelerate the design process.
 These 3D printers bring professional 3D printing to
consumers desktops or small team workspaces.

8. SPECIFICATIONS OF IDEA SERIES 3D
PRINTERS

9. DESIGN SERIES 3D PRINTERS

10. DESIGN SERIES 3D PRINTERS
 Stratasys' Design Series 3D printers are built as
affordable and office- friendly AM systems.
 They are meant primarily for concept modelling,
creating product replicas and some functional
testing capabilities.
 Under the Design Series, there are two categories
of 3D printers
 Precision3D printers
 Performance 3D printers.

11. DESIGN SERIES 3D PRINTERS
 Precision 3D printers are based on PolyJet 3D
printing technology.

On the other hand, there are three machines in the
Performance 3D printers.
 Series Dimension 1200es
 Dimension Elite
 Fortus 250mc
 These are powered by FDM technology.

12. DESIGN SERIES 3D PRINTERS

Performance 3D printers use ABS plus thermoplastic to
produce the 3D models.
 The parts are durable and dimensionally stable, making
them perfect for tough testing.
 The raw materials are affordable, allowing frequent
iterative 3D modelling.

13. DESIGN SERIES 3D PRINTERS

14. PRODUCTION SERIES 3D PRINTERS

15. PRODUCTION SERIES 3D PRINTERS

Stratasys' Production Series 3D printers can create
large products on the factory floor, having a build size
larger than the office-friendly
Performance Series or the desktop Idea Series.
 They can create low- volume assembly fixtures and
jigs directly from computer-aided design (CAD) data.
 Thus they can be used for prototyping, tooling and
digital manufacturing for designers and engineers.

16. PRODUCTION SERIES 3D PRINTERS
 There are three FDM machines in the Production
Series
 Fortus 380mc
 Fortus 450mc
Fortus 900mc
 The Fortus 900mc 3D Production System offers
the use of the widest range of FDM materials.
 They include high- performance thermoplastics for
durable and accurate parts with strong mechanical ,
chemical and thermalproperties.

17. PRODUCTION SERIES 3D PRINTERS

18. MATERIALS

Stratasys Ltd. offers a wide range of AM materials,
including clear, rubberlike and biocompatible
photopolymers for the PolyJet machines.
 Tough high-performance thermoplastics for the FDM
machines.
 The wide range of materials enables designers and
engineers to build practically anything at any stage of
the product development cycle, from fast and affordable
concept modelling, to detailed, realistic and functional
prototyping, to certification testing, and to agile, low-risk
production.

19. MATERIALS
 Furthermore, FDM thermoplastics are used to build
tough, durable parts that are accurate, repeatable
and stable over time.
 Materials used include ABS, polycarbonate, FDM
Nylon-12 and ULTEMTM, a thermoplastic
polyetherimide (PTI) that has good thermal
resistance, high strength and stiffness, and broad
chemical resistance.

20. PROCESS
 In Stratasys' patented process,' a geometric model of a
conceptual design is created on CAD software which uses
.STL or Initial Graphics Exchange Specification (IGES) files.
 It can then be exported from the CAD software into the AM
systems where it is processed using Insight software or
CatalystEX software, which automatically generates
supports.
 Within this software, the CAD file is sliced into horizontal
layers after the part is oriented for the optimum build
position, and any necessary support structures are
automatically detected and generated.

21. PROCESS
 The slice thickness can be set manually anywhere
between 0.127 and 0.330 mm (0.005–0.013 in.)
depending on the needs of the models and the
machine.
 Tool paths of the build process are then generated
and downloaded to the FDM machine.

22. PROCESS
 Modelling material is in the form of a filament very much
like a stiff fishing line and is stored in a cartridge or
spool.
 The filament is fed into an extrusion head and heated to a
semi-liquid state.
 The material is then extruded through the head and then
deposited in ultra-thin layers from the FDM head, one
layer at a time.
 Since the air surrounding the head is maintained at a
temperature below the material's melting point, the exiting
material quickly solidifies.

23. PROCESS
 Moving on the x-y plane, the head follows the tool path
generated by the software, fabricating the desired
layer.
 When the layer is completed, the base plate moves
down one layer and the head starts creating the new
layer.
 Two filament materials are dispensed through a dual
tip mechanism in the FDM machine
 a primary material is used to produce the model geometry
 A secondary material, or release material, is used to
produce the support structures.

24. PROCESS
 The release material forms a bond with the primary
modeller material and can be broken away or washed
away with detergent and water upon completion of the
3D models

25. SCHEMATIC DIAGRAM OF FDM
PROCESS

26. STRENGTHS
 Fabrication of functional parts:
 Able to fabricate prototypes
 Fully functional parts can be fabricated using ABS
 They have 85% of the strength of the injection
moulded parts.
 This is especially useful in developing products that
require quick prototypes for functional testing.

27. STRENGTHS
 Minimal wastage:
 The FDM process builds parts directly by extruding
molten semi-liquids onto the model.
 material wastages are minimised
 There is little need to clean up the model after it has
been built.

28. STRENGTHS
 Ease of support removal:
 Breakaway support materials
 Soluble support materials
 They can be easily snapped off or simply washed
away in a water-based solution.
 Can get finished products very quickly
 There is very little or no post processing

29. STRENGTHS
 Ease of material change:
 Build materials, supplied in spool or cartridge form
 easy to handle
 can be changed readily when the materials in the
system are running low.
 This keeps the operation of the machine simple.

30. STRENGTHS
 Large build volume:
 FDM machines, especially the Fortus 900mc,
offer a larger build volume than most of the other
AM systems available.

31. WEAKNESSES
 Restricted accuracy:
 Parts built with the FDM process usually have
restricted accuracy due to the shape of the material used,
that is, the filament form.
 Typically, the filament used has a diameter of 1.27 mm
and this tends to set a limit on how accurate the part can
be achieved.
 However the newer FDM machines have made
significant improvements in mitigating this issue by using
better machine control.

32. WEAKNESSES
 Slow process:
 The building process is slow, as the whole cross-
sectional area needs to be filled with building materials.
 Building speed is restricted by the extrusion rate or the
flow rate of the build material from the extrusion head.

33. WEAKNESSES
 Unpredictable shrinkage:
 As the build material cools rapidly upon deposition from
the extrusion head, there will be thermal contraction
and stresses induced.
 As such, shrinkages and distortions in the model are
common and are usually difficult to predict.
 With experience, users may be able to compensate for
these issues by adjusting the process parameters of the
machine.

34. APPLICATIONS
 (1) Models and prototypes for conceptualisation and
presentation:
FDM 3D printers can create models and prototypes for new
product design and testing and build finished goods in low
volumes.

(2) Educational use: Educators can use FDM technology to
elevate research and learning in science, engineering, design
and art.

(3) Customisation of 3D models: Hobbyists and
entrepreneurs can use FDM to manufacture products in their
homes creating gifts, novelties, customised devices and
inventions.