Keywords
Citation
(1999), "Powder based rapid prototyping system", Aircraft Engineering and Aerospace Technology, Vol. 71 No. 4. https://doi.org/10.1108/aeat.1999.12771dab.004
Publisher
:Emerald Group Publishing Limited
Copyright © 1999, MCB UP Limited
Powder based rapid prototyping system
Powder based rapid prototyping system
Keywords: Umak, Rapid prototyping
A new rapid prototyping process for 3D solid models that is thought to be between three and ten times faster than more traditional systems and works directly from a printer port connection to a PC or CAD system is launched in the UK by Umak of Birmingham.
Umak, which has had extensive success with the Helysis rapid prototyping process in companies such as the Ford Motor Company and Nottingham University, sees the new Z402 Concept Modeller as a complementary product widening the application of the technology.
The Z402, manufactured by Z-Corporation of Somerville in Massachusetts, creates a model up to 250mm x 200mm x 200mm by distributing a layer of non-toxic cellulose powder onto a movable platen. This is followed by a programmable routine whereby a two-axis head with 128 individual jets, similar to an inkjet printer, sprays a 14mm wide trail of binder fluid over the model build area only covering the cross-sectional area solid portion of the shape programmed from the CAD file.
Once the platen has been covered by the travelling jet head, it is lowered equal to a depth of one powder layer thickness, which could be between 0.1mm and 0.2mm, and the next layer of power spread ready for the process to be repeated. Build rate is fast, at up to 50mm per hour and, once complete, the component is simply dusted or vacuumed to remove any excess powder that is not fused to the 3D shape.
Once removed from the machine, the 3D model can be coated with a hot wax or epoxy solution to give extra strength and stability.
In the USA, users such as NASA, Kodak, Toyota and Pratt & Whitney have reportedly saved over $20,000 on tooling costs and used the process for investment casting aluminium and titanium, sand castings and prototype components. Another more macabre application has been the production of complete skulls to help surgeons prepare for special surgical operations.
Motorola is utilising a Z402 machine in its Cell Phone Division where engineers have been able to design, print and revise their concepts in a single day and at a leading automotive company build time for a block and two heads is typically just over eight hours and a manifold in five hours. Says Tony Parker of Creative Technical Solutions in the USA, "In little over a year we have often built dozens of parts a day. Almost 300 companies have benefited from our service".
Details from Umak Limited, Birmingham, B11 2RQ. Tel: +44 (0)121 766 8844; Fax: +44 (0)121 766 8998. Further details of the Z402 machine are available on http://www.corp.com