Manufacturing Science and Technology: Technologies

Rapid Prototyping


	SL & SLS Assembly

	Pumps Picture Courtesy of ZCorp

The Rapid Prototyping Laboratory (RPL) supports internal design, manufacturing, and process development with three rapid prototyping (RP) technologies: Stereolithography (SL), Selective Laser Sintering (SLS), and 3D Printing (3DP).

Rapid prototyping uses advanced computer and laser technologies to produce complex three-dimensional prototypes in a fraction of the time required by more traditional technologies. The rapid prototyping process begins with a CAD solid model output to the appropriate RP file format. The file data is sliced into cross sections of 0.003 to 0.010 in. thickness. The cross sections are then fabricated in a layer additive process using one of the three available RP technologies.

The SL technology uses an ultraviolet laser to cure thin layers of epoxy photo-polymer. SL is used in the design iteration process to manufacture proof-of-concept models, models for design reviews, fit-check models, functional parts and patterns for castings or RTV molds. Accuracy is generally ±0.001 inch/inch with a minimum of ±0.002 inch.

The SLS technology uses a carbon dioxide (CO2) laser to fuse powdered polymer cross sections in a layer additive fashion. SLS is used to fabricate functional parts, pattern masters, conceptual models, fit check models, and mandrels made from DuraForm PA, a nylon based material. Typically, accuracy of the SLS process is ±0.002 inch/inch with a minimum of ±0.005 inch.

The 3DP technology uses ink-jet heads to print binder to fuse powdered polymer or ceramic cross sections in a layer additive fashion. This system has the capability of printing in full-color, communicating important information about parts, including engineering data, labeling, highlighting and appearance simulation. Parts are typically used as appearance prototypes for design and data review, and mock-ups for form and fit testing. The accuracy of the 3DP process is in the ±0.5% range.

Capabilities:


	Blade Picture Courtesy of ZCorp

Manufacturing of prototype components or assemblies from CAD solid models
CAD solid modeling
File manipulation and conversion
Reverse Engineering
Classified and proprietary SL and 3DP parts
Color printing for data analysis, labeling and appearance simulation
RTV molds and mold masters for urethane, epoxy, and RTV parts
Tooling for wax or foam parts
Investment casting patterns
Mandrels for composite structures
Special coatings for RP parts
Precision model assembly

Resources:

Three Stereolithography machines
Selective Laser Sintering machine
3D Printing machine with full RGB color capability
CAD solid modeling using Pro Engineer or Solidworks
Ability to utilize and manipulate a wide variety of data including: CAD solid models, radar, topographical, medical images, finite element analysis, MEMS design
State-of-the-art metrology laboratory including: coordinate measuring machine, video measuring system, and non-contact surface analyzer
Three-dimensional laser digitizing system
Complete machine shop including: three-, four-, and five-axis computer numerical control (CNC) mills, CNC lathes, electrical discharge machine, lathes, mills, and grinders

Accomplishments:


	MEMS Model


	Patient-Specific Pedicle Screw Placement Jigs

	Mini-Autonomous Robot Vehicle (MARV)

Fabrication of macro-scale MEMS components for design verification and visualization
Ability to support various government agencies with 3D topographic maps from either Synthetic Aperture Radar or USGS data
Design of complete process for fabrication of patient-specific pedicle screw placement jigs for foolproof spinal fusion surgeries
Quick turnaround of precision fixtures for neutron generator production
Uni-body fabrication to support development of mini-autonomous robot vehicle (MARV)
Support penetrator design and development through fabrication of scaled mock-ups
Fabrication of satellite boxes to support mock-up bench testing
Provide technical support and prototype fabrication resources to small businesses

Related articles

Sandia's Rapid Prototyping Expertise Could Help Surgeons Alleviate Chronic Back Pain, Sandia Lab News, May 17, 2002 [pdf]
Sandia Modelers Make Life Easier For New MEMS Designers, Sandia Lab News, August 10, 2001 [pdf]
Smart Machines: The Robotics Revolution, Sandia Technology, Volume 2, Number 2, Summer 2000 [pdf]

Contact:
Bart D. Chavez
Jeremy Palmer

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Rapid Prototyping