Laminated Object Manufacturing (LOM) – models and specifications, process, working principle, applications, advantages and disadvantages, case studies. Fused Deposition Modeling (FDM) – models and specifications, process, working principle, applications, advantages and disadvantages, case studies. Solid Based Rapid Prototyping Methods The basic common feature among these system is
that they utilize solids (in one form or the other) as the
primary medium to create the prototype.
Laminated Object Manufacturing Laminated Object Manufacturing (LOM) is an additive manufacturing system that produces 3D models with paper, plastic, sheet metal or composites.
Helisys, Corp. In, Torrance, CA developed LOM, led by
Michael Feygin.
LOM is actually more of a hybrid (combination) between
subtractive and additive processes, where the models are built up with layer of material, which are cut individually by a laser in the shape of cross section is being cut away. Laminated Object Manufacturing LOM is one of the fastest AM processes for parts with
larger cross sectional areas, which makes it ideal for
producing larger parts.
Laminated Object Manufacturing Principle of Operation:
LOM involves layer by layer lamination of paper
material sheets, cut using a CO2 laser, each sheet
reperesenting one cross sectional layers of the CAD
model of the part.
In LOM, the portion of the paper sheet which is not
confined within the final part is sliced into cubes of
material using a cross hatch cutting operations.
Laminated Object Manufacturing Principle of Operation:
Laminated Object Manufacturing (LOM), process
divided into three basic steps:
1. Pre – Processing
2. Building Processes
3. Post – Processing Laminated Object Manufacturing Principle of Operation: 1. Pre – Processing: This phase includes several operations. The initial steps include generating an image from CAD derived STL file of the part to be manufactured, processing input data and creating secondary structures. These are fully automated by LOM slice, the LOM system software, which calculates and controls the slicing functions to determine the layer thickness. Orienting (positioning) and merging the part on the LOM system are done physically. Laminated Object Manufacturing Principle of Operation: 1. Pre – Processing: These tasks are aided by LOM Slice, which provides a menu – driven interface to perform transformation (e.g., translation, scaling and mirroring) as well as merges. Laminated Object Manufacturing Principle of Operation: 2. Building Processes: In the building phase, thin layers of adhesive material are subsequently bonded to each other (layer by layer) and individually cut by CO2 laser beam. LOM Slice creates a cross section of the 3D model measuring the exact height of the model and slices the horizontal plane accordingly. Laminated Object Manufacturing Principle of Operation: 2. Building Processes: The laser beam power is designed to cut exactly the thickness of one layer of material at a time. The platform with the stack of previously formed layers descends and a new section of material advances. Laminated Object Manufacturing Principle of Operation: 3. Post Processing: The last phase, post processing, includes separating the part from its support material and finishing it. Normally a hammer and a putty knife are all that is required to separate the LOM block from the platform. The surrounding wall frame is lifted off the block to expose the cross hatched pieces of the excess material. Cross hatched pieces may then be separated from the part using wood carving tools. Laminated Object Manufacturing Principle of Operation: 3. Post Processing: Laminated Object Manufacturing Steps involved in LOM: Laminated Object Manufacturing Steps involved in LOM: 1. Create a 3D CAD file and translate it to LOM machine in STL format. 2. Process the STL file for orientation and slicing. 3. Once the machine is ON, the paper material is brought to the build surface. 4. Sheet is adhered to a substrate with a heated roller. 5. Laser traces desired dimensions of prototype. 6. Laser cross hatches non – part area to facilitate waste removal. Laminated Object Manufacturing Steps involved in LOM: 7. Platform with completed layer moves down out of the way. 8. Fresh sheet of material is rolled into position on the platform. 9. Platform move down into position to receive next layer. 10. The process is repeated until the part is build. Laminated Object Manufacturing LOM Materials: 1. Adhesive – Coated Sheet 2. Plastics 3. Metal Laminate. 4. Ceramics 5. Composites Note: Any sheet material with adhesive bonding can be utilized in Laminated Object Manufacturing Process. Laminated Object Manufacturing Process Parameter of LOM: 1. Laser Power: High power laser may burns excess material and cause poor part quality. Low power laser are suitable. 2. Heater Speed: High speed will not help in good adhesion. Slow Speed preferable to get good bonding between layers. 3. Material Advance Margin: Paper feed rate should be optimum in such a way that the fresh sheet and the burnt sheet will not meet. Laminated Object Manufacturing Process Parameter of LOM: 4. Support Wall Thickness: This controls the outer support of the part. It is better to keep same thickness value during build. 5. Heater Compression: It is the distance travelled by the heater in vertical direction to press the paper for bonding. 0.4 – 1 mm is optimum. Laminated Object Manufacturing Advantages: Process is not expensive. Fast build time. Finished part will have good accuracy and strength. Parts are not subjected to any chemical phase change. Process is capable of building large components. No need extra support structure. Laminated Object Manufacturing Disadvantages / Limitations: Only suitable for the materials in the sheet form. Sometimes the parts need some surface coating. Difficult to build small sized parts. Not able to withstand the mechanical loading. Time consuming during removing of support parts. Laminated Object Manufacturing Applications: Conceptual models. Investment castings pattern. Master patterns for silicon rubber injection tools. Medical devices Aerospace. Laminated Object Manufacturing Model and Specification of LOM Machine: Fused Deposition Modeling Process Fused Deposition modeling is an extrusion based additive manufacturing process, where the parts are produced by layer – by – layer techniques as other AM systems.
The other name of FDM is FFF (Fused Filament
Fabrication).
FDM was developed and commercialized by Stratasys,
Inc., of Eden Prairie, MN, in the early 1990’s as a concept modeling device which is now used more for creating casting masters and direct use prototyping. Fused Deposition Modeling Process Working Principle:
The principle of the FDM is based on the layer technology,
surface chemistry, and thermal energy. The material in filament (in spool) form is melted in a specially designed head, which extrudes it through the nozzle. As it is extruded, it is cooled and, thus solidifies to form the model. The model is built layer – by – layer. FDM depends on the STL data file for input and is capable of using multiple build materials Fused Deposition Modeling Process Working Principle: Fused Deposition Modeling Process Working Principle:
Loading of material (most of the times plastics)
Liquification of the material (melting of the material)
Application of pressure to move the material through
nozzle (to plot the material on the substrate)
Extrusion of the liquified filament.
Plotting according to a predefined path and in a controlled
and well – organized manner.
Fused Deposition Modeling Process Working Principle:
Bonding of the material to itself or any other build
materials to form an articulate solid structure.
Addition of support structures to enable complex
geometrical features. Fused Deposition Modeling Process Working Principle: Fused Deposition Modeling Process Heating Chamber: Fused Deposition Modeling Process Heating Chamber: The component of an FDM machine serves as two primary functions: 1. One is to change the direction of the filament flow, so that the material is extruded vertically downwards. 2. Secondly, to serve as a melting source for the material. The heating element is electronically control and has feedback thermocouple to allow for a suitable temperature all the way through. Fused Deposition Modeling Process Heating Chamber: The heating elements are maintained just above the melting point of the material, so that the filament passing from exit to the chamber is in a semi – liquid state. This allows for smooth extrusion as well as tight control on the material placement. Fused Deposition Modeling Process Process Parameters:
1. Liquefier / Chamber Temperature: High temperature
material melts quickly (but viscosity will be less). Low
temperature may not be sufficient to heat the filament.
Moderate temperatures (slightly above melting point of
the filament) would help in proper deposition.
Fused Deposition Modeling Process Process Parameters:
2. Stand – off Distance: This is the distance between
the nozzle tip to platform. High SOD leads to no control over deposition (deflection will be more). Low SOD leads to wide layer will affect the part accuracy.
3. Feed Rate: Higher feed rate can cause chamber
overflow if we use narrow nozzles. Low feed rate, the liquid material will be insufficient for deposition. Fused Deposition Modeling Process Process Parameters:
4. Nozzle Diameter: More diameter road width is high
and this affects the part accuracy. Less diameter, part accuracy is high but consumes more time.
5. Deposition Speed: High speed, deposition rate will
be high, but the amount of material deposited on the platform will be less (thin beads). Low speed, results in wider beads (affects the part accuracy). Fused Deposition Modeling Process Process Parameters:
6. Material Type: Material with low viscosity should be
deposited at low temperature. Material with high
viscosity should be deposited slightly high temperature.
7. Road Width: Depends on the nozzle diameter. If the
road width is high, Part accuracy is not up to the mark.
Narrow roads lead to good accuracy.
Fused Deposition Modeling Process Process Parameters:
8. Fill Spacing: If the space between two adjacent layer
is more, it affects part strength. If the space is too less
and they are deposited too close, it leads to bulging of
the component. Fused Deposition Modeling Process Advantages:
Fabrication of functional parts.
Can build end user components with all types of
thermoplastic materials.
Minimal wastage material.
Ease of support removal.
Ease of material Change.
Large Volume parts can build
Fused Deposition Modeling Process Disadvantages / Limitations:
Process is slower than laser based processes.
Building small features will be difficult to build with
FDM.
Few materials suffer from shrinkage.
Fused Deposition Modeling Process Applications:
Models for conceptual and presentation.
Prototype for design, analysis and functional testing.
Master pattern and tooling.
Medical applications. Fused Deposition Modeling Process Model and Specification of FDM Machine:
