Sold freeform fabrication: a new manufacturing paradigm

Article Abstract:

Solid freeform fabrication (SFF), a term which takes in desktop manufacturing, rapid prototyping or layered manufacturing, potentially can accurately produce structurally sound 3-D objects designed with a computer and produced directly from a CAD database without part-specific tooling and without intervention of a human. The product could be available to the user in hours or even minutes. About 30 technologies address this area. In low-volume production, SFF cuts cost dramatically and drastically shortens time to completion. The new manufacturing technologies involved go into computer-integrated manufacturing environments well. SFF workstations may work with liquid, powder, gas, or sheets and light, often from laser sources, to solidify resins, and cost $50,000-$500,000. They may come from Z-Corp or Stratasys at the low end or from 3D Systems and DTM at the high end. Average build volume is about 250 mm3. Companies discussed include Scientific Measurement Systems Inc. (Austin, TX), which manufactures high-power X-ray scanning systems and works with the Laboratory for Freeform Fabrication at The University of Texas, Austin.

Process control instruments, Instruments and Related Products Manufacturing for Measuring, Displaying, and Controlling Industrial Process Variables, Electronic computers, Software Publishers, Electronic Computer Manufacturing, Plastic Products, Plastics Product Manufacturing, Production management, Communications Equipment, Communications Equipment Manufacturing, Graphics Software Pkgs (Micro), Process Instruments, Controls, Machine Tool (Metal Cutting Types) Manufacturing, Computer-Aided Design, Machine tools, metal cutting types, N/C Cutting Tools, Telecommunications equipment, Graphics software, Process control equipment, Numerically controlled machine tools, Cutting machines, 3D Systems Corp., DTM Corp., Z Corp., Stratasys, Scientific Measurement Systems Inc., SCMS

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Medical and prosthetic applications

Article Abstract:

A promising area for application of solid freeform fabrication (SFF), or of similar technology, is the making of replacements for body parts. The complex shapes are not easy to achieve. At the University of Texas, Austin, research is being carried out on the usefulness of selective laser sintering (SLS) with biocompatible material systems and on prosthetics, including sockets for below-the-knee amputees, made using SFF. For bone implants, calcium phosphate powder coated with poly-methyl methacrylate, as a binder, has been used in a spray dryer. A laser melts the coating, and later the parts are infiltrated with calcium phosphate solution and fired to remove the binder. Sintering at higher temperature is carried out. BioMedical Enterprises Inc., San Antonio, TX, has made preliminary studies with animals and it appears that in time mineralized bone fills in implants. Companies discussed include DTM Corp.

Science & research, Surgical Appliance and Supplies Manufacturing, Surgical appliances and supplies, Medical Instruments and Supplies, Medical Equipment and Supplies Manufacturing, Prosthetic Appliances, Medical Plastics, Medical equipment and supplies industry, Medical equipment industry, Prostheses and implants, Prosthesis, Plastics in medicine

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Integrating electronic and mechanical design

Article Abstract:

Design Edge Inc., Austin, TX, uses solid freeform fabrication (SFF) to get across the gap from electrical engineering, where 2-D CAD is used, to mechanical engineering and industrial designing, where 3-D CAD is used. Different computer platforms are often involved and the design activities often are located at a distance from one another, even in one enterprise. Design Edge puts together 3-D computer files of component parts. The files are used by affiliated prototyping services to turn out a desired item with such technologies as stereolithography apparatus (SLA) or selective laser sintering (SLS). Companies discussed include Honeywell, Symbol Technologies, 3M Telecom Systems and Parametric Technology, which has an E-CAD software module called Pro/Engineer that will work with electrical layout programs.

Services information, Industrial design, Three-dimensional graphics, Three dimensional graphics, Design Edge Inc.

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