Rapid prototyping applications for manufacturing

Recent advances in stereolithography and selective laser sintering have had a significant impact on the overall quality of parts produced using these rapid prototyping processes. The development and implementation of 3D System`s QuickCast{sup TM} resin and software for building investment casting patterns have proven to be major steps toward fabricating highly accurate patterns with very good surface finishes. As participants in the Beta test program for QuickCast{sup TM} resin and software, we experienced a steep learning curve and were able to build accurate parts in a short period of time. It is now possible using this technology to produce highly accurate prototype parts as well as acceptable first article and small lot size production parts. We use the Selective Laser Sintering (SLS) process to fabricate prototype wax patterns for investment casting. DTM Corporation recently introduced the use of their polycarbonate material for fabricating investment casting patterns. The polycarbonate material is processed significantly faster with improved strength, dimensional stability, and without a support structure during the build process. Sandia is currently changing from investment casting wax to polycarbonate for the fabrication of investment casting patterns using the SLS process. This report will focus on our successes with these new materials frommore » the standpoints of application, accuracy, surface finish, and post processing. Also presented will be examples of parts manufactured by these processes. 6 refs., 10 figs.« less