RAPID PROTOTYPING APPLICATIONS FOR MANUFACTURING

Recent advances in stereolithography and selective laser sintering hav e had a significant impact on the overall quality of parts produced us ing these rapid prototyping processes. The development and implementat ion of 3D System's QuickCast(TM) resin and software for building inves tment casting patterns have proven to be major steps toward fabricatin g highly accurate patterns with very good surface finishes. As partici pants in the Beta est program for QuickCast(TM) resin and software, we experienced a steep learning curve and were able to build accurate pa rts in a short period of time. It is now possible using this technolog y to produce highly accurate prototype parts as well as acceptable fir st article and small lot size production parts. We use the Selective L aser Sintering (SLS) process to fabricate prototype wax patterns for i nvestment casting. DTM Corporation recently introduced the use of thei r polycarbonate material for fabricating investment casting patterns. The polycarbonate material is processed significantly faster with impr oved 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 castin g patterns using the SLS process. This report will focus on our succes ses with these new materials from the standpoints of application, accu racy, surface finish, and post processing. Also presented will be exam ples of parts manufactured by these processes.