SL is used in the more » design iteration process to produce proof-of-concept models, hands-on models for design reviews, fit-check models, visual aids for manufacturing, and functional parts in assemblies. Sandia utilizes Stereolithography (SL) and Selective Laser Sintering (SLS) capabilities to support internal design and manufacturing efforts.
The driving force behind integrating these evolutionary processes into the design and manufacture of prototype parts is the need to reduce lead times and fabrication costs, improve efficiency, and increase flexibility without sacrificing quality. In the age of concurrent engineering and agile manufacturing, it is necessary to exploit applicable new technologies as soon as they become available. The introduction of rapid prototyping machines into the marketplace promises to revolutionize the process of producing prototype parts with production-like quality. Also presented will be examples of parts manufactured by these processes. This report will focus on our successes with these new materials from the standpoints of application, accuracy, surface finish, and post processing. Sandia is currently changing from investment casting wax to polycarbonate for the fabrication of investment casting patterns using the SLS process. The polycarbonate material is processed significantly faster with improved strength, dimensional stability, and without a support structure during the build process. DTM Corporation recently introduced the use of their polycarbonate material for fabricating investment casting patterns. We use the Selective Laser Sintering (SLS) process to fabricate prototype wax patterns for investment casting. It is now possible using this technology to produce highly more » accurate prototype parts as well as acceptable first article and small lot size production parts. The SLS process is used to fabricate patterns from materials such as investment casting wax, polycarbonate, and a new material called TrueForm PM resin and software, we experienced a steep learning curve and were able to build accurate parts in a short period of time. Sandia National Laboratories uses patterns generated from rapid prototyping processes to reduce the cycle time and cost of fabricating prototype and small lot production parts in support of a program called FASTCAST. Relatively recent advances in DTM Corporation`s selective laser sintering (SLS) and 3D Systems stereolithography (SL) processes have had a significant impact on the overall quality of patterns produced using these rapid prototyping processes. The quest for fabricating complex metal parts rapidly and with minimal cost has brought rapid prototyping (RP) processes to the forefront of the investment casting industry.
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