UNIVERSITI TEKNIKAL MALAYSIA MELAKA DESIGN IMPROVEMENT ON SUPPORT SYSTEM FOR RESIN BASED 3D PRINTER This report submitted accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Manufacturing Design) with Honours. by CHE ROZAIDA BT CHE MOD FACULTY OF MANUFACTURING ENGINEERING MAY 2009
UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA JUDUL: Design Improvement on Support System for Resin Based 3D Printer SESI PENGAJIAN: 2008/2009 Semester 2 Saya : CHE ROZAIDA BT CHE MOD mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: (TANDATANGAN PENULIS) Alamat Tetap: Lot.501, Kg. Cherang Melintang, 16210 Tumpat, Kelantan. Tarikh: (TANDATANGAN PENYELIA) Cop Rasmi: Tarikh: ** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh Laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
ABSTRACT Stereolitography is one of the rapid prototyping systems that can produce a part with high accuracy and good surface finish. Stereolitography is a three-dimensional building process and can produce a solid plastic model. The device that is called Stereolitography Apparatus (SLA) is used to produce the part using stereolitography system. Nevertheless, SLA has its own disadvantages. This apparatus needs support structures. Other than that, there is a problem occurred on the support system. This project presented the research on the support system for resin based 3D printer and E-Darts machine is used for this purpose. Overall system for this machine understands first including support system. Then, the specimen is design using CAD software and produces it using E-Darts machine while the ultraviolet (UV) laser traces twodimensional cross-sections on the surface of a liquid resin(photosensitive liquid plastic). Problem occurred on the support system can be examined. Suggestion for designs improvement can be create. The better design is chosen to make an improvement. Thus, the problem occurred on the support system can be reduce.
ABSTRAK Streolitografi merupakan salah satu sistem rapid prototyping yang boleh menghasilkan sesuatu bahagian (objek) dengan ketepatan yang tinggi dan permukaan yang baik. Stereolitografi merupakan proses pembentukan tiga dimensi dan dapat menghasilkan model pepejal plastik. Peralatan yang dikenali sebagai Aparatus Stereolitografi (SLA) digunakan untuk menghasilkan sesuatu bahagian (objek) meggunakan sistem stereolitografi. Walaubagaimanapun, Aparatus Stereolitografi (SLA) mempunyai keburukan yang tersendiri. Apparatus ini memerlukan struktur sokongan. Selain daripada itu, terdapat juga masalah yang berlaku pada sistem sokongan. Projek ini dijalankan untuk menunjukkan kajian terhadap sistem sokongan bagi pencetak resin tiga dimensi dan mesin E-Darts digunakan bagi tujuan ini. Keseluruhan sistem bagi mesin ini difahamkan terlebih dahulu termasuklah sistem sokongan. Kemudian, spesimen direka bentuk menggunakan software Reka bentuk Terbantu Komputer (CAD) dan seterusnya dihasilkan menggunakan mesin E-Darts di mana laser ultra-ungu mengesan keratan rentas pada permukaan cecair resin (cecair plastik fotosensitif). Masalah yang berlaku pada sistem sokongan dapat dikaji. Cadangan bagi pembaikan rekabentuk sistem sokongan dapat diberikan. Reka bentuk yang terbaik akan dipilih untuk dibuat pembaikan. Dengan itu, masalah yang berlaku pada sistem sokongan dapat dikurangkan.
DEDICATION To my beloved family.
ACKNOWLEDGEMENT First of all, I would like to express special appreciation to my supervisor, En Wahyono Sapto Widodo for his great patience guiding me, give an advice, opinion, help and also support me in the process to finish this project. Thank you so much for your good support, various suggestion and comments. I also would like to express gratitude to Puan Ruzy Haryati Bt Hambali as my supervisor for PSM 1 with her guidance start from the title selection. Then, I want to express my special appreciation to my parent, brother and sisters for their encouragement and support during doing this project. Also to En. Mohd Fairus B. Ninggal, thanks for your advice and suggestion. Finally, thank you to all of the lectures and staff of Faculty of Manufacturing Engineering UTeM that give me full cooperation to carry out this project.
TABLE OF CONTENT Abstract Abstrak Dedication Acknowledgement Table of Contents List of Tables List of Figures List of Abbreviations i ii iii iv v ix x xiv 1. INTRODUCTION 1 1.1 Background 1 1.2 Problem Statement 2 1.3 Objective 3 1.4 Scope 3 2. LITERATURE REVIEW 4 2.1 Rapid Prototyping 4 2.1.1 What is the Rapid Prototyping? 4 2.1.2 Classification of the Rapid Prototyping Processes 5 2.1.3 Characteristic of Additive Rapid-Prototyping 7 2.2 Liquid-Base Rapid Prototyping System 9 2.2.1 Additive Processes 9 2.3 Stereolitography 10 2.3.1 Process of Stereolitography 10 2.3.2 Principle of SLA 12 2.3.3 Advantages and Disadvantages of SLA 13 2.4 Photopolymers 13 2.4.1 Photopolymerization 14 2.5 Supports System 16
2.5.1 Supports 16 2.5.2 Support System for Stereolitography 18 2.6 Support System for another Rapid Prototyping System 20 2.6.2 Support System for Fused Deposition Modeling System 24 3. METHODOLOGY 25 3.1 Flow Chart 25 3.2 Details of Methodology 29 3.2.1 Get the Title for PSM 29 3.2.2 Understand About the Title 29 3.2.3 Identify Requirement of the Title 29 3.2.4 Search the Information about Rapid Prototyping, Types and Process 29 3.2.5 Search Journals about Support Structure for Resin Based 3D Printer 29 3.2.6 Review the Journals 29 3.2.7 Gather the Information 30 3.2.8 Design the Specimen Using Software 30 3.2.9 Produce the Specimen Using Resin Based 3D Printer 30 3.2.10 Study the Support Structure 30 3.2.11 Investigate the Problem Occurred On Support System 30 3.2.12 Suggestion Improvement for the Support System 30 3.2.13 Validation 30 3.2.14 Design Improvement 30 3.2.15 Documentation for Final Project 31 4. PROJECT DESIGN 32 4.0 Project Background 32 4.1 Details of the Project 33 4.1.1 Apparatus 34 4.1.2 Components inside E-Darts Printer 35 4.1.3 Materials 36 4.1.4 Procedures 37
4.1.4.1 Stage 1: Design the Specimen 37 4.1.4.2 Stage 2: Preparation for the Construction 38 4.1.4.3 Stage 3: Setting for the Construction Conditions 41 4.1.4.4 Stage 4: Construction 43 4.1.4.5 Stage 5: Study the Support Structure 47 4.1.4.6 Stage 6: Design an Improvement for the Support Structure 48 4.1.4.7 Stage 7: Produce the Prototype 60 4.1.4.8 Stage 8: Analyze the Design 64 5. RESULT 65 5.1 Designs with Screw 66 5.2 New Design with Screw 67 5.3 Prototype Produce by Using FDM Machine 68 5.4 Construction Base Holder and Support Base after Hole Making 69 5.5 Result from the Design Analysis Using CosmosXpress 70 5.5.1 Analysis for the Construction Base Holder 70 5.5.2 Analysis for the Support Base 74 5.5.3 Analysis for the Screw 78 6. DISCUSSION 82 6.1 Current Design 83 6.2 New Design (After Improvement) 85 6.3 Result Obtained from Stress Analysis Using CosmosXpress 88 7. CONCLUSION AND RECOMMENDATION 89 7.1 Conclusion 89 7.2 Recommendation 90 REFERENCES 91
APPENDICES A Gantt chart for PSM 1 B Gantt chart for PSM 2 C Design with Screw (1) Before Improvement D Design with Screw (2) After Improvement E Design with Clip F Design with Glue Gun G Current Design
LIST OF TABLES 2.1: Characteristic of Additive Rapid-Prototyping Technologies 7 A 1 Gantt chart for PSM 1 A 2 Gantt chart for PSM 2
LIST OF FIGURES 2.1 The Computational Steps in Producing a Stereolitography File 5 2.2 Schematic Illustration of the Stereolitography Process 11 2.3 The Principle of Stereolitography 11 2.4 Schematic Diagram of the Stereolitography (SLA) System 12 2.5 Schematic for A Simplified Free-Radical Photopolymerization 15 2.6 Transformation of Solid Model to Hatched Base Support 18 2.7 Support for Stereolitography System 19 2.8 E-Darts Process 20 2.9 Regions to Be Supported 22 2.10 Example of Self-Supporting Region 22 2.11 Region That Cannot Be Supported By Adjacent Sheet 23 2.12 Deflection of Sheet 24 2.13 Fused Deposition Modelling 24 3.1 Flow Charts for PSM 26 4.1 Computer 34 4.2 E-Darts Printer 34 4.3 Support Base (large size) 34 4.4 Support Base (small size) 34 4.5 Leveler 34 4.6 Syringe 34 4.7 Weighing Scale 35 4.8 Gloves 35 4.9 Inside E-Darts Printer 35 4.10 Support Base 35 4.11 Construction Base Holder 36 4.12 Side View of Construction Base Holder and Support Base 36 4.13 Liquid Resin Bath 36
4.14 Resin (KAYARD NAF-20) 36 4.15 Hardener 36 4.16 Specimen Design 37 4.17 Preparation for Construction 38 4.18 Preparation for Construction 38 4.19 Preparation for Construction 39 4.20 Preparation for Construction 39 4.21 Preparation for Construction 39 4.22 Preparation for Construction 40 4.23 Construction Base Holder and Construction Base 40 4.24 Windows E-Darts Controller 41 4.25 Parameter List Window 43 4.26 Start Support Construction 44 4.27 X, Y and Z Control Panel 45 4.28 Special Parameter Dialog Box 46 4.29 Holder Base and Resin Bath Condition 47 4.30 Support Base and Construction Base Holder 47 4.31 Current Design 48 4.32 Exploded View Drawing 49 4.33 Construction Base Holder Part 49 4.34 Construction Base Part 50 4.35 Support Base Part 50 4.36 Screw 51 4.37 Design with Screw 52 4.38 Exploded View 52 4.39 Exploded View Drawing 53 4.40 Design with Screw 54 4.41 Exploded View 54 4.42 Clip 55 4.43 Design with Clip 55 4.44 Exploded View 56
4.45 Exploded View Drawing 56 4.46 Glue Gun 57 4.47 Design with Glue Gun 58 4.48 Exploded View 58 4.49 Exploded View Drawing 59 4.50 FDM Machine (FDM 400mc) 60 4.51 Dimension for the Construction Base Holder Part 61 4.52 Drawing for the Construction Base Part 62 4.53 Material for New Support Base (acrylic) 63 4.54 Jigsaw 63 4.55 File 63 4.56 Hand Drill with Tool Size 2.5mm 63 4.57 Tap Wrench 64 4.58 Center Punch 64 5.1 Assemble Drawing for Design with Screw 66 5.2 Exploded View 67 5.3 Holder Part 68 5.4 Base Part 68 5.5 Construction Base Holder and Construction Base Part 68 5.6 Construction Base Holder 68 5.7 Support Base with New Size 69 5.8 New Design 69 5.9 Stress Result for Construction Base Holder 71 5.10 Deformation Result for Construction Base Holder 72 5.11 Design Check Result for Construction Base Holder 73 5.12 Stress Result for Support Base 75 5.13 Deformation Result for Support Base 76 5.14 Design Check Result for Support Base 77 5.15 Stress Result for Screw 79 5.16 Deformation Result 80
5.17 Design Check Result for Screw 81 6.1 Current Design 82 6.2 New Design 82 6.3 Construction Base with Constructions Base Holder 83 6.4 Support Base 83 6.5 Current Design 83 6.6 Construction Base Holder 85 6.7 Support Base 85 6.8 Screw (M3 x 8) 85 6.9 New Design 85 6.10 Current Size for Support Base 87 6.11 New Size for Support Base with Hole 87
LIST OF ABBREVIATIONS ABS Acrylo-nitrile Butadiene Styrene CAD Computer Aided Design CPU Central Processing Unit DSPC - Direct Shell Production Casting EB - Electron-Beam FDM - Fused Deposition Modeling PCA - Post-Cure Apparatus RP Rapid Prototyping RP & M Rapid Prototyping and Manufacturing SLA - Stereolithography SLS - Selective Laser Sintering UV Ultra-Violet 2D Two Dimensional 3D Three Dimensional i
CHAPTER 1 INTRODUCTION The purpose of this project is to make a design improvement on support system for resin based 3D printer. The basic concept of rapid prototyping must be understand first. Then, support system for resin based 3D printer was studied. By using 3D printer, 3D object can be created by layering a material (plaster, cornstarch, resins) and it consist of an inkjet layering printing system. 3D object can be created with a short time compared to the other method. To examine the problem on support system, the main cause was investigated and step to avoid this problem from occurred again will be done by doing a design improvement on the machine. Some improvement on the support system for resin based 3D machine is needed to make sure that this machine can perform it task with efficient and perfectly. By doing this research this problem can be solved. 1.1 Background Rapid prototyping (RP) is a terms which embraces a range of new technologies for producing accurate parts directly from CAD models in a few hours, with little need for human (Pham, D.T. and Gault, R.S. (1998)). This means that designers have the freedom to produce physical models of their drawings more frequently, allowing them to check the assembly and function of the design. RP technologies may be divided into the addition material and removal material. The most popular among currently available RP technologies is perhaps stereolitography. 1
Stereolithography is an additive fabrication process utilizing a vat of liquid UV-curable photopolymer "resin" and a UV laser to build parts a layer at a time ( Kalpakjian,S. and Schmid, S. (2000)). On each layer, the laser beam traces a part cross-section pattern on the surface of the liquid resin. Exposure to the UV laser light cures, or, solidifies the pattern traced on the resin and adheres it to the layer below. Stereolithography requires the use of support structures to attach the part to the elevator platform and to prevent certain geometry from not only deflecting due to gravity, but to also accurately hold the 2-D cross sections in place such that they resist lateral pressure from the re-coater blade. Supports are generated automatically during the preparation of 3-D CAD models for use on the stereolithography machine, although they may be manipulated manually. Supports must be removed from the finished product manually; this is not true for all rapid prototyping technologies. 1.2 Problem Statement Rapid prototyping is a most popular method to produce a product with a short time, low cost and easy to use. There are many types of rapid prototyping system for example stereolithography (SLA), selective laser sintering (SLS), fused deposition modeling (FDM), direct shell production casting (DSPC), 3D printers and direct fabrication processes. Stereolitography is a type of rapid prototyping system. This is a method and apparatus to produce solid objects by successively "printing" thin layers of the curable material and inkjet printing system will be used. The apparatus that is used to produce a part using this system is E-Darts machine. This machine not always can be function perfectly and requires support structures. Structures that have overhangs and undercuts must have supports that are designed and fabricated together with the main structure. The problem may be occurred on this machine for example on the support system. This project will be performing to examine the problem and design an improvement for this support system. 2
1.3 Objective Objective of this project are: a) To understand the basic concept for rapid prototyping system. b) To understand about the operation of resin based 3D printer c) To examine the problem occurred on the support system for resin based 3D printer. d) To design an improvement on the support system for resin based 3D printer. e) To examine the improvement of the resin based 3D machine. 1.4 Scope This project will be concentrate on resin based 3D printer which can produce prototype with faster compared to the other method. The machine that will be used is E-darts machine. This machine will be operating to produce the specimen. Problem on this machine will be examined. By examine the cause of this problem the solution can be make and improvement on this machine also can be done by crate new design of the support system. 3
CHAPTER 2 LITERATURE REVIEW 2.1 Rapid Prototyping 2.1.1 What Is The Rapid Prototyping? In the development of a new product, there is invariably a need to produce a single example or prototype of a designed part or system before the allocation of large amounts of capital to new production facilities or assembly lines ( Kalpakjian,S. and Schmid, S. (2000)). The main reasons for this need are that the capital cost is very high and production tooling takes considerable time to prepare. Consequently, a working prototype is needed for design evaluation and troubleshooting before a complex product or system is ready to be produced and marketed. Rapid prototyping systems have become commercially available; they can offer a significant reduction in the product development life cycle (LIU, S. and WANG, Z. (1998)). Currently, most of the basic research work on rapid prototyping is focused on the development of new materials or techniques for deposition. New application-based research is critically needed to make the rapid prototyping technology more costeffective, efficient and versatile, particularly during the part design, process planning and support design stages. 4
2.1.2 Classification of the Rapid Prototyping Processes Rapid Prototyping is a technology that also can be called as solid free from fabrication. Rapid prototyping process can be divided into three different groups: subtractive, additive and virtual processes. Subtractive process will remove the material from a workpiece. The workpiece is larger than the final part. While the additive process will build up a part by adding the material to produce the final part. Virtual process will use an advanced computer-based visualization technologies. According to Kalpakjian, S. and Schmid, S the computational steps in producing a stereolitography file is shown in figure below. Figure 2.1: The computational steps in producing a stereolitography file. 5
(a) Three-dimensional description part. (b) The part is divided into slices (only one in 10 is shown). (c) Support material is planned. (d) A set of tool directions is determined to manufacture each slice. Also shown is the extruder path at section A-A from (c) for a fused-deposition-modeling operation. 6