The Fifth International Conference on Rapid Prototyping June 12-15, 1994

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1 Proceedings of The Fifth International Conference on Rapid Prototyping June 12-15, 1994 The Dayton Convention and Exhibition Center Dayton, Ohio U.S.A. Richard P. Chartoff, Allan J. Lightman, Joseph A. Schenk editors Sponsored by The Rapid Prototype Development Laboratory The Management Development Center The University of Dayton and The Edison Materials Technology Center (EMTEC) endorsed by The Society of Manufacturing Engineers (SME) The Society for Experimental Mechanics (SEM) 1994, The University of Dayton

2 Proceedings of The Fifth International Conference on Rapid Prototyping Table of Contents SESSION 1: NEW TECHNOLOGY SESSION CHAIR: Richard Chartoff, The University of Dayton Research Institute 3D PRINTING SURFACE FINISH IMPROVEMENTS THROUGH ON - LINE CONTROL, Eli Sachs, D. Brancazio, J. Milner, J. Bredt, J. Lee, A. Curodeau, M. Cima, J. Serdy, MIT 1 SOLID MODEL RAPID PROTOTYPING, A. Metcalf, Sanders Prototypes Inc. 11 SAHP - A PLAIN PAPER 3D PRINTER/PLOTTER PROCESS, E. Inui, K. Sugiyama, S. Morita & N. Kawaguchi, KIRA Corporation 15 THE DEVELOPMENT OF RAPID PROTOTYPING OF METALLIC COMPONENTS VIA ULTRA UNIFORM DROPLET DEPOSITION, M. Orme, K. Willis, J. Courter, University of California - Irvine 27 ULTRA HIGH RESOLUTION STEREOLITHOGRAPHY FOR 3D MICRO FABRICATION, K. Ikuta, T. Ogata & K. Hirowatari, Kyushu Institute of Technology 37 AN ADDITIVE FABRICATOR FOR HIGH SPEED PRODUCTION OF ARTIFICIAL LIMBS, J. Rovick, Northwestern University Medical School 47 ui

3 SESSION IT: TECHNOLOGY IMPROVEMENTS SESSION CHAIR: Eli Sachs, MIT RAPID PROTOTYPING WITH THE SELECTIVE LASER SINTERING & POLYFORM PROCESSES, J. Easwaran & L. Kimble, Western Michigan University & DTM Corporation 57 VIDEO-BASED CALIBRATION SYSTEM FOR GALVANOMETRIC SCANNERS, M. Pellechia & A. Lightman, Eastman Kodak & The University of Dayton 67 PRECISE & OPTIMIZED PROCESS REALIZATION FOR SOLID GROUND CURING, D. Kochan, T. Himmer & R. Hovtun, Dresden University & SINTEF 77 AUTOMATED FIBER REINFORCED COMPOSITE PROTOTYPES, R. Charan, T. Renault, A. Bagchi & A. Ogale, Clemson University 91 DEVELOPMENT OF A TABLE-TOP STEREOLITHOGRAPHY & ITS APPLICATION TO SOLID MODELING OF HUMAN SOFT TISSUE, M. Pellechia & A. Lightman, Eastman Kodak & The University of Dayton 99 REDUCING WARPAGE IN STEREOLITHOGRAPHY THROUGH NOVEL DRAW STYLES, J. Ullett, R. Chartoff, A. Lightman, D. Murphy & J. Li, The University of Dayton & 3D Systems 109 SESSION III: REVERSE ENGINEERING SESSION CHAIR: Tim Gornet, The University of Louisville CONVERTING 3D POINT DATA FILES INTO CAD SURFACES/MODELS, C. Schuster, Laser Design REVERSE ENGINEERING USING COMPUTED TOMOGRAPHY, R. Yancey, J. Stanley, D. Eliasen, S. Neel, R. Dzugan, ARACOR & EMTEC 141

4 SESSION IV: MATERIALS SESSION CHAIR: Ed Gargiulo, Du Pont VERIFYING FINITE ELEMENT ANALYSIS USING STEREOLITHOGRAPHY, R. Farrell & D. Roth, Penn State University - Erie 151 CONTROL PARAMETERS & MATERIAL SELECTION CRITERIA FOR FUSED DEPOSITION MODELING, J. Comb, W Priedeman & P. Turley, Stratasys, Inc. 163 INTERLAMINATE STRENGTH & PROCESSING EFFICIENCY IMPROVEMENTS IN LAMINATED OBJECT MANUFACTURING, S. Pak & G. Nisnevich, Helisys, Inc. 171 STEREOLITHOGRAPHY PROCESS MODELING: SHRINKAGE PREDICTION, L. Flach & R. Chartoff, The University of Dayton 181 SESSION V: SOFTWARE SESSION CHAIR: David Tait, Laserform PREFERRED DIRECTION OF BUILD FOR RAPID PROTOTYPING PROCESSES, D. Frank & G. Fadel, IWB Technical University of Munich & Clemson University 191 A GENETIC ALGORITHM FOR OPTIMIZING MULTIPLE PART PLACEMENT TO REDUCE BUILD TIME, J. Wodziak, G. Fadel & C. Kirschman, Clemson University 201 AN OBJECT-ORIENTED KNOWLEDGE BASED SIMULATION ESTIMATION OF THE DTM RAPID PROTOTYPING COSTS, R. Ragade, T Gornet, T. Osborne & K. Ellis, University of Louisville 211 COMPUTER AIDED SUPPORT STRUCTURE DESIGN FOR STEREOLITHOGRAPHY MODELS, D. Webb, V Gerdes & C. Chassapis, Stevens Institute of Technology 221 A NURBS-BASED APPROACH FOR RAPID PROTOTYPING REALIZATION, P. Vuyyuru, C. Kirschman, G. Fadel, A. Bagchi & C. Jara-Almonte, Clemson University 229 HOLLOWING RAPID PROTOTYPING PARTS USING OFFSETTING TECHNIQUES, M. Ganesan & G. Fadel, Clemson University 241

5 SESSION VI: APPLICATIONS SESSION CHAIR: Frost Prioleau, Plynetics RECENT DEVELOPMENTS IN THE USE OF RAPID PROTOTYPING TECHNIQUES TO PROTOTYPE DIE CAST PARTS, T. Mueller, Prototype Express 253 RAPID PROTOTYPING OF CENTRIFUGAL PUMP IMPELLERS, G. Clasby, Duriron 259 RAPID TOOLING - HOW DOES RAPID PROTOTYPING DELIVER?, D. Girouard, DTM Corporation 269 A NEW RAPID TOOLING METHOD FOR SHEET METAL FORMING DIES, D. Walczyk & D. Hardt, MIT 275 RAPID PROTOTYPE CASTING: THE FUNDAMENTALS OF PRODUCING FUNCTIONAL METAL PARTS FROM RAPID PROTOTYPING MODELS USING INVESTMENT CASTING, B. Sarkis, S. Kennerknecht, Cercast 291 QUICKCAST & RAPID PROTOTYPING: A CASE HISTORY AT FORD MOTOR COMPANY, K. Denton & P. Jacobs, Ford Motor Company & 3D Systems 301 SESSION VII: BUSINESS SESSION CHAIR: Joseph Schenk, The University of Dayton GLOBAL IMPLEMENTATIONS OF RAPID PROTOTYPING, A. Lightman & T. Wohlers, The University of Dayton & Wohlers Associates 321 RAPID PROTOTYPING COST ANALYSIS, D. Tait, Laserform 327 A BENCHMARKING COMPARISON OF COMMERCIAL TECHNIQUES IN RAPID PROTOTYPING, L. Schmidt, Chrysler Corporation 333 PROTOTYPE WAX PATTERN DIES USING STEREOLITHOGRAPHY, T. Mueller, Prototype Express 353 HOW CHRYSLER IS USING STEREOLITHOGRAPHY RAPID PROTOTYPING SURVEY RESULTS, L. Schmidt, Chrysler Corporation 359 VI

RAPID PROTOTYPING. Principles and Applications. RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA

RAPID PROTOTYPING. Principles and Applications. RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA RAPID PROTOTYPING Principles and Applications RAFIQ NOORANI, Ph.D. Professor of Mechanical Engineering Loyola Marymount University Los Angeles, CA WILEY JOHN WILEY & SONS, INC. CONTENTS Preface Acknowledgments