Rapid prototyping applications at Sandia National Laboratories

Abstract

The Manufacturing Technologies Center at Sandia National Laboratories is responsible for manufacturing prototype mechanical and electromechanical components using state-of-the-art manufacturing processes. Stereolithography (SL) and Selective Laser Sintering (SLS) are rapid prototyping processes used to reduce product realization cycle time. Improvements in accuracy, surface finish, and overall part quality have had a significant impact on the functional use and applications of these processes. Stereolithography and selective laser sintering are laser based, layer additive processes that fabricate complex prototypes directly from three-dimensional CAD solid models. Materials currently available for use by the SL process are acrylic polymer, vinyl ether, and epoxy resins. Materials used by the SLS process are polycarbonate, investment casting wax, nylon, glass-filled nylon, and polymer coated metal. Sandia uses patterns generated from these processes to reduce the cycle time and cost of fabricating prototype investment castings to support internal programmatic requirements, as well as to support cooperative industrial projects focused on casting technology. Additional uses of the prototype models are verification of form, fit, and function, visual aids for manufacturing, master patterns, and rapid tooling. This presentation will focus on applications, case studies, accuracy, and unique uses of these processes at Sandia.The Manufacturing Technologies Center at Sandia National Laboratories is responsible for manufacturing prototype mechanical and electromechanical components using state-of-the-art manufacturing processes. Stereolithography (SL) and Selective Laser Sintering (SLS) are rapid prototyping processes used to reduce product realization cycle time. Improvements in accuracy, surface finish, and overall part quality have had a significant impact on the functional use and applications of these processes. Stereolithography and selective laser sintering are laser based, layer additive processes that fabricate complex prototypes directly from three-dimensional CAD solid models. Materials currently available for use by the SL process are acrylic polymer, vinyl ether, and epoxy resins. Materials used by the SLS process are polycarbonate, investment casting wax, nylon, glass-filled nylon, and polymer coated metal. Sandia uses patterns generated from these processes to reduce the cycle time and cost of fabricating prototyp...