Study of an Innovative LOM-Based Multi-Materials Rapid Prototyping Process
Date Issued
2008
Date
2008
Author(s)
Li, Hsin-Chih
Abstract
The evolution of the new generation rapid prototyping (RP) technology has brought RP technology a new terminology named Rapid Production or Rapid Manufacturing. The efficient production of functional parts including RP part with insert, assembly part, and the multi-materials mock-up has been paid much attention in the current rapid prototyping technology. The inherent restrictions of the processes and materials are the main causes to refrain most of the rapid prototyping systems from making multi-materials functional parts. The Laminated Object Manufacturing (LOM), a kind of RP system, has great potential in this aspect since various materials are applicable to the process. On the other hand, the de-cubing problem of waste material of the process impedes its practical progress. In order to explore the new frontier of the RP technology in making multi-materials functional parts, a novel multi-materials LOM process is proposed in this study. In the proposed approach, two-stage cutting processes where a post cutting process following the normal cut-bond process are adopted to remove the waste material in-process such that manufacturing of multi-materials RP part can be accomplished. The object definition is the key concept in this new process. Each 2D contour in a layer is transformed as an object. Then the object manufacturing process is carried out according to the object definition of material, layer hierarchy, and related group. An algorithm together with its simplifying method is proposed to take all steps needed for different objects in one layer. A unique multi-material feeding mechanism is proposed in this study to achieve a reasonable tolerance of layer geometry. In addition, it can provide laminating materials with different thicknesses so that the number of the laminating layer can be reduced and the process efficiency can be significantly enhanced. More, a new forming methodology of the special supporting structure is also proposed by defining the blank area (waste-material area) as the object made of water-soluble material. Two case studies are investigated in the thesis. It is verified that not only the complex hollow part but also the multi-materials object is manufactured. The proposed new multi-materials laminated object manufacturing process is expected to make LOM more competitive besides opening up a new application field of RP technology.
Subjects
Rapid Prototyping
LOM
On-line De-cubing
Multi-Materials Layer Manufacturing
Functional Gradient Material
Type
thesis
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