Rapid prototyping of complex 3D designs into models

Citation

(2003), "Rapid prototyping of complex 3D designs into models", Aircraft Engineering and Aerospace Technology, Vol. 75 No. 4. https://doi.org/10.1108/aeat.2003.12775dab.003

Rapid prototyping of complex 3D designs into models

Rapid prototyping of complex 3D designs into models

Keywords: Stereolithography, Rapid prototyping, Design

Helping to convert often complex concepts and ideas into real 3D models, QinetiQ, one of the Europe's leading science and technology research organisation, has extended its Stereolithography Rapid Prototyping facility to provide a "one-stop shop" design and modelling service to the end-user market.

QinetiQ's Stereolithography Rapid Prototyping facility has built an enviable reputation within the UK product design and prototyping industry for fast, cost-effective, quality prototypes. To date these have mainly been supplied into the RP industry, but with a recent system upgrade and internal restructuring, QinetiQ is extending the bureau service to the commercial market.

Working directly with QinetiQ's Concept Modelling Design Office (CMDO), the stereolithography machine creates plastic components from a liquid photopolymer by building them in thin layers. The data for each layer is computer generated and is cured by an ultraviolet laser. Starting at the bottom layer, each subsequent layer is then "overcured" to the previous layer until a complete model has been formed. Creating a component in layers means the most complex 3D geometry's are simple to this technology.

"Producing a one-off component is a rapid way of proving a design, which can be beneficial when patenting. The availability of two resins provides customers the bureau service with the option of specifying finished prototypes that are more closely to the mimic production components", said Adrian Blackwell, QinetiQ RP Manager. "Complex Prototype fabrication can take months and cost thousands of pounds to produce using traditional methods. QinetiQ believes that it can produce the same prototype at a fraction of the time and cost."

QinetiQ's Stereolithography machine has been upgraded to the latest specification (SLA-5000) by the addition of a solid-state laser and Smart Sweep software.

The addition of DSM Somos 7120 and DSM Somos 9120 materials has also complemented the upgrade, giving customers a choice of specific application resins. DSM Somos 7120 is described as a rigid, humidity tolerant, high accuracy epoxy resin.

DSM Somos 9120 has similar properties to "polypropylene". It is a "functional" epoxy material, which is said to exhibit durability, robustness, superior fatigue and strong memory retention.

The models produced have many different uses, including "visual" concepts, spatial fit and function, tooling patterns, direct tooling and technical demonstrators. The largest individual component that can be produced is 500 x 500 x 585mm to produce. Larger models can be achieved by permanently bonding individual components together.

With extensive experience in using Stereolithography, QinetiQ's RP team advises customers on the best solution available, including post processing of components, for example, hand finishing, bonding, surface treatments or painting.

Details available from: QinetiQ. Tel: +44 (0) 1252 394627.