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College of Engineering

Mechanical Engineering Department

Rapid Prototyping Lab

The Rapid Prototyping Laboratory at Michigan State University is now offering testing services to researchers and limited availability to the general public.

What is Rapid Prototyping?

Rapid Prototyping (RP) is the ability to generate three-dimensional models that need no machining or tooling. RP adds material layer by layer until the desired shape is achieved, instead of cutting away material by machining. RP allows for more flexibility than machining because the complexity of the model does not give any limitations to its production. RP generates 3D models quickly and accurately which can greatly reduce the research and development phase of product development, which can yield a lower cost to market.

The Machines and the Process

ZCorp 310 Plus

 

 

 

 

 

 

 

 

 

 

The ZPrinter 310 Plus creates physical models directly from digital data in hours instead of days. The ZPrinter 310 Plus is fast, versatile and simple, allowing engineers to produce a range of concept models and functional test parts quickly and inexpensively. The system is ideal for an office environment or educational institution, providing product developers easy access to a 3D Printer. The ZPrinter 310 Plus' sleek design and straightforward user interface make it the ideal entry-level rapid prototyping system. In addition, the versatility of the machine allows users to make parts quickly for early concept evaluation and testing, painted parts for a finished look, or patterns for casting applications.

 

The Materials

High Performance Materials

High Performance Composite Material can be used to make strong, high-definition parts and is the material of choice for printing color parts. It consists of a heavily engineered plaster material with numerous additives that maximize surface finish, feature resolution, and part strength. This material is ideal for:

New for 2007:

Casting Materials

Investment Casting Material can be used to quickly fabricate parts that can be dipped in wax to produce investment casting patterns. The material consists of a mix of cellulose, specialty fibers and other additives that combine to provide an accurate part while maximizing the absorption of wax and minimizing residue during the burn-out process.

Direct Casting Material can be used to create sand casting molds for non-ferrous metals. This material is a blend of foundry sand, plaster and other additives that have been combined to provide strong molds with good surface finish. It is designed to withstand the heat required to cast non-ferrous metals.

Specialty Materials

Snap-Fit Material has been optimized for infiltration with our Z-Snap™ epoxy to create parts with plastic-like flexural properties which are ideal for snap fit applications. It is a plaster-based system that produces parts with a more porous matrix, allowing them to absorb a greater quantity of the Z-Snap infiltrant.

Elastomeric Material has been optimized for infiltration with an elastomer to create parts with rubber-like properties. The material system consists of a mix of cellulose, specialty fibers and other additives that combine to provide an accurate part capable of absorbing the elastomer, which gives the parts their rubber-like properties.

 

In addition to the material options, Z Corp. parts can be sanded, drilled, tapped, painted and electroplated, further expanding the options available for finished part characteristics.

 

310P System Specifications

Build Size:

8” x 10” x 8”
(203 x 254 x 203 mm)

Layer Thickness:

User selectable at the time of printing; 0.0035”-0.008” (.089-.203 mm)

Material Options:

 

 

 Stratasys FDM1650

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An FDM1650 Stratasys Rapid Prototyping Machine is used to produce tangible models of products designed using a computer aided design system. The FDM1650 uses Fused Deposition Modeling (FDM) to turn computer-aided design (CAD) geometry into models that can be used for design reviews, manufacturability studies, investment casting patterns, and marketing. Each CAD file is converted to an .stl format. The .stl file is read into Stratasys' slicing software called insight. Insight breaks the model into individual slices, with each slice representing one layer of material. Insight then generates tool paths to fill the slices, which form the Stratasys Modeling Language (.sml) file. The .sml file is then downloaded to the FDM Hardware for modeling. In the FDM hardware, the FDM head moves in two horizontal axes across a foundation and deposits a layer of material for each slice. The material is heated by the FDM head so it comes out in a semi-liquid state. The successive layers fuse together and solidify to build up an accurate, three-dimensional model of the design. The overall tolerance is +/- 0.005" in the X, Y, and Z axes. Actual results depend on the model.

The Materials

Michigan State University uses a variety of inert, nontoxic materials for its models:

FDM1650 System Specifications

Build Size Parts up to 254mm x 241mm x 254 mm (9.5" x 9.5" x 10") can be built
Achievable Accuracy Models can be produced within an accuracy of
±.127 mm (±.005 in)
Modeling Materials ABS
Investment Casting Wax
MABS (methyl methacrylate ABS)
Layer Width / Thickness Operator may optionally select road widths between
.254 to 2.54 mm (.010 to .100 in) and thickness from .05 to .762 mm (.002 to .030 in)

The Drawing Files

Michigan State University can receive your drawing files in the following formats:

.prt (Unigraphics)   .sml   .stl   .dxf      IGES

You can send your drawing files, in one of the above formats, via e_mail to chalou@egr.msu.edu at MSU to be converted into RP files.