design and analysis of sla printer

ME 54600 CAD/CAM Tools and Application Fall 2016

Prof. Daniel Aw Prof. Hazim El-Mounayri

PROJECT FINAL

DESIGN AND ANALYSIS OF A

STEREOLITHOGRAPHY PRINTER

Satyajeet Udavant

IUPUI, Indianapolis

ME 546 CAD/CAM satyajeet udavant

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PARTICULARS

Sr no Topic Page

1 OBJECTIVE 3

2 INTRODUCTION 3

3 SUMMARY OF ACCOMPLISHMENTS 6

4 CAD 6

5 Analysis 9

6 Meshing 10

7 Constraints 13

8 Results from modal analysis 14

9 CFD Analysis 19

10 Results and conclusion 20

11 References 21


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OBJECTIVE

The objective is to have a sound knowledge of the procedure start to finish in making of a 3d printer with

special focus on the following:

I. Design components of SLA 3d printer.

II. Assembly.

III. Finite Element Analysis - Using Ansys for structural

IV. Finite Element Analysis - CFD

INTRODUCTION

SLA printer sold since 1988 and costs from 5,000 USD to 450,000 USD. In this process a polymer, creating

a solitary layer of set tar - the principal cut of the question under development. The underlying layer is

then brought down incrementally by the stature of the following cut, where upon the layer is recovered

with pitch and another is followed on top of it. This methodology is rehashed until the whole part is

manufactured. By space resolved laser induced polymerization of a liquid monomer into a solid polymer

complex shapes can be quickly produced in SLA. Recently the technology is developed in different areas.

Like DLP, where a complete plane is scanned as compared to line tracing of laser. CLIP, is even faster as it

uses LED as photon source for polymerization.

The solid modelling software CREO Parametric is a software used to create the various part modules and is also used for assembling those parts together to create an appropriate mechanism.

For the final project of the 3 credit course, I worked for all the three aspects of a product development to make the project more complete.

1. Design – The SLA printer under consideration is similar to that of any vat polymerization printer. Ex Fromlabs 2. Most of the design parameter and data is used from online sources. The printer designed is similar to that of the BeamMaker.


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2. Assembly- the various parts that are created are assembled so that it can be tested for the further

analysis. 3. Analysis – we used Ansys Workbench for the structural and modal analysis. 4. Materials: For this project the ideal materials needed and required considering overall aspect of

the printer is fiberglass. Fiberglass (or fibreglass) is a type of fiber-reinforced plastic where the reinforcement fiber is specifically glass fiber. The glass fiber may be randomly arranged, flattened into a sheet (called a chopped strand mat), or woven into a fabric Fiberglass batt insulation is made by forming spun-glass fibers into batts. At an insulation plant, the product feedstock is weighed and sent to a melting furnace. The raw materials are melted in a furnace at very high temperatures. To be used in fiberglass, glass fibers have to be made with very low levels of defects. Fiberglass is a strong lightweight material and is used for many products. Although it is not as strong and stiff as composites based on carbon fiber, it is less brittle, and its raw materials are much cheaper.


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Relevant information was also taken by measuring the outside dimensions of the SLA printer Formlabs 2

available in Additive Manufacturing Lab, SL 009, IUPUI.

Following is the fig of the printer whose dimensions are measured to be as

58 x 58 x 72 cm outside build of Form 2

This printer is available in AM lab. All the different resins and post processes and curing is all available for students use.


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SUMMARY OF ACCOMPLISHMENTS

CAD

Cad designs for this projects are as follows.

1. Magnifying glass housing

2. Mirror support


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3. Side structures and supports

4. Support for wall structure for magnifying glass


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5. Front wall structure

6. Back support and structure

7. Lead screw


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ASSEMBLIES

These are few of the parts and the assembly used for the analysis as follows:

Analysis

For analysis we used three different types of meshing for better results

Printer in Ansys- before meshing


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Meshing comparison

1. Mesh size coarse and medium smoothness

Here the following parameters are used for meshing


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2. Element size medium and medium smoothness

And the mesh parameters are follows


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3. Fine and high smoothing

And parameters used for these are


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Constraints

Displacement

Constraints were applied at the bottom of the printer. Bottom displacement kept to be zero, the blue

parts are high lightened in figure

Max Modes


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Results from modal analysis

Total deformations and the displacement are as follows


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We can conclude that the modal is safe as in all the results are within the safe limits.


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CFD Analysis

CFD and heat transfer phenomena are carried out with finite element methods. It is applied in order to

improve element shape. Since some of the curing process are expensive by using laser device, if any

mistake happens during the application of laser device it cost a lot because of effort, material, time.

Because of this reason finite element method simulation has been applied in studying, one of the most

important device’s characteristics such as exit cooling fluid’s temperature.

Temperature field simulation:

Since cooling fluid’s temperature influence on appropriate lase device functioning, it involves

computational fluid dynamics (CFD). The simulation was done, considering the fact that it should get

better by discovering errors and miss-functioning of laser device before manufacturing its components

from the expensive required materials. All the sharp edges in the printing model should be chamfered,

small sized regions of material should be removed. Then only the FEM gives out good results. The velocity

field of cooling fluid can significantly influence the temperature distribution.

Fig: Model

Fig: Model mesh with a detailed view of the inflated surface.


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Fig: Temperature distribution field-with streamlines

CONCLUSION

1.1. The parts were successfully modelled to the required dimensions and assembled using the right

constraints.

1.2. The material selection and corresponding meshing results were achieved.

1.3. The Assembly of the parts are completed

1.4. The Ansys analysis of the 3d printer for modal frequency is successfully completed and found to

be within the safe limits.

1.5. CFD analysis was completed successfully

Reference

Applied Finite Element Method Simulation in 3D Printing M. Iliescu, E. Nuţu, B. Comănescu

https://formlabs.com/

http://www.fibreglast.com/

https://sites.google.com/site/dkenglishednotes/sla-research-paper

https://formlabs.com/

http://www.fibreglast.com/

https://sites.google.com/site/dkenglishednotes/sla-research-paper

design and analysis of sla printer

Engineering