investigation of detail resolution on basic shapes and ... shapes and... · horizontal upskin •...

Investigation of detail resolution on basic shapes and development of design rules

Dominik Sippel Diploma student

15.04.2008

EOS 2008 · Thesis: Detail Resolution · Dominik Sippel

— General test condition

3

— Test geometries

4

— Tests and results•Font

5•Walls

11•Pins

15•Gaps

18•Holes

23

Content Page

Investigation of detail resolution on basic shapes and development of design rules

Source: EOS GmbH


Test conditions and test geometries describe the general test frame

— Maschine

/ Layer thickness•

P390 / 0.15mm

— Material•

PA2200

— Exposure Type•

Mechanic standard

— PSW3.3

— Material dependent scaling•

X: 3.2%•

Y: 3.2%•

Z (0): 2.2%•

Z (600): 1.6%

— Beam

offset•

0.33mm

Test conditions

Source: EOS GmbH


Test conditions and test geometries describe the general test frame

— Font

— Shapes•Walls•Pins

— Cutouts•Gaps •Holes

Test geometries

Source: EOS GmbH


Please see test parts to judge the labeling

quality

— Font type•Arial

— Small font size•8pt to 14pt

— Letter height outside & inside •0.2mm to 1.2mm

— Orientation•Vertical•Horizontal UpSkin•Horizontal DownSkin

— Test results

subjective

Font test specifications

Source: EOS GmbH


VerticalSkin

orientation offers very detailed labeling quality

Source: EOS GmbH

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14

VS inside [mm]

fon

t si

ze [

pt]

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14

VS outside [mm]

fon

t si

ze [

pt]

Design Chart - VerticalSkin


Font in UpSkin

orientation shows rather low labeling

quality

Source: EOS GmbH

Design Chart - upskin

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14

inside [mm]

fon

t si

ze [

pt]

US

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14fon

t si

ze [

pt]

US outside [mm]


Font in DownSkin

orientation shows good labeling

quality

Source: EOS GmbH

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14

DS inside [mm]

fon

t si

ze [

pt]

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6

689

10111214

>14

outside [mm]

fon

t si

ze [

pt]

DS

Design Chart - Downskin


Source: EOS GmbH

Overview of inside & outside font in all basic orientations

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6

6 68 89 9

10 1011 1112 1214 14

>14 >14

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6

6 68 89 9

10 1011 1112 1214 14

>14 >14

>1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1 >1,2 1,2 1,1 1,0 0,9 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 >0,1<6 <6

6 68 89 9

10 1011 1112 1214 14

>14 >14

inside [mm]

fon

t si

ze [

pt]

US

VS outside [mm]

fon

t si

ze [

pt]

US outside [mm]

outside [mm]

fon

t si

ze [

pt]

VS inside [mm]

fon

t si

ze [

pt]

fon

t si

ze [

pt]

DS inside [mm]

fon

t si

ze [

pt]

DS


Summary Fonts

— Higher detail resolution on VerticalSkin

and DownSkin

— Design chart is a suggestion how required information for designers can look like

— Are you interested in the test geometry ?

Source: EOS GmbH


The analysis of basic shapes creates fundamental design information

— Wall thickness•0.50mm to 2.00mm•in 0.05mm steps

— Orientation•Vertical

— Position•X-direction•Y-direction•30°

to X-direction

Wall test specifications

Source: EOS GmbH


The investigated test parts showed a max. deviation of ±0.06mm

Source: EOS GmbH

0,60

0,80

1,00

1,20

1,40

1,60

1,80

2,00

1 3 5 7 9 11 13 15 17 19 21 23 25 27

measurement points

wa

ll t

hic

kn

ess [

mm

]

nominal size

actual averagesize

deviation value:-0.06mm

deviation value:+0.06mm


Switch

from edge to contour exposure increase deviation up to 0.1mm

Source: EOS GmbH

Wall thickness:

0.65mm

0.70mm

Exposure type:

Edge

Contour

Nominal geometry


Summary walls

— Reliable minimum value: ≥0.80mm

— Maximum deviation

±

0.06mm

— Keep in mind that switch from edge to contour can cause higher deviation

Source: EOS GmbH



— Pin diameter•0.80mm to 2.00mm•In 0.05mm steps

— Orientation•Vertical

Pins test specifications

Source: EOS GmbH


The investigated pins showed an average deviation of -0.2mm

Source: EOS GmbH

0,50

0,70

0,90

1,10

1,30

1,50

1,70

1,90

2,10

1 3 5 7 9 11 13 15 17 19 21 23 25

measurement points

pin

dia

me

ter

[mm

] nominal size

actual average size

deviation averagevalue: -0.2mm

maximum tolerancevalue: -0.3mm


— Reliable minimum diameter:

≥0.8mm

— Average deviation:

-0.2mm

— Maximum deviation value:

-0.3mm

— Smaller diameters can produce unexpected results

Source: EOS GmbH

Summary pins



— Gap size•

Length: 10mm•

Width:0.50mm to 2.00mm•

in 0.1mm steps

— Wall thickness•

0.30mm to 6.00mm

— Orientation•

Horizontal

— Position•

X-direction•

Y-direction•

30°

to X-direction

Gap test specifications

Source: EOS GmbH


The gap deviation rises with increasing wall thickness

Source: EOS GmbH

0,00

0,50

1,00

1,50

2,00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

measurement points

ga

p w

idth

[m

m]

nominal size

wall thickness0.30mmwall thickness3.00mmwall thickness6.00mmdeviation average3.00mm: -0.1mmdeviation average6.00mm: -0.2mm


The gap deviation rises with increasing wall thickness

Source: EOS GmbH

0.5

0.6

0.7

0.8

0.30mm 3.00mm 6.00mm

Gap width

[mm]:

Wall thickness:


The design chart shows the usable area in the relation gap size/ wall thickness

Source: EOS GmbH

0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 4,8 5,1 5,4 5,7 6,00,50,60,70,80,91,01,11,21,31,41,51,61,71,81,92,0

gap

wid

th [m

m]

Wall thickness [mm]


Summary gaps

— reduce wall thickness for higher detail resolution

— Gap quality is a function of gap size/ wall thickness

— Design chart shows performance of gap in order to remove loose powder

Source: EOS GmbH



— Hole diameter•0.50mm to 2.00mm•in 0.1mm steps

— Wall thickness•0.30mm to 6.00mm•in 0.3mm steps

— Orientation•Horizontal

Hole test specifications

Source: EOS GmbH


The hole accuracy depends heavily on the wall thickness

Source: EOS GmbH

0,00

0,50

1,00

1,50

2,00

2,50

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

measurement points

ho

le d

iam

ete

r [m

m]

nominal size

wall thickness 0.30mm







The hole accuracy depends heavily on the wall thickness

Source: EOS GmbH

Hole diameter:

0.5mm

0.6mm

0.7mm

0.8mm

Wall thickness:

0.30mm

0.60mm


The design chart shows the usable area in the relation wall thickness / hole size

0,3 0,6 0,9 1,2 1,5 1,8 2,1 2,4 2,7 3,0 3,3 3,6 3,9 4,2 4,5 4,8 5,1 5,4 5,7 6,00,50,60,70,80,91,01,11,21,31,41,51,61,71,81,92,0

Wall thickness [mm]

diam

eter

[mm

]

Source: EOS GmbH


Summary holes

— For higher detail resolution reduce wall thickness or rather increase hole diameter

— Be aware of close relationship between hole diameter and wall thickness

— More investigation to express this function as an aspect ratio summarize in one number

Source: EOS GmbH


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