3. Overview of the RP workcell

Rapid prototyping (RP) refers to any of several emerging technologies with which physical part models can be fabricated in a short period of time. These part models are typically constructed from materials such as paper, ceramic or photosensitive polymers. RP models can serve as invaluable visualization aids, and are often used to verify how proposed assembly components would mate with one another.

RP systems typically build parts in layers, by decomposing three-dimensional CAD models into numerous thin, cross-sectional slices. In the case of the CAISR CAM-LEM system, these slices are laser-cut from sheet material, and are subsequently stacked and laminated to form a physical 3D realization of the original CAD description.

Much of the CAM-LEM research has focused on the use of advanced ceramics. Ceramic powder is tape-cast into thin sheets using a polymeric binder. Such sheet stock is laser cut, stacked, and fused in a subsequent sintering process to create fully-dense, monolithic structures. The same approach has been successfully demonstrated with powdered metals. In the present tooling application, we are exploring the use of polymeric materials (Plexiglas®, Delrin® and Teflon®).

Relatively thick (e.g., 1-2mm) sheets of these materials are laser-cut into contoured layers, which are mechanically assembled and fastened or bonded, avoiding the need for sintering. Fabrication and assembly of simple tooling can be accomplished in a matter of minutes.

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