Additive Layer Prototyping and Manufacturing techniques came into vogue in the late 1980s . They are currently widely being used to produce prototype parts and also parts for manufacturing where the quantity required is minimal. 3DPD has been a pioneer in adopting new RP technologies to provide Prototypes to its customers.

Each Rapid Prototype technique has its advantages and disadvantages.

At 3DPD we offer our customers the right solution for their requirement.



Stereolithography Apparatus (SLA)

Stereolithography is an additive manufacturing process which employs a vat of liquid ultraviolet curable photopolymer "resin" and an ultraviolet laser to build parts' layers one at a time. For each layer, the laser beam traces a cross-section of the part pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light cures and solidifies the pattern traced on the resin and joins it to the layer below. SLA parts have high accuracy and excellent feature details.

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Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM) works on an "additive" principle by laying down material in layers. A plastic filament or metal wire is unwound from a coil and supplies material to anextrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism, directly controlled by a computer-aided manufacturing (CAM) software package. The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle. Resultant parts from FDM are coarse and are generally strong.

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Selective Laser Sintering (SLS)

Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power laser CO2 laser to fuse small particles of Nylon powders into a mass that has a desired 3-dimensional shape. The laser selectively fuses the powder material by scanning cross-sections generated from a 3D CAD file, on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. SLS parts have very good strength and the surface finish is on the coarser side.

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3D Machining

CNC Machining takes 3D CAD data and generates a cutter path using the latest VX Visions software. Once the program in ready, block of different materials like ABS, Nylon, PP, PC, Acrylic, POM, Aluminium etc.,can be machined. The resultant parts are accurate, strong, have extremely high feature detail and have excellent surface finish.

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Rapid Tooling - Vacuum Casting

Vacuum Casting is a technology in the field of Rapid Prototyping for the fast production of plastic components that are functional and close or identical to production parts. Vacuum Casting begins with Silicone Mold which is made based on a master model, which has been built with one of the Rapid Prototyping machines or in a conventional way. Then the Silicone Mold is filled with a two part Polyurethane resin under Vacuum. Around 20 Polyurethane parts can be extracted from a single rubber mold.







PROCESS

  • An RP part is used to create a master pattern.
  • The RP part is then putty finished to achieve the desirable finish on the PU parts.
  • The master pattern is fitted with a sprue and gate and then surrounded by a parting surface, which establishes the parting line for the mold. Alternatively, the cured mold can be cut carefully to form the parting line.
  • The assembly is fixtured in a wooden box, the size of which is determined by the size of the master.
  • The liquid RTV is degassed in a Vacuum casting machine, which eliminates air bubbles trapped in it. The degassed liquid RTV is then poured over the pattern and parting surface combination.
  • Once cured, the RTV is removed from the box and separated from the pattern and parting line surface to yield the two halves of the molding tool.
  • Thermoset resin such as urethane is first degassed in the Vacuum chamber and then poured or injected into the mold.
  • Finally, the finished part is removed from the mold. Undercuts are overcome by distorting the mold, which springs back to its original shape as long as distortion is not too severe.
  • The part must then be post-processed by trimming any flash.

PU MATERIALS

  • A range of polyurethane materials are available for Vacuum casting applications.
  • PU materials which mimics properties of various materials can be poured to a single silicone rubber mold without worrying about shrinkage allowances, since these PU materials have negligible or zero shrinkage.

We at 3DPD stock close to 20 different PU materials to meet your needs. We always maintain a healthy stock of raw material to meet your requirement. Click on the link below to know about some of PU materials

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Metal Prototyping

Our sister concern Total Prototyping Pvt Ltd is involved in prototyping of metal components.


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News
  • April 2012: Added 2 VMC CNC centres for 3D machining.
  • November 2011: Conducted a workshop on " Product Innovation - Concept to reality" at The Taj Gateway , Bangalore.
  • Jan 2011: Inauguration of new state of the art RP facility in Veerasandra Bangalore.
  • April 2008: Started rapid Vacuum Investment Castings through its sister concern Total Prototyping.
  • February 2000: Commenced operations for Rapid Prototyping in Bangalore.
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