ProtoCAM Rapid Prototyping Blog

Prototyping Large Parts: Why We Have No Size Limitation

2008-04-18T10:19:00.002-04:00

One question that I get asked on a regular basis is "How large a part can you build?" Rapid prototyping machines have a fixed size, and many of them have a relatively small area where they can build parts (their "build envelope"). Our largest machines, the SLA-7000s, have a build envelope of 20" x 20" x 23", but this doesn't limit the size of the parts we can deliver. By sectioning your CAD model into 20" x 20" chunks, we can build parts of any size.

When we receive a large part for quotation, we cut it into sections in a way that minimizes cost. The typical factors we consider are total height of the platen (if you don't know already, we use height and volume to estimate cost, and we adjust that based on part complexity), number of platens, and number of cuts. We then price it based on the machine's run time and finishing/gluing time, so you get a quote with the information you need to know -- how much it will cost you, and how quickly you can have it.

Once you give us the job, we go back and cut the part again, this time adding lap joints for strength. This step allows us to produce a part that is very strong along its seams, and that can be positioned back together accurately. For parts with complex cutting requirements, this step may be responsible, partly, for any additional lead time (beyond our typical 2-day turnaround) that you were quoted.

After the parts are cut in CAD, they are prepared for build in the 3D LightYear package, a proprietary software package built for stereolithography machines. This step comes up with the set of instructions that the SLA machine uses to build. (Conceptually very similar to the G-code used to run CNC machinery.)

Once finished, the parts are drained, removed from the perforated metal platen, separated from their supports, rinsed of excess resin, and cured in a UV oven. After this step, the lap joints are sanded so the parts can be fit together. Once the fit has been adjusted optimally, the parts are bonded with one or both of the glues that we've settled on using after years of experience. This leaves the seam with excess material and sometimes slight discoloration. The seam is then sanded until it is smooth to the touch. This process is repeated for each piece that needs to be glued together. Often times, our choice of glues leaves the seam stronger than the part.

With this proven process, we can deliver you prototypes of any size, from dashboards to wind tunnel models to tractor seats to chair backs. Large parts require extra care when shipping, but we have great experience doing that, from customers local to us in the Lehigh Valley to those on the other end of the country in California or Washington.

If you have any questions, drop me an email, give me a call (610)261-9010, or leave a comment here on the blog.

Todd Pederzani
Information Technology &
He-who-cuts-your-large-parts

What is Durometer?

2008-04-08T15:58:00.002-04:00

What is Durometer?

When new products are being developed, one of the most difficult tasks is to determine the material. Materials are typically selected based on several criteria:

Association - use material that has been used with similar products.

Mechanical properties - Flex Modulus, Tensile strength, Impact, HDT, etc.

Color - Part needs to be clear – Knowing the color can help to narrow the search

Durometer - measure of hardness in polymers, elastomers and rubbers.

I would like to discuss durometer. Durometer can be a very fast way to narrow your search for a material. Durometer is a value that indicates the hardness of a material, defined as the material's resistance to permanent indentation.

There are several scales of durometer, used for materials with different properties. The two most common scales, using slightly different measurement systems, are the ASTM D2240 type A and type D scales.

The A scale is for softer materials

The D scale is for harder materials

Durometer works together with association.

The chart below relates Shore A and Shore D values with production grade and some common materials

Shore A	Shore D	Material
30		Art Gum Eraser
40		Pink Pearl Eraser
50	15	Rubber Stamp
60		Pencil Eraser
70	30	Rubber Heel
80		Rubber Sole
90	45	Typewriter roller
100	55	Low Density Polyethylene
	70	Polypropylene PP
	75	ABS
	80	Polycarbonate PC
	85	GF Nylon
	90	Glass

In the Rapid Prototyping industry there are a number of resins that can simulate different production and common materials.

The chart below relates Shore A and Shore D values with Rapid Prototyping resins. The chart is only a guide to help direct you to a material that closely represents your final product.

Shore A	Shore D	Material
30		Tango Plus Cast Polyurethane
40		Cast Polyurethane
50	15	Cast Polyurethane
60		Tango Black Cast Polyurethane
70	30	Tango Gray Cast Polyurethane
80		Cast Polyurethane
90	45	Cast Polyurethane
100	55	Cast Polyurethane
	70	Cast Polyurethane
	75	Cast Polyurethane
	80	Accura 25 WaterClear Ultra 10122 Cast Polyurethane
	85	Accura 60 ProtoGEN 18420 WaterClear Ultra 10122 Cast Polyurethane
	90	ProtoGEN 18420 SL 5530 Cast Polyurethane

Durometer is a tool to use when selecting a material for a new product design. It’s one of many tools that can aid in the design and material selection process. Once a design is complete and a material has been selected – ProtoCAM will be glad to produce high quality prototypes.

Ed Graham

Engineering Manager

egraham@protocam.com

Tracey Collins joins ProtoCAM!

2008-04-03T10:24:00.001-04:00

As a new employee of ProtoCAM, I'd like to take a minute and introduce myself. My name is Tracey Collins and I have been working at ProtoCAM since November of last year. Some of you may already have spoken to me or received quotes from me.

Working at ProtoCAM has been challenging and fascinating at the same time. The environment is very diverse and fast paced. I love to see how we take someone’s idea and convert it into something you can hold in your hand! One of my favorite things about working here is how well we work together as a team. From start to finish, we all work closely to make your dream a reality. We start the process with a request for quote. Our engineers carefully process your request and then give them to either Faye or myself to format into a formal quote. When we receive your order, either Faye or I will follow through with creating the work order to your specifications and make sure everything is set for production. From engineering to finishing, we all work very closely together to make sure that the process goes smoothly and without interruption.

Even though the pace is hectic, we always find the time to smile and keep the atmosphere fun. The owners help with that too. For instance, the first day of spring Ray made a run to the local Italian Ice shop and we all enjoyed our first Gelati of the season. I’m really looking forward to this summer’s company picnic which will be held at a Reading Phillies baseball game. It will be nice to meet all the family members that I hear so much about.

Whether it’s watching your parts get built or meticulously hand finished, it gives me a wonderful sense of pride to be an integral part of supplying people with such high quality prototypes. I look forward to seeing your idea become a reality!

Tracey Collins

ProtoCAM adds two new SLA resins!

2008-03-14T10:02:00.003-04:00

ProtoCAM recently installed Somos® ProtoGen™ O-XT 18420 resin in our SLA-3500. This resin is a general purpose white resin that has ABS-like mechanical properties that offers superior chemical resistance and dimensional accuracy. The resin has high temperature capabilities (208ºF) and produces durable parts that are humidity tolerant.

ProtoCAM also recently installed Somos® Water Clear® Ultra 10122 in our two Viper SI SLA's.
This resin is optically clear, colorless and rigid. This resin also has ABS-like properties and produces accurate parts that simulate acrylic in appearance. This is ideal for applications requiring optical clarity such as lenses, bottles, and light pipes. The resin produces transparent parts right out of the SLA machine, but post processing is required to obtain true optical clarity.

Ronald Belknap
Managing Partner
rbelknap@protocam.com

ProtoCAM Joins 3D Systems Preferred Service Provider Network

2008-02-25T14:10:00.003-05:00

ProtoCAM, located in Northampton, Pennsylvania, is a leading service provider specializing in Rapid Prototyping and short-run Manufacturing solutions, with an extensive range of capabilities and a complete suite of design-to-manufacturing solutions. Because of our expertise in the area of 3-D modeling and Rapid Prototyping and manufacturing, ProtoCAM was recently appointed as an authorized Preferred Service Provider of 3D Systems. Customers using service bureaus within this network can be assured that their parts will be manufactured using the latest resins and technology.

This part is indicative of the quality and complexity of the types of parts ProtoCAM is able to produce.

Let ProtoCAM's engineering staff assist you from your beginning concept to the finished product. We can make your idea a reality by turning a 3D CAD into a solid object. Most Stereolithography prototypes can be completed in as little as 1-2 days. Please visit our website and use our request for quote button for you next project!

Ray Biery
Managing Partner
rbiery@protocam.com

New ProtoCAM Website Press Release Online

2008-02-11T12:53:00.000-05:00

Recently we did an online press release using PRWeb. The release is available at:
PRWeb release, Jan 31, 2008 - ProtoCAM Launches New Rapid Prototyping Website and Blog

Along with this, it is posted on Digg.com. If you like the release, please Digg it at:
ProtoCAM press release on Digg.

I was pleasantly surprised to hear from a Podcast website that focuses on small and medium sized manufacturers. I'll be doing the interview with them soon and I'll be sure to post a link to that once it is recorded and available.

- Ray Biery, ProtoCAM Managing Partner

New free STL viewer available based on Materialise Magics

2008-01-31T13:11:00.000-05:00

Getting good files in order to make quality rapid prototypes is something that we place a very high importance upon here at ProtoCAM. We always make an effort to work with whatever types of 3D CAD files we're provided, sometimes even by running them through a couple of applications until they produce sound, solid, 3D geometry, but even that isn't a cure-all. Currently, customers can export STL files and then download and view them with the (free) SolidView/Lite, which we have instructions to download and install on our home page, but it has limited functionality. Another software vendor in our industry, Materialise, has just put out a custom (and also free) version of their Magics software called MiniMagics. As a viewer of the full version of Magics, I'm excited about this application. It allows exporting to compressed MGX files (for faster transfer of large parts), measuring of extents, viewable sections, viewing bad triangles, viewing unshared edges, measurement, and annotation of parts. I'll evaluate it and update our STL viewing web page if appropriate.

Link to download MiniMagics

Todd Pederzani
tpederzani@protocam.com

ProtoCAM launches new rapid prototyping blog

2008-01-16T14:16:00.000-05:00

We have launched the new ProtoCAM website in early 2008 and will now use the new ProtoCAM Rapid Prototyping Blog to comment on the rapid prototyping (RP) industry, discuss new developments in the RP technologies, and talk about some interesting customer projects.

The ProtoCAM home page now features one of our more interesting pieces, the Mobeus gear.

Welcome to the Rapid Prototyping blog

2007-10-26T13:07:00.000-04:00

Welcome to the first post on ProtoCAM's blog. With lead times for most of our stereolithography projects being two days, we see a lot of neat projects come through our offices, and we have to think outside the box to find creative solutions to meeting customer needs. When possible (i.e. when allowed by the customer), we will share some of these projects with you. Other times, we may bring you news about new processes (like our high temperature castings) or materials (such as our Accura 25 or Accura 60 stereolithography resins). Or perhaps we will explain the technologies we can use to fulfill your requirements or limitations of them, so you can get the best use out of your rapid prototypes.

In addition to starting the blog, we have changed the look of our site, and expanded our content in a number of areas. If you experience any problems or have any suggestions for improvement, please let us know.

Todd Pederzani
Information Technology
tpederzani@protocam.com