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Fused Deposition Modeling (FDM):
The FDM process forms three-dimensional objects from CAD-generated
solid or surface models. A temperature-controlled head extrudes
thermoplastic material layer by layer. The designed object emerges
as a solid three-dimensional part without the need for tooling.
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Laminated Object Modeling (LOM):
A roll of paper, available in thickness from .95 mm (.0037")
to 2.5 mm (.0100") is fed a section at a time into a cutting
area. It is laminated to the previous layers with heat and pressure.
A laser then cuts out the outer and inner outlines of this layer
of the part and the process repeats for all layers until done. The
resulting part looks, feels, and acts like it was made of wood.
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StereoLithography (SLA):
The SLA machine builds the physical model, layer by layer, by scanning
each of the cross sections, one at a time, on the surface of the
liquid resin using an ultra violet laser beam. The UV energy of
the laser causes the liquid resin to instantly cure or solidify.
In between each layer the platform on which the model is being built
moves down into the vat of liquid by one layer thickness, typically
0.125mm: in this manner the model is built up by means of the process
known as Layer Manufacturing
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Silicon Mold:
This technique uses a stereolithography prototype as a master. A
mold of silicon is produced by poring it around the prototype and
after curing dividing it and removing the prototype. The silicon
mold is used to simulate injection molding and can produce 10 -50
parts depending on the size and the complexity. Several Epoxy resins
are available to provide different properties to closely relate
to the final production material.
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Selective Laser Sintering (SLS):
Sintering process to create solid three-dimensional objects, layer
by layer, from plastic, metal, or ceramic powders that are "sintered"
or fused using CO2 laser energy.
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Computer Numeric Control (CNC/Machining):
Our in house machine shop, including two full time machinists and
two CNC milling machines allows us to machine parts in less than
5 days.
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Direct Shell Process Casting (DSPC):
A layer of alumina powder is laid down on the table of the machine,
followed by a print jet which projects a fine stream of colloidal
silica (bond) to form the profile at that layer. The colloidal silica
bonds the alumina powder at that layer and affords adhesion for
the following slice. As each layer is completed the table descends
allowing for a further layer of powder to be deposited and bonded.
The surplus powder falls around the build shell offering support.
On completion, the shell is removed from the bin and that powder
filling the cavity of the shell is removed. As with the conventional
"Lost wax process" the shell mould must be fired prior
to casting.
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Sheet Metal:
Cutting, bending, and welding sheet steel or aluminum to form the
desired shape. Sheet metal parts can be prototyped in two weeks
and be in production in 4-6 weeks.
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Quick Turn Plastic Injection Mold:
Liquid resin (i.e. plastic) is injected under pressure into a steel
mold cavity. The finished part solidifies as it cools and is ejected
from the mold.
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Thermojet & Investment Casting:
Low melting point metals are injected into a mold cavity machined
from a heat resistant material. The metal solidifies as it cools
into the finished part and is ejected from the mold.
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