V - Plastics to 3D Printing Flashcards
Material which is solid at room temperature, but as temperature rises, it becomes a viscous liquid. Generally EXTRUDED
THERMOPLASTICS
Extrusion machine which operates at lower temperature and pressure, which includes a die to shape the plastic pellets which have been melted.
PLASTICS SCREW EXTRUDER/ PLASTIC EXTRUDING MACHINE
The plastics equivalent of metal “Die Casting”. A charge of material is forced into a die cavity.
INJECTION MOLDING
INJECTION MOLDING can also be used for _____________.
Ex. Placing one type of plastic over another or molding a plastic handle on a metal screwdriver shaft.
OVERMOLDING
Molding technique where metal parts are imbedded in the plastic mold
INSERT MOLDING
Manufacturing process for forming hollow plastic parts. It is also used for forming glass bottles or other hollow shapes.
BLOW MOLDING
Technique used to make beverage bottles. A “gob” of input charged is blown with hot air into a injection molded precursor called a ______. The _____ is projected down into a split mold cavity.
BLOW MOLDING
PARISON
Technique used to make trash bags. Pellets form a hopper are fed to a heat screw conveyer that squirts the plastic vertically out of an annular nozzle. “— —–” gather the cooled plastic film together.
BLOW MOLDING- “Nip Rolls”
Plastics equivalent of “Centrifugal Casting” Only spun around 2 axis.
ROTATIONAL MOLDING
Steps of ROTATIONAL MOLDING
charging
heating
cooling
demolding
Machine in which ROTATIONAL MOLDING is performed. Biaxially spinning machine.
ROTOMOLDING MACHINE
What products are made in a ROTOMOLDING MACHINE?
Plastic Trash Cans
Plastic Tanks
Plastic Containers
Technique where there isn’t a metalworking equivalent. Used to form a plastic sheet into a 3D shape with one open side.
THERMOFORMING (food tray, jet fighter canopies)
Type of THERMOFORMING which involves a vacuum to pull down the sheet of plastic onto the mold
Vacuum Forming
Type of THERMOFORMING which involves air pressure to push down the sheet of plastic onto the mold
Pressure Forming
What technique is used to create THERMOFORMING MOLDS
Powder Metallurgy (PM)
A plastic manufacturing process that has a glass making equivalent, it is the same as “Pressing”, and similar to “Cold Extrusion” of metals.
COMPRESSION MOLDING
Similar to metal casting, however, no heat is utilized. Can also be used for “Encapsulation”
PLASTIC CASTING
Which type of plastic is usually utilized in PLASTIC CASTING
EPOXY URETHANE
Plastic process that resembles some aspects of metal rolling and other aspects of glass sheet manufacturing. The
process is different from the one used in the textiles and paper industries, and is employed in the mass production of
plastic sheet or film
CALENDERING
What are the products of CALENDERING?
Plastic sheet or film
Embossed sheet
Laminated sheet
Natural formation found inside bee hives and are used by
the colony to hatch eggs and store food (honey)
This shape is made up of interlocking hexagonal cells which results in a very efficient use of space.
HONEYCOMBS
Examples of materials in the man-made HONEYCOMB structures:
paper
cardboard
plastic foil
metal foil
HONEYCOMBS are combined with rigid cover sheets. They are LIGHT and STIFF and used within aerospace/ commercial aviation (flooring).
STRUCTURAL HONEYCOMBS
GRP
Glass Reinforced Plastic
CFRP (used for military aircraft flooring)
Carbon Fiber Reinforced Plastic
General term for a number of individual additive manufacturing methods.
3D PRINTING
Categories of 3D PRINTING:
- Material Extrusion – FDM, FFF
- Vat Polymerization – SLA, DLP, MSLA (or LCD)
- Powder Bed Fusion (Polymers) – SLS
- Material Jetting – MJ, DOD
- Binder Jetting – BJ
- Powder Bed Fusion (Metals) –DMLS, SLM, EBM
3D Printing competitor technique. Beginning to emerge as a faster option, although not quite ready for “prime time” just yet
VOLUMETRIC PRINTING
- MATERIAL EXTRUSION- typically used 3D Modeling technique, commercially available and the cheapest. Most common material is PLA, poor surface finish.
FDM- Fused Deposition Modeling
FFF- Fused Filament Fabrication
- VAT POLYMERIZATION-The method essentially uses a laser to photo-polymerize a special light sensitive liquid polymer. Brittle plastic and translucent, smooth finish.
SLA- Stereo Lithography (first type of 3D printing method invented)
DLP- Digital Light Processing
LCD- Liquid Crystal Display
SLA technique where a projector casts a light over the entire layer to cure it all at once
DLP- Digital Light Processing
SLA technique where a screen masks a projector’s light or uses its own light to cure a layer
LCD- Liquid Crystal Display
- POWDER BED FUSION (Polymers)- Can use multiple plastics, commonly Nylon. Different colors can be used.
SLS (Selective Laser Sintering)
The polymer used is normally NYLON 6,
NYLON 11, or NYLON 1
method where a laser selectively switches on and off as it is scanned across a layer of material. The material is a very fine powder.
SLS (Selective Laser Sintering)
- MATERIAL JETTING- The parts are used for investment casting patterns.
works in a very similar way to an inkjet printer, except
that droplets of photopolymer are deposited rather than ink.
DOD
Drop On Demand
Hybrid between SLS and BJ. A bed of powder is used for the part body, but the particles are locally bound together not by laser fusion, but instead by a print head depositing droplets of a liquid binder (adhesive).
BINDER JETTING
(can also be used for building of molds and cores for metals casting by using sand instead of metal)
Last step of BINDER JETTING
SINTERING OVEN
- POWDER BED FUSION (Metals)
DMLS (Direct Metal Laser Sintering)
SLM (Selective Laser Melting)
(Currently very expensive)
Basically the same as SLS except that the build powder is
of metal, and the laser is powerful enough to melt the metal.
DMLS, SLM
Where an electron beam is used instead of the laser the process is called ——————- which is a faster process due
to superior energy density of the beam, but the need for a vacuum limits the size of parts that can be made.
EBM (Electron Beam Melting)
