“Rapid Technology” expresses 3D-CAM’s overall strategy to provide an array of prototyping techniques and processes that will assist our customers in determining the best solution for their needs.

In this section, we introduce the rapid prototyping services that produce plastic parts directly from CAD models through the new technology of additive manufacturing.  These services include Stereolithography (SLA) prototyping, Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM) processes.  Parts produced by these processes may be used directly or as forms in other fabrication processes.

Stereolithography (SLA)

Stereolithography, also known as 3D layering or 3D printing, produces three-dimensional solid, plastic,objects directly from CAD models. With stereolithography, engineers, designers and inventors can have dimensionally accurate plastic parts they can hold in a matter of a day or two. By conventional methods it could conceivably take months to prototype a part.

The SLA system consists of an ultra-violet laser, and a large vat of photo-curable polymer. Driven by a CAD model, stereolithography is a process by which the polymer (liquid plastic) is solidified in precise patterns by the laser beam, resulting in a solid realization of the 3D design.

Throughout its history, 3D-CAM has been a leader in high capacity stereolithography.
For some of our customers, SLA technology is all that’s required for rapidly developing a presentation or engineering model. For other customers, the use of the rapid prototyping and tooling services offered by 3D-CAM in both plastics and metals, create an SLA master pattern that can be used in the RTV tooling process.

The SLA process can be run in three modes. The Aces mode produces models with crystal-like transparency and exceptional strength at very high dimensional resolution. This mode of stereolithography is perfect for parts that require exceptional visual quality such as lenses and optical components, medical parts, and jewelry.

QuickCast is a stereolithography mode that creates quasi-hollow parts with a strong honeycomb interior that is 80% hollow. From a QuickCast prototype, metal parts can be made in three to five days. The Quickcast patterns are used in place of wax patterns in the investment casting process.

Finally, the Solid Weave mode boasts the quickest turnaround time of the SLA modes without compromising strength and precision. It is also the most economical of the three.

Stereolithography technology is incredibly flexible when it comes to size. The single SLA part build area is 20” x 20” x 24”, but 3D-CAM engineers can handle larger parts by modularizing designs and then bonding separate sections together. We have made stereolithography parts as large as 10 feet, and as small as a few tenths of inch. Resolutions down to three thousandths, four thousandths, and five thousandths of an inch are available.

Selective Laser Sintering (SLS)

Selective Laser Sintering converts CAD data into two-dimensional cross-sections or layers that are each sintered together on a platform as an additive process. The process is fast and parts can be nested to maximize economy, delivering a service far superior to those relying on traditional prototyping or pattern cutting processes.

The SLS process allows us the ability to build parts in both engineering type resins as well as disposable foundry waxes. The ability to produce a variety of parts quickly and accurately has given our customers a dramatic advantage in new product cycle times and overall time-to-market.  SLS parts can be made with materials that have properties closely resembling injection-molded materials.

The latest generation of Selective Laser Sintering machines has given 3D-CAM Product Development an additional avenue for generating patterns and prototypes.

Fused Deposition Modeling (FDM)

Fused Deposition Modeling is a solid-based rapid prototyping process that extrudes material, layer-by-layer, to build a model. It is used to produce functional ABS thermoplastic models directly from CAD data. The system utilizes a CNC-controlled, specially designed extruder-head, production quality thermoplastic, and a build platform. The melted thermoplastic material is delivered through the extruder-head nozzle onto a build platform. The finished part has the strength of the build material in the X and Y direction. Layer to layer adhesion, however, does not have the same characteristics of the build material and is somewhat weaker in strength.  Some accuracy is sacrificed with this process but there is the advantage of building directly with ABS or polycarbonate.