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Creating Wax Models

Creating Wax Models

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Creating Wax Models

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  1. Creating Wax Models as master patterns for Investment Casting Lyon, March 13th 2003 Joost Verheggen, Solidscape, Inc.

  2. CAD / CAM versus Handcarving Speed Quality Cost

  3. RapidManufacturing CAD / CAM M

  4. Solidscape RM machines .. .. provide the highest accuracy with superior surface finish in non-toxic wax with negligible thermal expansion and no residue at casting. .. create wax patterns for investment casting and rubber moulding based on 3D CAD files. RapidManufacturing

  5. Solidscape RM machines .. .. provide the highest accuracy with superior surface finish in non-toxic wax with negligible thermal expansion and no residue at casting. Ideal wax patterns for investment casting.

  6. Solidscape Corporate Overview • Founded in 1994 • Privately-held Corporation • Headquarters - Merrimack, New Hampshire • Manufacturing Facility – 3600m2 • Installed Base of Over 700 Units

  7. Solidscape Europe • Branch office opened in February 2003 • Utrecht, The Netherlands • Support European resellers • Direct sales in ‘open countries’.

  8. Outline • Software • Printing Technology • Specifications • Applications • Cost justification • Four generations machines

  9. Software stl CAD ModelworksTM BViewTM T66TM

  10. Build process CAD Interface - .STL File - .SLC File - .DXF File Control Software Jet Electronics Controls Vectored Jetting (Droplet Size - .0762 mm) X-Y Motion Precision Machining Dissolvable Supports Object Model Build Substrate Build Table Z – Motion

  11. Vector printing ENLARGED Jets can simultaneously move in the X and Y directions. This allows the jets to precisely trace curves Jet Traces Edge SMOOTH, CRISP EDGES SUPERIOR SURFACE FINISH Solidscape T66 Solidscape PatternMaster

  12. Raster printing ... ENLARGED .. .. Multiple jets move in one direction only and fire independently Jets Sweep Across Area TESSELLATED EDGES ROUGH SURFACE FINISH

  13. Precise Layer Machining WITH MACHINING Planer surfacer machines each layer to a precise thickness • Variable Layer Thickness • Custom Layer Configurations • Z-Axis Tolerance Precision • Power Failure Recovery • Good Surface to Deposition Next Layer Thinner Layers For Resolution .0127mm Thicker Layers For Speed .0762mm

  14. Dissolvable Supports • Complex Internal Cavities • Thin Wall, Small Features • Less Finish Work • Superior Surface Finish • Lower Labor Costs Small Features Remain Intact .0254mm Orange Support Material Dissolves Away Inside Cavities

  15. Support removal Release part from substrate Remove orange support material Support removal Dry part

  16. Specifications • Build envelope: 152 x 152 x 152 cm • Build layer: 0.013 mm to 0.076 mm) • Achievable accuracy: +/- 0.025 mm per 25 mm = 1/1000 • Surface finish: 32-63 micro-inches (RMS) • Minimum feature size: 0.254 mm

  17. Applications • Jewelry • Medical • Industrial

  18. Consumer Products Electrical Components Industrial Design Studios & RP Services Automotive Aerospace Recreation Toys Sporting Goods Model Hobbyists Industrial Applications

  19. Example dental area MERRIMACK, NH, March 7, 2003 - Traditionally, braces on the inside of the arch are based on standard brackets and an arch wire adapted to the customer’s needs. T.O.P. Service für Lingualtechnik, a leading company in lingual orthodontics, has developed a fundamentally different production method using CAD/CAM technology. The customized brackets are much smaller and lead to magnificent results.

  20. Jewelry

  21. Pricing T66 • $ 53,750 • including one year service contract • including start-up kit • excluding shipping and handling

  22. Cost justification $3 Cost of Material per pattern $60,000 Machine costs 60 months Lease 50 Patterns per month $200 Typical cost to purchase pattern

  23. Cost justification 50 patterns per month x $3 Cost of Material = $150 Cost of Material per month $60,000 ÷ 60 Months = $1000 per month = $20 Machine Cost per Pattern Total costs T66, 50 models per month: $ 23 per pattern or $ 1,150 per month

  24. Cost justification $ 200 Typical cost to purchase pattern $10,000 Estimated cost to purchase 50 patterns Total costs T66, 50 models per month: $ 23 per pattern or $ 1,150 per month

  25. Three generations of precision ModelMaker 6 Pro (rear) Introduced in 1994; attained acceptance for most accurate and precise patterns for investment casting “Lost Wax” process. 170 Units Shipped. ModelMaker II (center) Introduced in 1998; provided improved performance, reliability and larger build envelope for all applications. 350 Units Shipped. PatternMasterTM(front) Introduced 2000; targeted for the industrial market; supports faster build times for larger vector patterns, normally used in investment cast patterns and rapid tooling.

  26. Fourth generation of precision T66 Personal Modeler Introduced in September 2002. Targeted at the jewelry industry, the T66 provides 4th generation mechanics and electronics in system with a 15.24cm (wxdxh) build envelope and a revolutionary price.

  27. Summary • Amazing accuracy and surface finish • Works with most popular CAD/CAM software • Perfect patterns for casting, molding and tooling • Simple, easy-to-use operation • Low monthly lease payments available

  28. Speed Quality Creating Wax ModelsUse CAD/CAM Cost Lyon, March 13th 2003 Joost Verheggen, Solidscape, Inc.