The Product Realization Lab can take a hand-drawn sketch, a picture image, or a computer drafted design and turn it into a 3D solid that can evolve into a prototype. Models are drafted from scratch using AutoCAD, Inventor, SolidEdge, Magics, and Cobalt. Supported CAD files are: STEP, IGES, DWG, DXF, PART, STL. Additionally, we can easily convert files generated in many other CAD software.
Two machines made by Milicron-Fanuc, a 7-ton and a 110-ton, are housed in our Lab. Both are computer controlled machines capable of producing high quality, high volume parts. Parts are produced by injecting heated material (100's of resins available - including polyethylene) into a mold core and cavity. Once the mold is filled, the parts are allowed to cool for a few seconds. The mold then opens, the sprue cutter and ejection systems are activated, and the parts are created.
Machining services are available for manufacturing of assembly parts where tight tolerances on dimensions and metal finishes are required. The removal of material from a workpiece is performed using conventional equipment for drilling, milling and turning. (Our machine shop has limited prototype capabilities in four to five axes, with a circular capacity of 17 inches diameter x 6 feet long, and a mill capacity of 48 inches.)
We provide product development services from idea integration to the design and evaluation of potential new products. We work directly with companies and with JMU student sponsored companies.
(RP/RT) is a process that can replicate any 3D computer design out of plastics, metals, or ceramics using a "sintering machine." Rapid prototyping is widely used in the automotive, aerospace, medical, and consumer products industires. Although the possible applications are virtually limitless, nearly all fall into one of the following categories: prototyping, rapid tooling, or rapid manufacturing. The RP/RT component of the Center assists manufacturers to design and create mold cavities, "limited run" parts, and prototype parts quickly and inexpensively. Using this process, manufacturers can test and perfect parts, and create smaller numbers of parts, while keeping costs down. The Rapid Prototyping process is completed in three steps: (1)Create a functional CAD model of the product, (2) Construct the model layer by layer, and (3) Evaluation and post processing when necessary.
Using the 3DSystems 2500+ SLS machine, a 100 watt CO2 laser beam selectively fuses powdered materials, such as nylon, elastomer, and metal, into a solid object. Parts are built upon a platform, which sits just below the surface in a bin of the heat-fusible powder. A laser traces the pattern of the first layer, sintering it together. The platform is lowered by the height of the next layer and powder is reapplied. This process continues until the part is complete. Finished parts are extracted from the machine, blasted with glass beads to remove powder, and sanded if necessary. Parts from the CHPM's SLS machine are either nylon or a composite of 70 percent stainless steel and 30 percent bronze. The 2500+ has a build volume of 13 in. x 11 in. x 16 in.
Using the PROMETAL R2 machine, parts are built upon a platform situated in a bin full of powder material. An ink-jet printing head selectively deposits or "prints" a binder fluid to fuse the powder together in the desired areas. Unbound powder remains to support the part. The platform is lowered, more powder added and leveled, and the process repeated. When finished, the green part is then removed from the unbound powder, and excess unbound powder is blown off. Finished parts are infiltrated with structural sealants to improve durability and surface finish. Parts from the CHPM's 3DP are a composite 0f 60 percent stainless steel and 40 percent bronze. The R2 has a build volume of 8 in. x 8 in. x 6 in.
For more information about CHPM, contact Lynn Radocha
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