Rapid prototyping utilising the laser cutting method

Abstract

Due to the popularity of 3-dimensional CAD designs, the methods of manufacturing from these designs are increasing all the time. Rapid prototyping designers and manufacturers are now able to grow prototypes from the drawing files they have created. Stereolithography (SLA), selective laser sintering (SLS) and fused deposition modelling (FDM) processes are commonly known in South Africa and throughout the world. These methods, however, are restricted by the size of the model that can be produced and are very time-consuming. The SLA, SLS and Sanders prototypes and machines are generally too expensive for the designer or entrepreneur. This study presents an innovative method of producing engineering and architectural prototypes, i.e. the Cross-Section Prototyping (CSP) method. This method eliminates the problems that occur with other processes. The CSP method slices a 3-D model into evenly spaced layers with the aid of dedicated software. All the layers are referenced and the profiles are cut with a laser beam. The layers are laminated together to form the prototype at a reduced cost and in a shorter timespan. This method also allows models of larger geometry to be produced. The layout of the laser cutting machine and the CSP process are discussed in detail. This dissertation can serve as an instruction manual for users of the CSP method.