Product category:
Fast prototyping equipment, pattern-making and services
News Release from: Huntsman Advanced Materials | Subject: RenShape SL 7560 SL photopolymer material
Edited by the Manufacturingtalk Editorial
Team on 10 February 2003
SL material provides look-alike
prototypes
Stereolithography photopolymer is quickly prototyping close-tolerance braking components that look and feel like injection-moulded injection-moulded thermoplastic parts.
As a world leader in the development and manufacture of automotive braking systems, TRW, Birmingham, is quickly prototyping close-tolerance braking components that look and feel like injection-moulded thermoplastic parts using new RenShape SL 7560 material from Vantico The unique stereolithography (SL) photopolymer combines durability and rigidity to effectively simulate ABS to produce functional, long-lasting models and prototypes
This article was originally published on Manufacturingtalk on 5 Nov 2002 at 8.00am (UK)
Related stories
Website aimed at solving adhesive bonding puzzles
Showcasing an extensive adhesives product range at the touch of a button a new website is themed on solving "almost all bonding 'puzzles'" for a wide range of engineering substrates.
Functional hairdrier models produced in three days
Using an ABS-like stereolithography material, a Taiwanese company produced 28 highly complex and detailed parts for the functional model of a new portable hairdryer - in just three days.
Parts built with the material feature excellent reproduction of fine details, high-strength sidewalls and an outstanding smooth surface finish.
Background - TRW has more than 70 years of experience in designing and producing technologically advanced anti-lock braking systems (ABS), disc-braking components, advanced brake actuation systems and front-end brake modules for customers throughout the world.
The company currently supplies braking components to more than 40 vehicle manufacturers for installation in over 180 different automotive models.
Further reading
Adhesive bond has to put up with a grilling
As well as being able to cope with varied weather conditions an adhesively bonded joint in a front radiator grill and engine hood assembly had to be able to withstand 80degC during the paint cycle.
Casting system contributes to award-winning car
Casting system has been used to build an Michelin- award winning model car designed to meet the demands of 21st century urban living in China and exhibited at the Detroit Car Show earlier this year.
Modelling paste speeds wind blade moulding
Using a seamless modelling paste, combined with CAD/CAM and CNC, models to make the moulds for wind turbine blades are produced quickly and cost effectively.
A key component in braking systems is the valve that controls airflow into the Servo unit to assist in the braking effort.
The valve body is a cylindrical component with a complex internal geometry that controls valve movement and directs airflow.
Production components are injection moulded from 36% glass-filled polyester.
Servo valve prototyping - recently, TRW engineers were asked to evaluate new designs that would enhance the function of the valve body.
Prototype bodies had to perform like a production part but be produced using a process faster and less expensive than injection-moulding.
Material selection was also important.
If machined aluminum prototypes were used, for example, they would not simulate the performance of thermoplastics, eliminating the possibility of comparing prototype designs to production parts.
TRW is a member of the Rapid Manufacturing Consortium at Loughborough University; http://www.lboro.ac.uk/departments/mm/research/rapid-manufacturin g/index.htm so the problem was put to them.
After a thorough analysis of project requirements, the decision was made to build prototype valve bodies using stereolithography and Vantico's new RenShape SL 7560 ABS-like material.
The opaque white photopolymer was ideal for the application because it produces models and prototypes with a high gloss, smooth surface that looks as if it were injection moulded on a precision-cut metal tool (see Figure 2).
Moreover, parts can be used for functional testing, featuring good rigidity and durability at temperatures up to 60degC (140degF).
The material also produces models and prototypes with outstanding accuracy.
TRW built its initial valve body prototype in two parts and measured geometries at 11 different points.
Most tolerances were within 0.1mm to 0.05mm (0.004in to 0.002in) demonstrating the outstanding accuracy produced by the new material.
Even out-of-tolerance dimensions were close to the limits.
Surface finish was also examined by measuring average surface roughness in microns after initial.
The ability to produce an extremely smooth surface was important for the valve body application because the design contains a contacting lip seal that must maintain pressure during operation.
TRW engineers report that they were particularly impressed with "up"-facing surfaces on the insides of the prototypes because they featured the required seal straight from the vat.
After these studies, the design was modified slightly and built in one piece.
It is now being incorporated into a Servo unit for functional testing at lower-than-normal operating pressures.
Based on this project, TRW has confirmed that stereolithography parts built with advanced SL materials feature excellent geometric accuracy and are well suited for use as functional components.
RenShape SL 7560 is one of 20 different materials manufactured and marketed by Vantico Ltd.
The full family of RenShape SL photopolymers features such diverse characteristics as humidity and high-temperature resistance and tough, polypropylene and ABS-like properties.
Vantico also manufactures and markets a broad range of epoxy and polyurethane systems for modeling, mouldmaking, prototyping and forming initial parts to the automotive, foundry, aerospace and general manufacturing industries.
The company has been a world leader in plastic tooling materials for more than 60 years.
TRW's global automotive business is a world leader in the design, development and manufacture of active and passive safety technologies, and in converging these technologies to yield even higher levels of passenger safety, comfort and convenience.
The business produces braking systems, steering and suspension systems, occupant restraint systems including air bags, seat belts and steering wheels, electronic control and security systems, engineering fastening systems, engine components, commercial steering systems and aftermarket replacement parts.
• Huntsman Advanced Materials: contact details and other news
• Email this article to a colleague
• Register for the free Manufacturingtalk email newsletter
• Manufacturingtalk Home Page
Search the Pro-Talk network of sites
