A novel method for rapid prototyping/tooling/manufacture - Shell Assisted Layer Manufacturing (SALM)

The present mainstream Rapid Prototyping/Tooling/Manufacture (RP/RT/RM) systems are based on Layered manufacturing technology (LMT). However, most of the commercial RP/RT/RM systems based on LMT are presently undergoing further research & development to improve process characteristics to cater for the demands of industry. Also, any new economically viable systems with improved accuracy, process speed and reliability are most welcomed by industry. This paper demonstrates the technology and fundamental experimental results of a novel process, Shell Assisted Layer Manufacturing (SALM), based on LMT for RP/RT/RM. The process has the potential to improve the quality, productivity and satisfactory process speed. The SALM process builds parts layer by layer. The process executes two essential steps to develop one layer of the part. Initially, it develops outer shell (boundaries) of the particular layer of the part using the Fused Deposition Modelling (FDM) technique and then the shell is filled with UV (Ultraviolet) curable resin. The deposited resin layer is then cured using a UV light source. This procedure is repeated until the complete part is built. Support structures are introduced when the necessity arises.