Soft Cad 3d

GM cuts time for labor-intensive design projects with rapid prototyping

The goal of rapid prototyping as shown here via media.gm.com is to achieve huge gains in creativity, flexibility and accuracy along with dramatic savings in time and money.

So, think finished parts for prototypes and concepts that come from powder and liquid in just hours. That is the world of rapid prototyping, also known as stereo lithography.

According to recent news release by General Motors Company (NYSE: GM), much of this occurs deep inside the GM Design building at the Warren Tech Center in Warren, Michigan, where this reporter once had the privilege of working with this process. This is where future products from Chevrolet, Buick, GMC and Cadillac take shape and substance, and an elite team fashions components, intricate sub assembles and entire scale model cars from highly specialized three-dimensional rapid prototyping manufacturing equipment.

The Rapid Prototype Laboratory features two fabrication processes – selective laser sintering (SLS) and stereo lithography apparatus (SLA). SLS is a dry powder, while SLA is a liquid material. Both processes build up finished products from raw material in layers.

“Think of it as the reverse of slicing off cold-cuts at the deli counter, where each slice is created and joined back to the whole,” said Dave Bolognino, director of GM Design Fabrication Operations. “RP technology eliminates tooling plus it permits the production and testing of multiple iterations of a part or assembly with superb precision at little to no incremental expense. It’s a game-changer of epic proportion.”

Selective laser sintering (SLS) machines are used to fuse plastic, metal, ceramic or glass powders in cross- sections. A laser scans a pattern on the surface of the powder, fusing the particles together adding a layer four-thousandths of an inch thick. As each new layer of powder is added, scanned and fused to the previous one the part gradually takes shape within the 28-inch-cubed reservoir. To the naked eye, the plastic used in the SLS process looks much like powdered sugar with individual grains measuring just 550 microns or about two-hundredths of an inch across.

Technicians carefully position as many jobs as they can together within that space to maximize the throughput of each build request. The SLS manufacturing process is self-supporting, meaning un-fused powder cradles the part as it is being fabricated, often without need for additional finishing or trimming. After it cools, the excess powder is shaken off and a portion is recycled with the finished part put to use immediately or joined with other components to make larger assemblies.

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