(Dr. David Rosen, advisor)

"Building Around Inserts in Stereolithography: Standardization and Process Planning"

Abstract

One of the most common Rapid Prototyping (RP) Machines, Stereolithography Apparatus (SLA) fabricates 3-dimensional parts using a layer-based, additive fabrication process by tracing part cross-sections on the top surface of a vat of liquid photopolymer.  Typically, usage of the SLA process has been limited to piece parts.  At RPMI, we are working on expanding the application of SLA and other RP technologies by fabricating assemblies of parts as working mechanisms or static, complex structures which we call “live” or “smart” models. This is achieved by building around embedded components, where these components are motors, printed circuit boards, metal bushings, etc.  The method is called Building Around Inserts.

The primary goal of this thesis is standardization and process planning for Building Around Inserts. The first part of the thesis is standardization of process and development of compositional design approach for building around inserts in existing Stereolithography Apparatus. The second part focuses on process planning and implementation for Generalized Stereolithography Apparatus developed in RPMI for building around inserts. The code is written in C++.