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Rapid Texture Prototyping Application
In
many rapid prototyping applications, surface texture is a major concern
of importance. Not all RP technologies produce finished parts, which
makes secondary processes, such as grinding or polishing, possible.
These additional steps add time and cost to prototyping. As the goal of
RP technology is to produce finished models quickly and at a low cost,
producing the right surface texture on RP parts is important.
Polyjet™
Technology can print textures (grains or patterns) and logos on
prototype parts, molds and models exactly as they would be on final
production molds or parts. If needed, the texture can be limited to
specified areas.
However, texture can also be added in a post-process using rapid texture prototyping applications.
As
a post-process, Objet 3-D printing technology can add high-quality
textures with remarkably fine detail to models so that both the models
and their related elements and materials have the same texture.
Also,
rapid texture prototyping can strengthen thin materials in lightweight
structures to improve aero-and fluid dynamics or can be used to fill in
layer lines on printed parts to provide a smooth surface, as well as
increase the thickness of a wall or a surface without having to make a
new part.
Akron Metal Etching are specializes in adding textures
to different materials and substrates. Akron developed a patented
post-process method specifically for texturing the surfaces of parts
made by PolyJet™ Technology, called Prototex™.
In fact, Akron
can put just about any texture on parts made from Objet 3-D printed
models. With an extensive design library of thousands of patterns and
textures including leather grains, geometric patterns and current
popular designs, Prototex lets end-users achieve just the right look
for their finished 3-D printed model.
“The advent of rapid texture
prototyping technology greatly reduces the effort required for applying
texture to printed models,” says Mr. Lee Eisinger, President of Akron
Metal Etching. “The goal of Akron Metal Etching has been to provide the
highest quality mold texturing based on our extensive experience in the
plastics and related industries. We help to work through the details of
texture selection and all the items pertinent to end-user tooling to
get parts with just the right textures out of the molds with ease”.
The Process for Adding Texture to PolyJet Printed Models:
First,
printed models are thoroughly cleaned and sanded using fine sandpaper.
Second, a coating layer is applied to mask the areas that will not be
textured (see picture 1). After the masking, the texture process is
built up onto the parts to the depth of the desired texture.
A
special device measures the thickness as it is being built. In general,
a tolerance of +/-0.01 mm (0.0005 in) is acceptable for texture depths.
With textures of thicknesses from 0.1mm to 0.375mm (0.004 to 0.015 in)
this step takes a relatively short period of time.
Picture 2
shows the material built to the proper thickness. The red areas are
masked off and will remain without texture in the finished parts. The
masking also defines texture changes if multiple textures are being
applied. The ability to add texture to specific areas adds realism to
the parts.
The next stage is to apply the texture patterns.
There are several different methods for applying patterns on parts’
surfaces. After a curing process the pattern masters are removed from
the surface along with the masking materials. A chemical treatment is
used to reveal the pattern.
Finally, after the textures are
examined and any necessary touch up work is completed, the textured
areas are lightly coated with an overcoat to seal the texture to the
parts. This can be seen in picture
6 in the light colored areas
between the dark blue areas of the pattern. The parts are then exposed
to light to cure the materials.
Spray painting the textured printed models produces a finished part look.
The
texture (grains or patterns) can be applied to both printed PolyJet
models and molds, bridging the gap between rapid tooling and expensive
hard tooling.
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Picture 1. PolyJet Model coated with base layer.
Picture 2. Masking areas before applying texture pattern.
Picture 3. Example of textured PolyJet model.
Picture 4. Example of textured PolyJet model.
Picture 5. Differnt texture patterns applied on Polyjet model.
Picture 6. Texture patterns.
Note: Information and pictures in this applications note are courtesy of Mr. Eisinger, President of Akron Metal Etching.
www.textureame.com
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