Several advantages of the ultra high-precision additive manufacturing technology

A breakthrough additive technology

Rapid prototyping techniques have been studied by now for nearly 20 years. Currently, four relatively mature RP&M processes are dominating on the commercial market: stereolithography (SL), selective laser sintering (SLS), fused deposition modeling (FDM) and laminated object manufacturing (LOM). Each of these four processes represent a special class of RP&M technologies.

New roll powder sintering (RPS) technology that combines the main advantages of the mature RP&M processes mentioned above and offer more competitive products with better quality, lower price and shorter fabrication time.

It is based on the commercially available inexpensive components, providing manufacturing of plastic, ceramic, metal and other objects with precision up to 77000×77000 dpi, a layer thickness of about 0.5 µm and processing volume of 1 m3 from CAD model during 1 hour.

The general view of RPS plant is illustrated in Fig. 1. The construction process consists in having a thin inexpensive compressible (at a wide interval) and perforated ribbon on the side for precise allocation. The required production accuracy determines the ribbon’s thickness and perforation method.

First, a ribbon roll is rewound in the direction shown by the arrows by extending the rollers and the supporting ribbon. When the compressible ribbon is being rewound, e.g. the laser perforates it in the places into which a powder needs to be poured, i.e. where the component is.

After perforating, the holes are filled with the powder from the upper bunker. Then, to provide better accuracy and sintering, the filled ribbon is flattened evenly from top to bottom by upper and lower pressure rollers.

When the whole component roll is rewound, it is ready for a sintering plant. Sintering is possible in wide range of conditions, at different temperatures, pressures, vacuum or gas states.

At the end of the manufacturing process, it is required to remove the ribbon. The leftovers of a compressible ribbon in cavities and other places can be easily removed by dissolving, e.g. by water.

The RPS technology can build more accurate products with a better smooth surfaces that has the potential to revolutionize micro-manufacturing, offering businesses a new way to produce micro-scale goods and parts for customers.

Additive manufacturing technology have received significant advantages from both object’s properties and performance due to the whole powders layers can be simultaneously sintered into final parts and it is probable to sintering several component rolls at the same time.