• DesignforRPmanufactureStratasysDimension.doc: This is the complete manual for using the Stratasys Dimension RP manchine

• The ABS is quite flexible at thicknesses below 3 mm. However, when designing springs it is important to build them in an orientation which ensures that the stress runs along the length of the layers rather than over the weaker interfaces between the individual layers.

RP hole diameter for RP shaft diameter:

Figure 2: Mapping for fits between RP shafts and RP holes

E.g. For an RP hole to give a tolerance fit on an RP shaft designed at 6.0 mm, the hole must be designed at ø 6.27 mm.

E.g. For a M6 bolt the tapping hole should be designed at ø 5.3 mm and the clearance hole should be designed at ø 6.4 mm.

RP countersink to house a metric nut

SUMMARY

1. MANUAL DOWNLOAD

2. QUICK REFERENCE DATASHEETS

• When saving as an STL file click ‘Options’ and ensure parameters match those specified in Figure 1. Failure to do so, whether changes to the dialogue are made or not, might result in the creation of a very small STL file.

Support material awareness

As explained in Section 1 of the full manual, support material will be induced for overhanging features. Support material should be avoided if possible as it will improve the efficiency of the build, improve the finish of the component and save time finishing the component post manufacture.

Please read the relevnt section in the manual to avoid the use of support material during a build.

MANUAL DOWNLOAD

Click on the link below to download the full manual:

http://reprap.org/pub/Main/HintsForUsingTheStratasysDimensionRPMachine/DesignforRPmanufactureStratasysDimension.doc

QUICK REFERENCE DATASHEETS

General points

This data sheet has been designed to accompany the RP Manual - Design for RP Manufacture (Sells, 2005). This data only applies to the Biomimetics Stratasys Dimension machine at the University of Bath, UK.

• Walls should be at least 0.4 mm thick – this is 99% reliable! There have been no recorded failures at 0.6 mm.
• The ABS is quite flexible at thicknesses below 3 mm. However, it is important to build springs in an orientation which ensures that the stress runs along the length of the layers rather than over the weaker interfaces between the individual layers.
• Inverse drafts (overhangs) may range from 0 ° to 45 ° without requiring support material.
• When saving as an STL file click ‘Options’ and ensure parameters match those specified in Figure 8. Failure to do so, whether changes to the dialogue are made or not, might result in the creation of a very small STL file.

Figure 1: STL export parameters

• To save an assembly as a STL file  Open a new part file  Click ‘Insert’ on the top menu bar  Click ‘Part copy’  Select required assembly (if not shown ensure ‘files of type’ is correct)  OK
• Check STL magnitude in Catalyst using F9 and F10.

• A typical profile for a casting channel is 1.6 mm wide by 2.0 mm deep.
• Casting channels incorporated into rapid prototype design should be at least 1.1 mm wide.
• Fences can be positioned as close as 0.2 mm to the primary component and still be easily peeled away.

RP hole diameter for true (non-RP) shaft:

Table 1: Simple metrics for designing RP hole diameters to achieve specific fits to true shaft diameters

E.g. Hole ø required for a clearance fit to a steel shaft, true ø 8.00 mm. Design hole ø at 8.00 + 0.4 = ø 8.4 mm.

RP hole diameter for self tapping screws:

Table 2: Hole compensation reference table for screw fits

E.g. For a gauge 8 self tapping screw the tapping hole should be designed at ø 3.8 mm and the clearance hole should be designed at ø 4.8 mm.

RP hole diameter for metric taps:

Table 3: RP hole diameters for metric taps

E.g. For a M6 bolt the tapping hole should be designed at ø 5.3 mm and the clearance hole should be designed at ø 6.4 mm.

RP hole diameter for RP shaft diameter:

Figure 2: Mapping for fits between RP shafts and RP holes

E.g. For an RP hole to give a tolerance fit on an RP shaft designed at 6.0 mm, the hole must be designed at ø 6.27 mm.

Design for RP manufacture on the Stratasys Dimension

EXECUTIVE SUMMARY

This manual has been designed for use with the Stratasys Dimension Rapid Prototyping (RP) machine. The purpose of this manual has been to capture specific knowledge and techniques directly associated with design and manufacture on the RP machine. In addition to information about typical builds, this manual also includes methods for ‘circuit inclusion’. This facility is a useful post-manufacture process should the user wish to include an electrical circuit. Consideration to this needs to be given at the design phase therefore details have been written in-line with typical design instructions. This manual has been designed for three types of user, shown in Table 1:

This manual is specific to the Stratasys Dimension rapid-prototyping machine and Solid Edge v14 (solid modelling software package licensed by the University of Bath). Therefore this manual will refer to techniques used in Solid Edge v14.

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