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About Project
Need a large, flat rack with a complex grid and bridge structure? At FacFox, we can handle intricate designs like these with our Selective Laser Sintering (SLS) 3D printing technology. This process allows us to create highly durable and functional prototypes or end-use parts, perfect for applications in storage, organization, or even specialized uses like aquarium fish tank bottom isolation boards.
Large, flat structures with intricate details can be challenging to 3D print. Traditional methods like FDM (Fused Deposition Modeling) might struggle with warping or deformation due to the material properties and printing process. This can lead to a compromised final product that doesn't meet your needs.
Our SLS 3D printing service offers a perfect solution. SLS uses a high-powered laser to precisely sinter layers of powdered nylon, resulting in exceptionally strong and dimensionally accurate parts.
Here's how we tackle large, delicate prints:
鈥 Splitting the Model:聽We can strategically split your large model into two or more sections. This reduces warping and allows for more efficient printing.
鈥 Interlocking Design:聽Our team will incorporate an interlocking mechanism into the design. This ensures seamless assembly of the separate parts into the final, robust structure.
鈥 Cost-Effective Splitting:聽Splitting the model also helps reduce transportation costs, a significant advantage for large prints.
Benefits of SLS 3D Printed Nylon Racks:
鈥 High Strength and Durability:聽SLS nylon is known for its excellent mechanical properties, making it ideal for functional applications.
鈥 Dimensional Accuracy:聽SLS printing delivers precise parts with minimal tolerance deviations.
鈥 Design Flexibility:聽Our technology allows for intricate grid and bridge structures within the rack design.
鈥 Cost-Effective Splitting:聽Smart splitting reduces both printing and transportation costs.
Whether you need a storage rack, an organizational tool, or a custom aquarium component, FacFox's SLS 3D printing with interlocking design is the perfect solution. Contact us today to discuss your project and get a free quote!
Solution
- Step 1: The design was then exported in a 3D printable file format. The SLS printer was prepared, which involved preheating the powder bed to just below the melting point of the nylon material.
- Step 2: The printing process began with the application of a thin layer of nylon powder over the build platform. A high-power laser selectively sintered the powder, tracing the cross-section of the model to solidify the first layer. This step was repeated, with the platform lowering incrementally after each layer, until half of the rack was completed.
- Step 3: To prevent deformation due to the large size of the model, the rack was designed to be printed in two halves. Each half was printed separately with an interlocking mechanism. After printing, the two halves were left to cool down within the unsintered powder, which supported them during the process and eliminated the need for additional support structures.
- Step 4: Once cooled, the two halves were removed from the powder bed and cleaned of excess powder. The interlocking mechanism allowed the two halves to be combined seamlessly into one piece. This modular design facilitated not only the reduction of potential deformation but also minimized transportation costs due to the smaller package size required for each half.
- Step 5: The final product, potentially used for storage, organization, or as an aquarium fish tank bottom isolation board, showcased the versatility and efficiency of SLS 3D printing for creating large, complex parts with functional mechanisms.
