The Department has two prototyping machines, The ZCorp Z400 and the Dimension.  The Z400 is capable of generating solid models using a plaster powder and a binder.  The Dimension creates solid models out of ABS plastic.

Characteristics:

Z400

The maximum size of a part is 8″x10″x8″.
You should avoid a shell thickness of less than 1/8″ otherwise the part may break
The part can be treated with an infiltrant hardener (Cyanoacrylate adhesive, e.g., Cyberbond Appollo 5005) of other more expensive epoxy hardeners to add strength.
The part can also be sanded and painted.

Dimension

The maximum size of a part is 8″x8″x12″.
You should avoid a shell thickness of less than 1/16″ otherwise the part may break
The part can be treated with methyl Chloride or typical ABS cleaner.
The part can also be sanded and painted.

Creating your model:

  1. To generate a model you must first create a 3-D model using ProE, IDEAS, or other CAD packages.  You must then save your model as an STL file format.For ProE you can do a Save As and select the STL format.  There are 2 parameters to control the resolution of the STL representation.
    • chord height – set this to 0 and it will be automatically replaced with a minimum value (0.0009)
    • angle control – set this to 1

    For more information about STL files see
    http://www.quickparts.com/encyclopedia/stl.asp

  2. Once you have the STL file you should get an estimate of the cost of producing the part: Z400
    1. Open the Zprint software and import your STL file.
    2. Click on View – Part Statistics – record the volume and surface area values
    3. Click on File – Print Time Estimator – record the number of pixels
    4. Open N:3dprinterZcorpZ400 Material Cost Estimator spreadsheet (available in xls and qpw format)
    5. Input the volume, surface area and pixels to get the cost

    Dimension

    • Open the Catalyst software and import your STL file.
    • Orient your part to have the least amount of support material
    • Select the appropriate options on the right side of the screen then click on the green flag.
    • Once the computer has finished with calculating  the paths click on the View log button and record the model and support material amounts.
    • Open N:3dprinterDimensionDimension Material Cost Estimator spreadsheet
    • Input the volume of both materials to get the cost.
  3. Once you have your model and the cost estimate you need to get approval from your project supervisor to generate the part.  If the part is for your own use you will have to pay for it yourself.
  4. Put the STL file on a MAE network drive or on a CD-ROM and fill out a Request Form
    If you are in ECOR 1010 or MAAE 2001 visit the appropriate webct for the proper procedure.
  5. Contact Stephan Biljan ext. 6716 sbiljan@mae.carleton.ca or go to room 2230 Mackenzie to have the part made.