Drill parts prototyped in clear resin
A
DSM Somos product story
Edited by the Engineeringtalk editorial team
Jul 24, 2001
DPT recently prototyped parts for a recently commercialized DeWalt drill from Black and Decker using DSM Somos 10120 WaterClear, a stereolithography resin with the optical clarity of polycarbonate
Design Prototyping Technologies (DPT) prototyped parts for a recently commercialized DeWalt drill from Black and Decker using DSM Somos 10120 WaterClear, a unique stereolithography resin with the optical clarity of polycarbonate.
The clear SL parts were built, finished and assembled into a working tool in only three days.
WaterClear is a composite of many desirable engineering properties, mimicking the flexural strength and modulus of polycarbonate, the notched izod impact strength of Nylon 66 and the tensile strength of ABS.
Ideal applications for this epoxy-based photopolymer include: flow visualization, complex assembly analysis, form/fit analysis and functional testing.
Its transparent appearance may be dyed in a secondary step for color tint.
According to Mike Rufo, President of DPT: "In the past when a designer wanted to see the inside of the tool during operation clear polycarbonate housings were injection molded using prototype or pre-production injection molding tooling.
The potential problem was at that point in the project the design process was nearly final and the ability to modify was constrained.
With Somos 10120 WaterClear, clear SL parts can be built early in the design process - as much as 6 months earlier than the previous approach using prototype or pre-production tooling.
Multiple iterations of these clear parts can easily be made as the design evolves." Rufo also notes that Somos 10120 WaterClear made it possible to use Plastite screws in the DeWalt drill model.
Plastite screws are self tapping and are used in production.
Using Plastite screws in earlier SL materials would either crack the boss material or the boss material would strip out because the material was too soft.
The solution was a combination of brass inserts and adhesive.
However, the boss size typically would need to be enlarged so the brass insert would fit.
Not needing to enlarge the boss results in one less design feature separating the prototype from production.
Not using inserts is also one less step in the prototyping process.
Somos 10120 WaterClear prototypes deliver exceptional durability, toughness, impact strength and also, in the case of the DeWalt drill models, had enough flex to accept a press fit bearing.
Other available grades of resin were either too soft for the application or too brittle to accept the press fit bearing.
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