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Composites to provide novel prototyping materials

Edited by the Engineeringtalk editorial team Jun 10, 2003

ProtoComposites are complex materials in which two or more distinct, complementary substances combine to produce functional properties not possible using individual components.

DSM Somos is nearing commercialisation of Somos ProtoComposites, liquid materials containing fillers allowing for a broader range of applications.

ProtoComposites are complex materials in which two or more distinct, complementary substances, especially metals, ceramics, glasses or polymers, combine to produce functional properties not possible using individual components.

ProtoComposite materials are a result of spending a significant amount of time and resources investigating the potential for ACT-SL (advanced composite technology for stereolithography).

Initially, the Somos ProtoComposites family will consist of two product groups: Somos ProtoTool and Somos SolidCast.

Somos ProtoTool is a filled material with high heat resistance providing "best-of-class" tensile strength, flexural strength and modulus plus a high heat deflection temperature (HDT) greater than 270C at 4.55bar.

ProtoTool has been developed as an answer to the problem represented by current resins that lose significant strength during the thermal cycling necessary to achieve high HDT.

In contrast, ProtoTool offers high HDT with superior strength.

Ideal applications include direct tooling as well as creation of strong, rigid parts.

Somos SolidCast, is hollow-spherically-filled material with low density and excellent investment casting pattern properties.

SolidCast will enable solid investment casting material that eliminates drainage and sealing concerns associated with a honeycomb structure, enhancing accuracy and surface quality.

Moreover, this material is characterised by a low density capable of producing large parts without the weight associated with other resins.

This is a key response to marketplace demands in that current resins have a density that averages 1.1g/cm3 which results in formation of large heavy parts, whereas SolidCast has a density of approximately 0.6g/cm3.

SolidCast can therefore form large, lightweight parts.

Stereolithography is a layer-additive rapid-prototyping process based on the use of photopolymer liquid resins which solidify when exposed to UV light.

A software program transfers the designer's 3D CAD model into an electronic file for stereolithography machines ('STL' format), composing the information into thin cross sections or layers.

A laser beam then traces each layer onto the surface of a vat of photopolymer resin, building the part in repeated layers until a solid replica of the original CAD model is completed.

DSM Somos ProtoFunctional resins for stereolithography DSM Somos has commercialised an entire range of ProtoFunctional resins to respond to the needs of new product development and industrial design.

Among the newest ProtoFunctional materials to be launched is the Raven 7600 series which creates dark coloured, rigid prototypes with high humidity and mechanical resistance; WaterClear 10100 series, the industry's first transparent, tough and durable resins; and the Somos 9100 series which allows material properties similar to polypropylene, with superior mechanical memory.

Each family of Somos photopolymer epoxy resins is comprised of materials specially formulated and optimised for the variety of stereolithography platforms commercially available: Somos XX'00' resins are for use in argon ion laser systems; Somos XX'10' for Helium Cadmium laser systems; Somos XX'20' resins for platforms using solid state laser systems.

DSM Somos also offers materials for selective laser sintering and is the first manufacturer of powder elastomeric polymer (Somos 201) that can be sintered to produce highly flexible parts with "rubber like" characteristics.