INDUSTRIAL SERVICES PROVIDES CAD / CAE and Rapid
Prototyping and Manufacturing lab.
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Electronic Drafting and 3D Modeling: Using the state of the art of CAD software, every product can be 2D drafted and 3D modeled electronically on the computer screen including complicated surfaces and details that can be captured using 3D Scanner. The electronic 3D Models can be sent to CAE software for stress analysis, simulation and design approval, CAM for traditional machining and 3D printing for the rapid manufacturing. Software Tools: Examples:
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CAE, Stress Analysis and Simulation: Using CAE software, the 3D modeled products can be studied under simulated working conditions such as static, dynamic and variant mechanical and thermal stresses. From the study results, important decisions can be taken to improve the design and the product added-value such as modifying the materials and weight, increasing wall thickness, modifying holes and fillets, etc. Product life time, durability, performance and human satiety factors can be also predicted from the analysis results. Software Tools:
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Rapid Prototyping and Manufacturing using REAL METALS: 3D printing - Rapid Prototyping - Rapid Manufacturing - Free Form Fabrication are all the new names for the technologies that are used to output the electronic model from the computer screen direct into real product - made from real materials - using only one machine. Our lab has installed m3Linear, the first machine in Africa and the Middle East that builds REAL METAL products that output directly from the computer screen. m3Linear uses laser to melt and micro weld the particles of the layered powders until the complete solid is formed. Metallic powder is hereby fully fused layer for layer to produce a 100% component density. A specially developed exposure strategy allows the generation of solid and large-volume components without any deformation. A patented surface post-treatment process directly after the construction process ensures the highest surface quality and hardness. Countless technical refinements such as automatic powder evacuation, a separately developed coating system and a circulating inert gas atmosphere make the M3 linear a machine concept in a class of its own.
The products have density up to100%, very homogeneous microstructure and industrial acceptable surface roughness. Small details and very thin walls up to 1 mm can be built efficiently without problems and near real strength. Products can be built by any type of metallic powder such as stainless steel, tool steel and alloy steel, etc. Products can be Metallic products: low productions batches, spare parts, tools, die and mold inserts, medical implants, etc. Hardware Tools:
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3D printing - Rapid Prototyping - Rapid Manufacturing - Free Form Fabrication are all the new names for the technologies that are used to output the electronic model from the computer screen direct into real product - made from real materials - using only one machine. Using the Invision Si2 3D printer, every computer model can be output using high strength acrylic materials SR200 that give the following properties:
The 3D Printing technology is suitable for the fast and rapid production of models for concept development, design validation, presentation, marketing and selling aids, bid packages, prototypes for form and fit analysis and patterns for casting or molding.
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3D Digitizing, Scanning and 3D Contour Tracing: For the application of REVERSE ENGINEERING, complex 3D surfaces and product details need 3D digitizing techniques to be captured into CAD model. The accuracy of the CAD model and the final product depends on the accuracy of the scanning process. Hardware Tools:
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Developing Medical Implants from Medical CT / MRI Images: Medical implants are a major application for the CAD/CAE and Rapid Prototyping and Manufacturing. For the implant to be efficient and safe, it should be tailored according to specific human body details. Currently, medical doctors use CT or MRI images to explore the details of human bodies. Using advanced medical image to 3D model construction software such as MIMICS, these images can transferred to 3D Models that input to CAD and CAE software for the implant development. Finally, ONLY ONE - tailored to only one patient - medical implant is fabricated by using the metal Rapid Manufacturing machine and made from human friendly material such as stainless steel or titanium. The medical implants can be completely designed and built within few hours. The speed and accuracy of fabrication could safe many human lives. For more information about developing Medical Implants, Please click to download this file. Tools:
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Design and Manufacturing of Plastic Molds: The technology of the plastic production has evolved since many years in order to produce light weight, complex and human friendly products. On the other hand, many problems face the designers and manufacturer of plastic products due to unpredictable results because of the nature of this process where plastic materials are melted and injected inside closed metallic molds, then cooled and solidified to produce the final products within fraction of seconds in a fully automatic process.
There are unlimited factors affecting the properties of the resulted products which include: initial product design, mold design, machining accuracy, surface treatment and finish, materials selection, injection pressure, temperature and cooling cycles, mechanical system, etc. Each of these factors greatly affects the product quality and life time and significantly influences product global market value.
Using specialized CAD software for Mold Design such as Unigraphics NX4: Mold Wizard and DelCAM Power Shape, very complicated molds can be designed and produced.
In addition, Moldflow: Mold Advisor 7.2 is used also to verify the accuracy of the mold by simulating the inside plastic flow, pressure and temperature in order to predict the defects of the products before consuming money and time in incomplete production process. Hardware Tools: Examples:
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