The impact of layer thickness on the performance of additively manufactured lapping tools

Wesley B. Williams

doi:10.1117/12.2195995

11 October 2015 The impact of layer thickness on the performance of additively manufactured lapping tools

Wesley B. Williams

Proceedings Volume 9633, Optifab 2015; 963304 (2015) https://doi.org/10.1117/12.2195995
Event: SPIE Optifab, 2015, Rochester, New York, United States

Abstract

Lower cost additive manufacturing (AM) machines which have emerged in recent years are capable of producing tools, jigs, and fixtures that are useful in optical fabrication. In particular, AM tooling has been shown to be useful in lapping glass workpieces. Various AM machines are distinguished by the processes, materials, build times, and build resolution they provide. This research investigates the impact of varied build resolution (specifically layer resolution) on the lapping performance of tools built using the stereolithographic assembly (SLA) process in 50 μm and 100 μm layer thicknesses with a methacrylate photopolymer resin on a high resolution desktop printer. As with previous work, the lapping tools were shown to remove workpiece material during the lapping process, but the tools themselves also experienced significant wear on the order of 2-3 times the mass loss of the glass workpieces. The tool wear rates for the 100 μm and 50 μm layer tools were comparable, but the 50 μm layer tool was 74% more effective at removing material from the glass workpiece, which is attributed to some abrasive particles being trapped in the coarser surface of the 100 um layer tooling and not being available to interact with the glass workpiece. Considering the tool wear, these additively manufactured tools are most appropriate for prototype tooling where the low cost (<$45) and quick turnaround make them attractive when compared to a machined tool.

Citation Download Citation

Wesley B. Williams "The impact of layer thickness on the performance of additively manufactured lapping tools", Proc. SPIE 9633, Optifab 2015, 963304 (11 October 2015); https://doi.org/10.1117/12.2195995

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