Solid Freeform Fabrication (SFF) is a process that uses computer files and controlled equipment to build three-dimensional components layer by layer. Four common types of SFF include selective laser sintering, laminated object manufacturing, stereolithography, and fused deposition modeling. SFF is used in research and development, manufacturing prototypes and custom components, and has military applications. A bachelor’s degree is usually required for careers in this field.
Solid Freeform Fabrication (SFF) is the production of specific parts and components without the need for custom molds and dies. They are manufactured in a free-form process with the use of computer files and carefully controlled equipment to build them layer by layer. Several methods are available, all based on Computer Assisted Design (CAD) and process control tools. Plastics, metals, and resins can be used to make a variety of fully functional and usable three-dimensional components and prototypes.
Four common types of solid freeform fabrication are in use. They begin with the generation of a computer file that accurately represents the object to be produced in three dimensions. The computer slices the object into a series of slices, based on the thickness of the materials that will be used in production, and sends them to a production unit. Layer the slices one at a time, building the object until it’s complete.
One option is selective laser sintering, where a laser melts powdered materials to create each layer. In manufacturing laminated objects, the computer creates a series of layers and connects them to each other. Stereolithography uses a platform sunk in a pool of resin. The platform is exposed to ultraviolet light to cure a layer and then lowered so the process can be repeated. When the platform falls, the object takes shape.
Another form of solid freeform fabrication is fused deposition modeling. This uses heated plastic that is forced through a nozzle to create a layer. Each successive layer builds on the last as it hardens, creating a finished solid object. The best production method may depend on the materials used and the type of item being crafted.
Universities use solid freeform fabrication in research and development, where engineers are also working on new technologies to make the process faster and less expensive. This may include research into entirely new production methods, some of which are intended to make them accessible to end consumers. Instead of buying products, for example, consumers could buy files that feed their personal three-dimensional printers and create instant output.
Manufacturers use this technology in creating prototypes and custom components. Creating one-of-a-kind tools, for example, can be much more cost-effective with this method. There are also military applications for solid freeform fabrication, with ongoing research and development in defense settings. Careers in this field are very varied and a bachelor’s degree is usually required to work in solid freeform fabrication.
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