Shape Deposit Manufacturing
Shape Deposition Manufacturing (SDM) was developed in Stanford University.
In this approach, when a complicated model is to be made, the cutting and deposition are alternatively used after the model is decomposed into the smallest level. This system has been developed as a hybrid system combining 5-axis CNC equipment and a powder based Rapid Prototype (RP) machine.
SDM is a RP process that systematically combines the flexibility of the additive layer manufacturing process with the precision and accuracy attained with the subtractive CNC machining process.
The basic SDM fabrication methodology is that the material is firstly deposited, and then the part is transferred to the shaping station center where the material is removed by CNC machining to form the desired or net shape of the part, thence sacrificial support material is deposited to support the part.
This method can fabricate a wide variety of materials, including metals, plastics (plastic manufacturing), ceramics, etc. In addition, it has the ability to build heterogeneous structures due to both permitting pre-fabricated components to be embedded within the built shapes and using support materials.
With the continuous development of SDM, its deposition process is increasingly diversified, including extrusion, microcasting, thermal spraying, etc.
Although this approach is not desirable for a large prototype, it can be applied to a geometrical shape with interior cavities or holes where a traditional machining cannot be used. Particularly, it has advantages of depositing high quality materials and making a model with embedded components.
It can also be used in Rapid Tooling (RT), which makes prototypes with a high precision. Further advances are made towards laser-assisted micro-SDM, which integrates micro-deposition and micromachining, aiming at fabricating 3D heterogeneous micro-components.
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