Presbyterian church of New York

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Presbyterian church of New York
By Mcinturf Architects Douglas Galofalo
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powder-coated, stainless steel,
Foam patterns for casting
freeform architectural column prototype.
CNC milled from ProEngineer CAD models
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materials
Reinforced concrete
Metal
Wood
Advanced composites
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STL- Stereolithography
Divides a computer model into very thin
horizontal layers.
cure
deposit
bind
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ProEngineer
Alias/Wavefront
SolidWorks
M O D E L I N G S O F T W A R E
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Types of Rapid Prototyping
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Stereo Lithography Apparatus (SLA)

• applicable for both rigid and flexible material
• UV laser beam
• fluid polymer
• support is required

• Form fit analysis
• Concept model
• Presentation models
• Sales marketing samples

Applications
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Stereo Lithography Apparatus (SLA)
files converted to SLA format
Model converted into slice files to create
layers
Finished object cured in ultraviolet oven
Object formed removed from the vat and cleaned
laser beam solidify liquid polymer resin, layer
by layer
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Selective Laser Sintering (SLS)

• closely represent the physical properties of the
  materials
• CO2 laser heat is used for hardening
• for functional testing
• thermoplastic powder is used
• no support is required

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Selective Laser Sintering

• data transferred into the Sinterstation system
• powder SLS material added by leveling roller
  across the platform
• CO2 laser beam causes the affected powder grains
  to sinter and glue together

• surrounding unaffected powder serves as support
  for the sinter part
• process repeated layer by layer
• cleaning after object formed

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3D Printing

• for fast concept models for quick review
• less costly prototype
• uses a heated plastic/wax material
• two print heads on the machine
• submerged into a vat of solvent and the support
  material is dissolved away.

• Steps
• exported as .stl file
• sliced into thin layers
• Sliced model sent to machine
• Parts larger than the platform can be built in
  section

• Advantages
• Minimal user input
• Quiet, safe and compact
• No special venting required
• Non-toxic, suitable for office environment

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Fused Deposit Modeling (FDM)

• Similar to the 3DP
• Small material is fed through a heated print
  head and deposited layer by layer
• Support material is then removed

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Fused Deposit Modeling (FDM)

• Providing better control of the process
• Support structures easily removable
• Better layer to layer bonding
• Non-toxic and can be installed in office
• No clean-up necessary

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Layer Object Manufacturing (LOM)

• layers of paper used
• paper drawn through an opening and laminated
  (glued) to the the layer below it
• a laser then draws the shape of the object being
  made. 

• the parts inside must be removed. 
• products are like wood in nature and can be
  painted and worked on just like wood. 

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Advantages vs. disadvantages

• Still too expensive except for making relatively
  small parts

• More freeform a components geometry may be
  produced

• Advanced solid and surfacing programs needed