How Does it Work?

First import a stereolithography file or create a solid model then load the model or stereolithography file into JP5 program and configure. At this point chose what material will be used and then orient model for slicing. Be sure to determine whether or not subparts are needed, and divide part accordingly; this may include rotating (sub)parts for optimal slicing, and determining whether or not the (sub)part should be made in absolute size or scaled down (relative). The software will then slice the object into cross-sections.

a sample CAD drawing sliced into cross sections

Secondly prepare a layout of slices in preparation for cutting each of the subparts, meaning that you must choose either major or minor registration according to the cross-sectional dimensions, determine the number of sections needed, determine the number of sheets needed, create section separations, and enclose each slice.

a sample layout for one printed sheet with six layers on it

The JP System 5 software converts slices to an HPGL plot file format which will enable the sheets to be sent to a sign-making plotter which will slice each sheet onto adhesive paper. To feed a sheet into the cutter align the first sheet onto the registration board.

a sheet being fed to the machine

Then align remaining sheets, one by one, on a registration system using registration cuts in each section, removing backing material each time. Once all of the sheets have been placed on the registration board, cut sections from base and sheets and assemble. Finally put on the finishing coat.

assembling the layers

How is data transmitted

The user creates a CAD drawing of the object and saves it as a stereolithography file (*.stl). That file is then imported into a program called SilverScreen, which translates it into a plotter file with multiple layers per page. Each page is then sent to the plotter individually.

sample cad design before being sliced

Materials, Size and Shape

The plotter can cut foam or soft wood, but the most common and versatile material is sticker paper. With sticker paper, you can make a multi layered object. The size limitations are anything smaller than 11” by 17”. It can be as tall as you like, but its going to take a long time to assemble. The shape can be pretty much anything, but some shapes would be more difficult than others.

How Much Do Parts Cost?

Type	Machine	Material	Hourly
Stereolithography	>$100,000	$500/gal	$100
LOM	$100,000	$1.00/cu. in	$75
FDM	$100,000	~$20/part	$75
Sintering	$375,000	$20/part	$100
JP System 5	<$7000	$.70/cu. in.	$15

How Quickly Can Parts Be Produced?

The longest process involved in the JP System 5 method is layering the paper sections. From our research we have determined that it can be expected to take about an hour for an experienced person to combine an inch worth of layers. As we do not have any experience using JP System 5 we are expecting it to take 3-5 hours to become familiar with the software, set up the machine, and manipulate the cut sheets to our high standard of quality.

some finished prototypes

Section C Shaft 1 Team: Spring 2003
Andrew Brodlieb
Matt Horton
Aubrey Shick