JP_SYSTEM

JP SYSTEM 5
Layered Object Manufacturing

WHAT IT IS:

¨ A rapid prototyping process which uses layers of adhesive paper to construct inexpensive prototypes.

¨ Ideally used for educational purposes.

HOW IT WORKS:

Import a Stereolithography File or create a solid model

Load model or Sterolithography file into JP5 program

Configure the JP5 program

Choose what material the prototype is to be made from

4. Orient model for slicing

Determine whether or not subparts are needed, and divide part accordingly

Rotate (sub)parts for optimal slicing

Determine whether or not the (sub)part should be made in absolute size or scaled down (realtive)

Size the (sub)parts accordingly

Top pair: desired part; Bottom pair: properly oriented part

Picture of object in JP5 program aligned before slicing

5. Software slices object into cross-sections

6. Prepare a layout of slices in preparation for cutting

For each subpart:

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
Enclose each slice

Diagram of one sheet of slices

7. Send sheets to a plotter, which will slice each sheet onto adhesive paper

JP System 5 software converts slices to an HPGL plot file format, which is sent to a sign-making plotter

A sheet being fed into the cutter

8. Spray adhesive onto registration board

Align first sheet on registration board

Align remaining sheets, one by one, on a registration system using registration cuts in each section, removing backing material each time

Once all sheets have been placed on the registration board, cut sections from base and sheets and assemble

Put on finishing coat

A JP5 prototype being layered together

TRANSMITTING DESIGN INFORMATION:

¨ SilverScreen® (CAD software) - direct importation

¨ . STL (Stereolithography)file (i.e. from Autocad®, Ideas®, Microstation®, and ProEngineer®)

MATERIALS:

¨ Paper

Standard (8.5" x 11")

fine, medium, or thick semi gloss

fine high gloss

17"x11"

¨ Foam

very big

medium VB

¨ Vinyl

SIZE AND SHAPE LIMITATIONS:

¨ Actual

-If the dimensions of the largest cross section of the part are less than 11" x 17", part can be made to size

¨ Relative

-If the dimensions are larger than mentioned above, part may be scaled down

¨ Subparts

-If a part's dimensions are larger than mentioned above, the part can be split into subparts, which can be pieced together after all the sections have been layered together

¨ Inverted Build Direction

-If a part has overhanging, unsupported components, those sections can be layered together in an inverted matter

¨ Accuracy

-The accuracy of the prototype is ditectly related to the thickness of the material used

-The care taken by the builder while piecing the sections together plays a large role in the accuracy of the prototype

COST:

Type	Machine	Material	Hourly
Stereo	>$100,000	$500/gal	$100
LOM	$100,000	$1.00/cu. in	$75
Fused deposition	$100,000	$10-$20/part	$75
Sintering	$375,000	$20/part	$100
JP System 5	<$7000	$.70/cu. in.	$15

Source: Thomas, et. al. Shapemaker I: An Inexpensive Introduction to Rapid Prototyping.

TIME:

¨ Approximately 3-5 hrs to construct one part, depending on:

experience with program and software

size and detail of part

patience of the constructor

WHY?

¨ Nature of our part

2 1/2 - Dimensions (third dimension does not change)

importance in strength/durability with respect to the other parts of the project

CyberCut

tpourch@andrew.cmu.edu