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1

Experimental investigation of stereolithography and digital light processing additive manufactured pallets

Bairapudi Anil, Sastry C. Chandrasekhara, Krishnaiah J., Sundeep Dola, Eswaramoorthy KV

Materials Science Poland

|

2024

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Vol. 42, No. 1

1--31

EN

Pallets are a tertiary form of packaging used for stacking, storing, protecting, or transporting goods in supply chains. They are utilized as a base for the unitization of goods for logistics and warehousing. Moreover, pallets can be manufactured using wood, plastic, metal, and corrugated paper, which can be used as material-handling equipment. With several products being transported worldwide and with year-on-year growth, it would be beneficial to make lightweight pallets. Such pallets are recyclable, easy to clean, cheap, and durable to maintain and store. Though most of the pallets are widely available for basic purposes, applications involving high-end bio-packings and transportation of special chemicals require specialized pallets to be manufactured like polymers to ensure a negligible chemical reaction, light in weight, and attenuation in freight capacity, thereby widespread reduction in wastage. With advancements, job to job and immediate requirements, additive manufacturing has the potential to close the gap for jobs with short lead times. If the design process of new pallets has limits the creation of specific codes, the transitions will be smoother in rapid prototyping. This work describes the development of polymer pallets by taking advantage of stereolithography (SLA) and digital light processing (DLP) technology for 3D printing pallets in correlation to injection moulding. After the pallets are designed and manufactured, AM technologies can be applied to specified standards, and the pallets then undergo tensile strength, elongation, and hardness tests. The analysis was carried out for configurable geometries adapting to fork lifting, conveyor, racking, and stacking conditions. Analytical and numerical solutions were carried out to understand the stress and deflections for each geometry and its wide range of applications for pallets.

2

An innovative approach to fabrication with photo-cured resins by shell-printed-core-casting

Szymczyk Emil, Rećko Maciej, Dzierżek Kazimierz, Sapiołko Karol

Acta Mechanica et Automatica

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2023

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Vol. 17, no. 4

485--489

EN

Modified LCD-based method was used to print three-dimensional (3D) elements. This innovative method combines printing the external shell and filling, thus obtaining mould by casting resin. In order to compare the properties of prints obtained with this method with the ones fabricated in a standard procedure, we conducted bending tests of vertically/horizontally printed and shell-printed cast specimens. The shell-cast samples showed higher flexural strength and larger values of apparent Young’s modulus. The presented results also concern the kinetics of curing samples obtained with different fabrication routes.

3

Material investigations on poly(ethylene glycol) diacrylate-based hydrogels for additive manufacturing considering different molecular weights

Klimaschewski Sven F., Küpperbusch Janine, Kunze Annika, Vehse Mark

Journal of Mechanical and Energy Engineering

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2022

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Vol. 6, No 1

33--41

EN

The aim of this case study is to generate several poly(ethylene glycol) diacrylate-based hydrogels using additive manufacturing processes. The interest here is in determining different material properties. The test specimens are produced using a commercial stereolithography system. For this purpose, three formulations are prepared. The basis in each case is PEGDA with average molecular weights of 700 Mn, 575 Mn and 250 Mn. A photoinitiator and a UV absorber are added to ensure spatial and temporal cross-linking. Furthermore, the formulations are tested for their material properties according to ISO standards using tensile, compression and hardness tests. An equivalence can be found in the tensile and compression tests. The results with the molecular weights of 700 Mn and 575 Mn show values close to each other. However, the results of the material tests with the molecular weight of 250 Mn are ten times higher. The Shore A hardness values also correlate with the previous tests. These results between molecular weight and material property are particularly striking. A novel aspect of this method could be that the properties determined of these tailor-made high-performance polymers can be applied to different areas of application in an organism.

4

Effect of parameters of the stereolithography process on the part quality

Lewiński Tomasz, Kukiełka Krzysztof, Chaciński Tomasz, Jaskólski Piotr

Journal of Mechanical and Energy Engineering

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2022

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Vol. 6, No 2

1--12

EN

This paper investigates the effect of additive manufacturing parameters on the manufacturing quality of selected gear mechanism components. Three input variables, and two output variables were determined. The result was the determination of the most optimal combination of key parameters and the determination of regression equations. The concept of manufacturing objects of a very complex shape, by any person, under various conditions through the use of a low-cost device became the basis for this thesis topic. Curing time, layer thickness, and lift speed are among the basic parameters, with a large range of manipulation. A hypothesis was formulated that these three parameters are crucial to produce a part with the smallest possible deviations from the computer model. A handheld scanner was used to scan the samples and compare them with the CAD model. Based on the study, optimal parameters for layer thickness, curing time and lift speed were proposed.

5

Time Distribution Analysis of 3D Prints with the Use of a Filament and Masked Stereolithography Resin 3D Printer

Paśnikowska-Łukaszuk Magdalena, Korulczyk Katarzyna, Kapłon Kamil, Urzędowski Arkadiusz, Wlazło-Ćwiklińska Magda

Advances in Science and Technology. Research Journal

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2022

|

Vol. 16, no 5

242--249

EN

The article focuses on the subject of 3D printing. 3D printing technology and currently used solutions are described. The materials used in printing with the use of a filament printer and a resin printer are discussed. The fused deposiotion modeling technique and the LCD-based stereolithography. Printing technology were presented. Samples were prepared using 3D modeling software. The software used to make the models is discussed. The designed models were printed on two types of printers, using different model orientations. Printouts were measured several times. The obtained data was analyzed and the conclusions, proposed solutions and possible improvements to 3D printing were presented at the end. The article deals with the subject of the possibility of accelerating 3D prints due to their location, but also the influence of warming up the printer during subsequent prints was checked.

6

Additive manufacturing for health technology applications

Klimaschewski Sven F., Raschke Robert, Vehse Mark

Journal of Mechanical and Energy Engineering

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2019

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Vol. 3, No 3

215--220

EN

In this study we demonstrate an overview about possibilities in using additive manufacturing for tissue engineering and orthopedic prosthesis. We show the possibilities to produce scaffolds by using a low cost commercial stereolithography system under the use of biocompatible hydrogels like Poly(ethylene glycol) diacrylate. We also demonstrate that it is possible to use a low cost selective laser sintering system to produce individual prostheses to support the healing process in many orthopedic issues.

7

Numerical modelling of resins used in stereolitography rapid prototyping

Miedzińska Danuta, Małek Ewelina, Popławski Arkadiusz

Applied Computer Science

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2019

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Vol. 15, no 4

16--26

EN

The presented research deals with the development of the numerical model for resins used for stereolithography (SLA) rapid prototyping. SLA is an additive method of production of models, prototypes, elements or parts of constructions with the use of 3D printing that covers photochemical processes by which light causes chemical monomers to link together to form polymers. Such method is very useful in design visualization, but also can be applied in numerical modelling for the purpose of validation and verifi-cation. In this application the resin strength parameters must be described and on the base of them the numerical material model is developed and validated. Such a study for SLA resins was presented in the paper.

8

Studying the Technology of Creating Cortical Electrode Instruments using the Rapid Prototyping Technology

Ablyaz T. R., Shumkov A. A., Muratov K. R.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 2

157--162

EN

This paper shows the results of studying the technology of manufacturing cortical electrode-instruments (EI) with the use of indirect methods of the Rapid Prototyping technology. Functional EI prototypes were made by layered synthesis of the photopolymer material with the use of the stereolithography technology (SLA - Stereo Lithography Apparatus). The article is focused on two methods of indirect EI manufacturing. One of the EI prototypes was used for making a molded wax model for hot investment casting, followed by applying copper coating. The second prototype was used for applying copper plating to a prepared current-conductive layer. As a result of EDMing a steel workpiece, both EIs reached the desired depth, which is 1 mm. The copper plating applied to the EI preserves its integrity. Through the use of the casting technology, there is a possibility to cut the economic costs by 35%. Using a prototype with preliminarily applie conductive coating makes it possible to make geometrically-complex EIs.

9

Assessing the Surface Distortion of Plaster Molds Made with the Use of SLA Models

Shumkov A. A., Ablyaz T. R., Muratov K. R.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 3

123--126

EN

The method of determining the accuracy of polymer molds in plaster forms has been discussed. Distortion of the surface of molds and plaster molds has been assessed. It has been found that the presence of monolithic and porous structure in the samples does not change the accuracy of the surfaces when forms are prepared for removing the material of the model. It has been found that in case of full-mold casting it is more expedient to form the mold cavity with cellular adjustable structures of molding prototypes.

10

Możliwości wykorzystania drukowania przestrzennego metodą stereolitografii w projektowaniu architektonicznym

Furmanek A. F.

Mechanik

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2016

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R. 89, nr 12

1920--1921

PL

W artykule przedstawiono wybrane aspekty zastosowania stereolitografii w projektowaniu architektonicznym. Głównie skupiono się na wykorzystaniu tej metody drukowania przestrzennego do wykonywania modeli i makiet architektonicznych. Omówiono zalety i wady tego zastosowania zauważone podczas pracy z drukarką 3D działającą w tej technologii.

EN

The article presents several issues on the application of the stereolithography in the architectural design. Mainly, it focuses on using this method of additive manufacturing to making the architectural models. There are discussed in the paper advantages and disadvantages of this application, which were noticed during the work with the 3D printer operating in this technology.

11

Accuracy of polymeric dental bridges manufactured by stereolythography

Dikova T, Dzhendov D., Katreva I., Pavlova D.

Archives of Materials Science and Engineering

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2016

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Vol. 78, nr 1

29--36

EN

Purpose: Purpose of this paper is to investigate the accuracy of dental bridges produced via digital light projection stereolithography process. Design/methodology/approach: 3D printer Rapidshape D30 was used for manufacturing of two groups of samples – temporary four-part bridges and cast patterns for permanent bridges. The temporary bridges were made of NextDent C+B polymer, while the cast patterns - of NextDent Cast. The samples were manufactured with different layer’s thickness (0.035 mm and 0.050 mm). The geometrical and adjusting accuracy were investigated by measuring of the samples’ dimensions and silicone probe, while the surface roughness was studied out by profile meter and optical microscopy. Findings: It was established that the dimensions of the temporary bridges and the cast patterns, printed with layer thickness 50 µm, are larger than that of the virtual 3D model with 0.1-0.3 mm. Decreasing the layer thickness to 35 µm leads to 0.29%-1.10% smaller sizes of dental bridges and cast patterns in comparison to that of the virtual 3D model. The average roughness deviation Ra of the 3D printed temporary bridges and cast patterns is larger than that of the initial model. As the surface roughness depends on the layer’s thickness, the samples with 0.035 mm layer characterize with lower Ra values. The silicone probe shows that the temporary bridges as well as the cast patterns need additional adjusting in the dental office or corrections during design of the virtual 3D model and 3D printing process in the dental laboratory. Practical implications: The stereolithography as part of CAD/CAM manufacturing process characterizes with high accuracy as a whole. But present study reveals that additional adjusting or preliminary corrections of the design of 3D printing process are needed for dental constructions produced by SLA. Originality/value: The geometrical and fitting accuracy as well as the surface roughness of dental bridges, produced by stereolithography were evaluated. The data, shown in the present study, will help dentists and dental technicians to precise the manufacturing regimes for production of dental constructions with high accuracy.

12

Zastosowanie metod Rapid Prototyping w procesie kształtowania skomplikowanych struktur kostnych

Budzik G., Burek J., Dziubek T., Markowska O., Turek P.

Problemy Nauk Stosowanych

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2014

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T. 2

47--58

PL

Wstęp i cel: W pracy oceniono wpływ zastosowanej metody Rapid Prototyping w procesie kształtowania skomplikowanych struktur kostnych. Materiał i metody: Przedstawiono 6 urządzeń do kształtowania przyrostowego (SLS, SLA, FDM, 3DP, PolyJet oraz Bioplotter). Oceniono wpływ wymienionych metod na użyteczność zastosowania ich w procesie wykonania gotowych biomodeli. Wyniki: W wyniku przeprowadzonych badań stwierdzono iż każda metoda wydruku 3D ma swoje wady i zalety, które związane są z różnymi właściwościami materiałów, sposobami i czasem wykonania modeli oraz wymaganiami stawianymi gotowym modelom Wniosek: Pomimo różnorodności i dostępności wielu metod, żadna z nich nie dominuje w zastosowaniach medycznych.

EN

Introduction and aim: The aim of this study was assessed the effect of the method of Rapid Prototyping in the process of manufacturing biomodels. Material and methods: It demonstrates six Rapid Prototyping methods (SLS, SLA, FDM, 3DP, PolyJet and Bioplotter) and assessed influence this methods for manufacturing biomodels. Results: The research found that each method of 3D printing has its advantages and disadvantages that are associated with the different properties of the materials, methods of manufacturing models and requirements for the finished models Conclusion: Despite the diversity and availability of a variety of Rapid Prototyping methods, none of them dominates in medical applications.

13

Surface roughness characteristic of components created by stereolitography method

Dzionk S., Przybylski W.

Archives of Mechanical Technology and Automation

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2012

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Vol. 32, no. 2

21-29

EN

Stereolithography is an additive rapid prototyping method. This method is based on the principle of solidifying a liquid photopolymer (resin) by laser radiation. Models obtained with this method are characterized by a specific surface structure called "stairstep effect". It causes that, the surface should be processed by additional finishing (postprocessing). To minimize the additional machining process, the model should be set in the relation to incremental layers so that the roughness of significant surfaces is optimal. In order to optimize this process, surface roughness models of components are created using Stereolithography method. This paper presents the various models of surface roughness described in the literature and also compares the consistency of mapping models with the actual surface.

PL

Modele wykonywane metodami szybkiego prototypowania, a w szczególności metodą stereo-litografii, mają charakterystyczną strukturę powierzchni, określaną mianem "schodkowa", która wymaga dodatkowej obróbki. Poznanie zależności wielkości nierówności od usytuowania modelu na platformie pozwoli zminimalizować efekt schodkowy, a tym samym dodatkową obróbkę wykańczającą. W artykule opisano modele profilu chropowatości powierzchni elementów wykonywanych metodą stereolitografii i badania weryfikujące.

14

Impeller pump development using rapid prototyping methods

Przybylski W., Dzionk S.

Advances in Manufacturing Science and Technology

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2011

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Vol. 35, nr 1

15-23

EN

Integrated product development based on Rapid Prototyping methods, aided with computer 3D design and computer engineering enables fast and full new product verification and validation, both from technological and customer requirements point of view. A case study derived from industrial practice, using pomp rotor construction is also included.

PL

Metody szybkiego prototypowania, przy wspomaganiu komputerowym projektowania 3D wraz z systemami wspomagania inżynierskiego, pozwalają uzyskać wyrób o prognozowanych właściwościach technologicznych i użytkowych. W artykule przedstawiono studium przypadku zastosowania metod szybkiego prototypowania w rozwoju elementów pomp wirowych.

15

Wykorzystanie materiałów fotoutwardzalnych w procesach szybkiego wytwarzania

Górski F., Wichniarek R.

Zeszyty Naukowe Politechniki Poznańskiej. Budowa Maszyn i Zarządzanie Produkcją

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2010

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Nr 13

25-34

PL

W artykule przedstawiono możliwości, jakie wiążą się z wykorzystaniem materiałów foto-utwardzalnych (fotopolimerów) w procesach szybkiego wytwarzania prototypów. Opisano budowę i właściwości fotopolimerów oraz możliwości ich modyfikacji w celu uzyskania pożądanych dodatkowych właściwości. Zamieszczono przegląd metod rapid prototyping wykorzystujących fotopolimery. Zaprezentowano również zestawienie wybranych, nowoczesnych fotopolimerów i opisano ich właściwości, także w porównaniu z innymi materiałami wykorzystywanymi do szybkiego wytwarzania prototypów w celu wykazania użyteczności materiałów fotoutwardzalnych i technik je wykorzystujących do szybkiego wytwarzania prototypów.

EN

This paper presents possibilites related with application of photohardened materials (photopo-lymers) in rapid prototyping. Composition and properties of photopolymers were described, along with modification possibilites for obtaining new properties. Paper also contains a short review of RP methods involving photopolymers. Several selected modern photopolymer materials were characterised, also in comparison with other RP materials, aiming to demonstrate usefulness of photopolymers and techniques which use them for rapid prototyping and manufacturing.

16

Prototyping of bevel gears of aircraft power transmission

Budzik G., Markowski T., Sobolak M.

Journal of KONES

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2007

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Vol. 14, No. 2

61-66

PL

Artykuł przedstawia proces wykonania prototypu stożkowej przekładni napędu lotniczego. Szybkie wykonywanie prototypów przekładni o nietypowych zarysach zębów jest możliwe metodami "Rapid Prototyping". Jedną z najdokładniejszych metod szybkiego prototypowania jest stereolitografia, która polega na warstwowym utwardzaniu promieniem lasera fotopolimeru. Metoda ta pozwala zbudowanie modeli kół zębatych o dowolnych kształtach. Za pomocą urządzenia stereolitograficznego SLA-250 wykonane zostały modele kół zębatych przekładni stożkowej. Modele stereolitograficzne mogą służyć do wykonania odlewów. Istotną zaletą prototypów kół zębatych wykonanych z fotoutwardzalnej żywicy jest ich przezroczystość. Zaleta ta pozwala na obserwację chwilowego śladu styku kół zębatych przekładni. Chwilowy ślad styku jest jednym z podstawowych parametrów opisujących prawidłową pracę przekładni. W tym celu przygotowane zostały specjalne modele kół zębatych o zmniejszonej grubości ścianki. Taka budowa pozwoliła na bardziej precyzyjną obserwację śladu styku oraz na zmniejszenia kosztów wykonania modeli. Śledzenie dynamiczne chwilowego śladu styku jest niemożliwe do wykonania tradycyjnymi metodami badawczymi. Zastosowanie metod szybkiego prototypowania daje dobre rezultaty w procesie badań nowych prototypowych przekładni zębatych napędów lotniczych.

EN

The article presents manufacturing process of bevel gears of aircraft power transmission. Rapid prototyping of gears with complex tooth forms is possible with the use of modern methods. One of such methods is the stereo-lithography, where a model is obtained as a result of resin curing with laser beam. This method allows creating gear model with arbitrary tooth form. Bevel gears was carried out by method of stereolitography on SLA 250 apparatus. Gear wheel prototypes were predestined for casting by method losing patterns. One of the best advantages of stereolitography model is its transparency. This advantage allow to observation instantaneous contact ellipses of gear. Instantaneous contact ellipses of gear is one of the most important parameters describe correctly work of gear. Research of instantaneous contact ellipses of gear requires special construction of model gear with thin wall. This construction allows costing reduction of prototype. Observation of instantaneous contact ellipses of gear is not possible by traditional research method. Rapid Prototyping method give good results in research process of new prototype of aircraft transmission gear.

17

Hybrid foundry patterns of bevel gears

Budzik G., Markowski T., Sobolak M.

Archives of Foundry Engineering

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2007

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Vol. 7, iss. 1

131-134

EN

Possibilities of making hybrid foundry patterns of bevel gears for investment casting process are presented. Rapid prototyping of gears with complex tooth forms is possible with the use of modern methods. One of such methods is the stereo-lithography, where a pattern is obtained as a result of resin curing with laser beam. Patterns of that type are applicable in precision casting. Removing of stereo-lithographic pattern from foundry mould requires use of high temperatures. Resin burning would generate significant amounts of harmful gases. In case of a solid stereo-lithographic pattern, the pressure created during gas burning may cause the mould to crack. A gas volume reduction may be achieved by using patterns of honeycomb structure. However, this technique causes a significant worsening of accuracy of stereo-lithographic patterns in respect of their dimensions and shape. In cooperation with WSK PZL Rzeszów, the Machine Design Department of Rzeszow University of Technology carried out research on the design of hybrid stereo-lithographic patterns. Hybrid pattern consists of a section made by stereo-lithographic process and a section made of casting wax. The latter material is used for stereo-lithographic pattern filling and for mould gating system. The hybrid pattern process consists of two stages: wax melting and then the burn-out of stereolithographic pattern. Use of hybrid patterns reduces the costs of production of stereolithographic patterns. High dimensional accuracy remains preserved in this process.

18

Generation of a finite element model of the thoracolumbar spine

Tyndyk M. A., Barron V., McHugh P. E., O'Mahoney D.

Acta of Bioengineering and Biomechanics

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2007

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Vol. 9, nr 1

35-46

EN

The goal of this study was to generate a realistic 3D FE model of the seven level thoracolumbar spine. This research focused on the development of a robust and efficient procedure for generating anatomical 3D FE models, directly from a series of medical images, i.e., CT data. A complex model of the spine was created by combining two different modelling approaches, namely the CAD and STL-CAD methods. In addition, the entire meshing procedure for the vertebrae was significantly speeded up by combining 3D tetrahedral elements with brick elements, relative to conventional mapped mesh generation procedures. The resulting model generation method allowed for flexibility in element choice and in element type combinations. The model was subjected to various compressive loads to asses the overall behaviour of the spine. This case study was performed to illustrate the usefulness of the FE model. In the authors’ opinion, the model presented is an important tool in computational spine research as it can provide general information on spinal behaviour under various loading conditions whether healthy, diseased or damaged.

19

Podstawy kształtowania modeli użytkowych z polimerów metodami przyrostowymi

Sikora R., Zimniak J.

Zeszyty Naukowe. Chemia i Technologia Chemiczna / Akademia Techniczno-Rolnicza w Bydgoszczy

|

2006

|

z. 11

151-154

PL

W artykule zaprezentowano zagadnienia dotyczące sposobów i środków technicz-nych do kształtowania modeli użytkowych i wytworów z tworzyw polimerowych w produkcji jednostkowej. Bliższej analizie poddano metodę stereolitografii (SL) oraz selektywnego spiekania laserowego (SLS).

EN

Some problems concerning shaping of plastic functional models and products have been revealed in this paper. Following methods like stereolithography (SL) and selective laser sintering (SLS) will be discussed.